Bettis Q-Series - Release 2 - 2019 Owner's Manual

Bettis Q-Series - Release 2 - 2019 Owner's Manual
Installation, Operation and Maintenance Manual
DOC.IOM.BQ.E Rev. 3
April 2019
Bettis Q-Series
Pneumatic Actuators with Integrated Controls
Installation, Operation and Maintenance Manual
DOC.IOM.BQ.E Rev. 3
Table of Contents
April 2019
Table of Contents
Section 1: Before You Start
1.1
1.2
1.3
Installation, Operation and Maintenance Reference Documents..................... 1
Warehouse Storage........................................................................................ 2
On-Site Storage.............................................................................................. 2
Section 2: Introduction
2.1
2.2
2.3
Identification.................................................................................................. 3
Intended Use.................................................................................................. 5
Specifications................................................................................................. 5
Section 3: Configuration Code
Section 4: Installation
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Before You Start............................................................................................. 9
Actuator Rotation Direction........................................................................... 9
4.2.1 Valve Rotation..................................................................................... 9
4.2.2 Position After Failure......................................................................... 10
Principles of Operation................................................................................. 11
4.3.1 Pneumatic Operation of the Base Actuator........................................ 11
4.3.2 Ingress Protection (IP) Rating............................................................ 12
4.3.3 Control Module Operation................................................................ 12
4.3.4 Double-Acting Operation with Fail-In-Last Position Function............. 14
4.3.5 Spring-Return Actuators.................................................................... 16
4.3.6 Position Feedback............................................................................. 18
Actuator Assembly Codes............................................................................ 19
Actuator to Valve Installation....................................................................... 21
Mounting of Control Modules or Generic Control and Feedback Accessories..... 24
Recommended Tubing Sizes......................................................................... 24
Section 5: Mechanical Stroke Adjustment
5.1
Travel Stop Adjustment................................................................................ 26
5.1.1 Double-Acting Actuators................................................................... 26
5.1.2 Spring-Return Actuators.................................................................... 27
5.1.3 Angular Displacement....................................................................... 28
Section 6: Maintenance
6.1
6.2
Normal Maintenance.................................................................................... 29
Inspection and Repair................................................................................... 30
6.2.1 Service Kits........................................................................................ 30
6.2.2 Spring-Return Actuator..................................................................... 30
Section 7: Decommission (Out of Service)
7.1
7.2
Table of Contents
Before You Start........................................................................................... 31
Removing the Actuator from the Valve......................................................... 32
I
Table of Contents
Installation, Operation and Maintenance Manual
April 2019
DOC.IOM.BQ.E Rev. 3
Section 8: Disassembly
8.1
8.2
8.3
8.4
8.5
8.6
8.7
Removing End Caps (Size 40 to 600)............................................................ 34
Removing End Caps (Size 950 to 1600)........................................................ 36
Removing Spring Cartridges or Springs........................................................ 37
Removing of Limit Stop Screws.................................................................... 38
Removing Pistons......................................................................................... 38
Removing Pinion.......................................................................................... 39
Cleaning the Components ........................................................................... 40
Section 9: Reassembly
9.1
9.2
9.3
9.4
9.5
9.6
Grease Instructions...................................................................................... 42
Reassembly of the Pinion.............................................................................. 43
Reassembly of the Pistons............................................................................ 44
Reassembly and Settings of the Limit Stops.................................................. 46
Reassembly of the End Caps......................................................................... 47
9.5.1 Double-Acting Actuators................................................................... 47
9.5.2 Spring-Return Actuators (Size 40 to 600)........................................... 48
9.5.3 Spring-Return Actuators (Size 950 to 1600)....................................... 50
Basic Function and Air Leak Test................................................................... 52
Section 10: Troubleshooting
10.1 Mechanical Problems................................................................................... 53
10.2 Pneumatic Problems.................................................................................... 54
10.3 Electrical Problems....................................................................................... 55
Section 11: Parts List and Spare Parts Recommendations
11.1 Actuator Size Q40 to Q600........................................................................... 56
11.2 Actuator Size Q950 to Q1600....................................................................... 57
Appendix A: Spring Load Removal
A.1
Spring Load Relief......................................................................................... 58
Appendix B: Tool & Torque Table
Appendix C: Full Stroke Adjustment Option
C.1
C.2
C.3
II
Full Stroke Adjustment Option..................................................................... 62
Convert a Standard Actuator into a Full Stroke Adjustment Version.............. 63
11.2.1 Procedure......................................................................................... 64
Full Stroke Adjustment Setting..................................................................... 65
11.2.2 Factory Setting Procedure................................................................. 65
11.2.3 Setting the Full Stroke Adjustment Screw to the Required Angle....... 66
Table of Contents
Installation, Operation and Maintenance Manual
Section 1: Before You Start
April 2019
DOC.IOM.BQ.E Rev. 3
Section 1: Before You Start
This section explains:
•
Base safety procedures.
•
Where to find detailed information relating safety.
•
Storage guidelines.
Installation, adjustment, putting into service, use, assembly, disassembly and maintenance
of the pneumatic actuator must be performed by qualified personnel.
NOTICE
Failure to follow the above guidelines will void warranty.
WARNING
Actuator must be isolated both pneumatically and electrically before any (dis)assembly starts.
Before mounting or (dis)assembly, the actuator consult the relevant sections of this manual.
1.1
Installation, Operation and Maintenance
Reference Documents
Before you start, read the following documents:
•
All Sections in this manual.
•
Safety Guide (Document No. DOC.SG.BQ.EN).
Mounted Control modules are shipped with the applicable installation guide:
QC41, QC42 or QC43: Document DOC.IG.BQC41.1.
QC40: Document DOC.IG.BQC40.1.
QC54: Document DOC.IG.BQC54.1.
For Safety Instrumented Systems application, read the following document:
•
SIL Safety Manual Bettis Q-Series (Document No. DOC.SILM.BQ.EN).
NOTICE
Failure to read the Safety Guide will void the warranty.
Not following the instructions of the Safety Guide can lead to failure of the product and
harm to personnel or equipment.
Before You Start
1
Section 1: Before You Start
Installation, Operation and Maintenance Manual
April 2019
1.2
1.3
DOC.IOM.BQ.E Rev. 3
Warehouse Storage
•
All actuators should be stored in a clean, dry warehouse, free from excessive
vibration and rapid temperature changes.
•
All actuators should not be stored directly to the floor surface - it must be placed in
racks/shelves or use a pallet.
On-Site Storage
•
All actuators should be stored in a clean, dry warehouse, free from excessive
vibration and rapid temperature changes.
•
Prevent moisture or dirt from entering the actuator. Plug or seal both air
connection ports.
NOTICE
Failure to follow the above guidelines (Warehouse and On Site Storages) will void warranty.
2
Before You Start
Installation, Operation and Maintenance Manual
Section 2: Introduction
April 2019
DOC.IOM.BQ.E Rev. 3
Section 2: Introduction
This section explains:
2.1
•
How to identify the received product.
•
The intended use of the product.
•
Construction details.
•
Actuator specifications.
Identification
The Bettis Q-Series Rack and Pinion actuators are available as double-acting or springreturn versions. 9 models are available, ranging from 40 Nm to 1600 Nm (354 to 14161 lbf.
in) nominal torque output.
The Bettis Q-Series package consists of an actuator with a module for control and position
feed back and forms an integrated concept for “On/Off” valve automation.
1.
Basic Actuators
The basic actuator supplies the torque, required to open and close valves and is available in various sizes (rated 47 to 1676Nm at 5.5barg or 413 to 14874 In.lb. at 80pisg).
Double acting and spring return executions are available. The spring return execution can be
equipped with multiple spring sets to cover a pressure range from 2 to 8 barg (30 to 120 psig).
The springs in the spring-return version allow a fail action in case of loss of air supply
pressure (Fail-to-Close or Fail-to-Open). As from size FD150 double-acting versions have
flat end caps to reduce actuator length and internal air volume.
The springs in the spring-return version allow a fail action in case of loss of air supply
pressure (Fail-to-Close or Fail-to-Open).
As from size 150 double-acting versions have flat end caps to reduce actuator length and
internal air volume.
2.
Control Modules
The Control Modules contain, next to the components for feedback switches, also all the
pneumatic control components.
Its compact and robust construction incorporates basic control and feedback functionality
and is suitable for indoor and outdoor use.
Introduction
3
Installation, Operation and Maintenance Manual
Section 2: Introduction
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 1
Identification
1
2
3
Size
4
End cap design 5
SR
DA
40 100
Left
Pinion bottom /
Insert design 2
Right
Maximum 12
spring cartridges
SR
DA
150 600
Left
Right
Maximum 12
spring cartridges
SR
950 1600
Spring design 6
DA
Left
Right
Maximum 6
loose springs
Notes:
1. Top auxilliaries according (VDI/VDE 3845; NAMUR). Bettis Q-Series comes with a proprietary pneumatic
interface for direct mounting of the Control modules.
2. Valve interface available according ISO5211 or DIN 3337. Actuator sizes 40 to 1600 can be fitted with drive
inserts with various inner shapes.
3. Spring-Return actuators: - with springs
4. Double-Acting actuators: - no springs
5. Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models. Actuator sizes
150 to 1600 have low end caps for double-acting models and high end caps for spring-return models.
6. Actuator sizes 40 to 600 are fitted with a maximum of 12 spring cartridges. Actuator sizes 950 and 1600
are fitted with a maximum of 6 loose springs.
4
Introduction
Installation, Operation and Maintenance Manual
Section 2: Introduction
April 2019
DOC.IOM.BQ.E Rev. 3
2.2
Intended Use
The Bettis Q-Series Rack and Pinion actuators are intended for the automation and
operation of quarter-turn valves like Butterfly, Ball and Plug valves.
Rack and Pinion actuators can also be used to operate dampers or any other quarter-turn
applications.
2.3
Specifications
Table 1.
Pressure Range
Actuator Type
Pressure
Double-Acting
0.2 to 8.3 barg (2.9 to 120 psig)
6 to 8.3 barg (87 to 120 psig), with maximum spring set
3 to 8.3 barg (43.5 to 120 psig), reduced spring quantity
Spring-Return
Table 2.
Operating Media
Actuator Type
Operating Media
Double-Acting and Single-Acting
Air, dry or lubricated and inert gases
Dew point at least 10K below ambient temperature
For sub-zero applications, take appropriate measures
Mentioned pressure levels are "gauge pressures".
Gauge pressure is equal to absolute pressure minus
atmospheric pressure.
1.
2.
For the base actuator the recommended air quality for normal operation
(according ISO 8573-1) is: 7-5-4.
In case Q-Series Control Modules are used, the operating media specification as mentioned in
the Installation Guide (shipped with each control module) are applicable.
QC41, QC42 or QC43:
Document DOC.IG.BQC41.1.
QC40:Document DOC.IG.BQC40.1.
QC54:Document DOC.IG.BQC54.1.
NOTE:
Use of filters, pressure regulators, lubricator and an oil/water separator mounted in the air
supply line, will allow a smooth and durable operation of the actuator.
For lubricated supply air, it is recommended to use a non-detergent oil without aggressive
additives, VG32, group 2 (ISO 3448).
Table 3.
Actuator Type
Temperature
Standard
-20°C to +80°C (-4°F to +176°F)
1.
Introduction
Temperature Range
In case Q-Series Control Modules are used, the temperature range as mentioned in
the Installation Guide (shipped with each control module) are applicable.
QC41, QC42 or QC43:
Document DOC.IG.BQC41.1.
QC40: Document DOC.IG.BQC40.1.
QC54: Document DOC.IG.BQC54.1.
5
Installation, Operation and Maintenance Manual
Section 2: Introduction
April 2019
DOC.IOM.BQ.E Rev. 3
Table 4.
Air Volumes and Consumption
Actuator volumes:
Maximum volume (in liters)
Actuator
model
Q 0040
Q 0065
Q 0100
Q 0150
Q 0200
Q 0350
Q 0600
Q 0950
Q 1600
Central1
chamber
End cap2
chamber
Displaced3
volume
0.26
0.40
0.6
1.0
1.3
2.1
3.6
4.9
7.9
0.37
0.56
0.9
0.8
1.0
1.9
3.3
4.6
7.3
0.15
0.22
0.3
0.5
0.7
1.2
2.1
3.2
5.4
Actuator volumes:
Maximum volume (Cu.in.)
Actuator
model
Q 0040
Q 0065
Q 0100
Q 0150
Q 0200
Q 0350
Q 0600
Q 0950
Q 1600
Central1
chamber
End cap2
chamber
Displaced3
volume
15.9
24
36
58
76
131
222
301
484
23
34
53
47
64
115
201
279
447
8.9
13.5
19.9
32
44
76
129
196
328
Consumption per stoke
(in liters, pressure in barg)
Outward Stroke
Inward Stroke
Double-Acting
Double-Acting only
and Spring-Return
2.0 barg 4.0 barg 8.0 barg 2.0 barg 4.0 barg 8.0 barg
0.67
1.02
1.5
2.4
3.2
5.5
9.4
13
21
1.2
1.8
2.7
4.3
5.7
9.8
17
23
37
2.2
3.4
5.0
8.1
11
18
31
43
69
0.89
1.3
2.0
2.1
2.8
5.0
8.7
12
20
1.6
2.4
3.8
3.6
4.9
8.8
15
22
35
3.1
4.7
7.2
6.7
9.1
16
28
40
64
Consumption per stoke
(in Cu.in., pressure in psig)
Outward Stroke
Inward Stroke
Double-Acting
Double-Acting only
and Spring-Return
40 psig
53
81
118
192
255
436
742
1025
1662
80 psig 120 psig 40 psig
96
148
216
352
466
796
1354
1854
2997
140
215
314
512
676
1157
1967
2682
4331
71
107
165
163
220
392
683
966
1560
80 psig 120 psig
133
200
310
293
397
709
1237
1735
2792
196
294
455
424
573
1025
1790
2505
4024
Notes:
1. Pistons at 90° outward position.
2. Pistons at 0° inward position.
3. Stroke is 90°.
Figure 2
Actuator Air Volumes
Central air chamber volume
Double-Acting and Spring-Return
A
6
End cap air chamber volume
Double-Acting only
B
Introduction
Installation, Operation and Maintenance Manual
Section 3: Configuration Code
April 2019
DOC.IOM.BQ.E Rev. 3
Section 3: Configuration Code
This section explains:
•
How to create or read the configuration code for a actuator.
QS 0150 - N U 40 CW AL TN - L17 S K B - 00 XX
Miscellaneous options
Internal code 1
Color / finish
Visual indicator
Temperature
Valve stem connection
Valve interface
Pinion material
Rotation
Spring set
Threads
Rotation angle
Size
Type
Type
FD
FS
Size
0040
0065
0100
0150
0200
Double Acting
Spring Return
Size 0040
Size 0065
Size 0100
Size 0150
Size 0200
0350
0600
0950
1600
Size 0350
Size 0600
Size 0950
Size 1600
Rotation Angle
N
90° rotation angle
Threads
M
Metric ISO 5211
U
UNC/NPT/Imperial
Spring Set
00
Double Acting (no springs)
10
Spring Set 10
40
20
Spring Set 20
50
30
Spring Set 30
60
Valve Stem Connection, Note 3
Square
Actuator Size
Dimensions
No insert
0040 & 0065
14mm / 0.551"
17mm / 0.669"
0100
19mm / 0.748"
17mm / 0.669"
0150
19mm / 0.748"
0200
22mm / 0.866"
22mm / 0.866"
0350
27mm / 1.063"
0600
27mm / 1.063"
22mm / 0.866"
0350
27mm / 1.063"
0600
27mm / 1.063"
0950
36mm / 1.417"
1600
46mm / 1.811"
Diagonal
Drive
Parallel
Drive
000
L14
D14
D17
L19
D17
L19
L22
L27
L22
L27
L27
L36
L46
D22
D22
D22
D22
D27
D36
D46
Temperature Range
S
Standard: -20°C to +80°C (-4°F to +176°F)
Spring Set 40
Spring Set 50
Spring Set 60
Visual Indication Code
K
Standard (Knob)
N
No Visual Indication
Rotation Direction
CW Spring to Close/Clock Wise
CC
Spring to Open/Counter Clock Wise
Finish
Pinion Material
AL
High Grade Aluminium, Hard anodized
Internal Code 1
00
Standard
Valve Interface, Note 2
TN
Standard ISO 5211 interface
SY
Small interface with center plate (DIN3337)
LY
Large interface with center plate (DIN3337)
Miscellaneous Options
XX
Standard: Suitable for Control module mounting
FS
Full stroke adjustement (only sizes 40 to 600)
B
Standard coating (Bettis Orange)
Notes:
See next page.
Configuration Code
7
Installation, Operation and Maintenance Manual
Section 3: Configuration Code
April 2019
DOC.IOM.BQ.E Rev. 3
Notes:
8
1.
The options, listed here, are all options available. Not all options apply to all
configurations. Check the actuator size page for valid configurations.
2.
Valve Interface:
——
Option "S"; Small Interface with Center Plate (DIN3337)
is not available for sizes 0950.
——
Option "L"; Large Interface with Center Plate (DIN33337)
is not available for sizes 1600.
3.
Contact your local Bettis Q-Series representative for additional insert options.
4.
PED Group 1 Label only available up to size 950.
Configuration Code
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
Section 4: Installation
This section explains:
4.1
•
The actuator rotation direction.
•
In which position the actuator will end after a failure.
•
Principles of operation:
——
Pneumatic operation.
——
Double acting and Spring return operation.
•
Assembly codes.
•
Actuator to valve assembly.
Before You Start
SAFETY
In case of an air or electrical failure, it is important to know the behavior of the actuator.
Before mounting the actuator on a valve, consult the following sections below.
4.2
Actuator Rotation Direction
4.2.1
Valve Rotation
For the following paragraphs we assume that valves rotate as indicated in Figure 3.
Figure 3
Normal valve rotation
The valve is closed after
a clockwise rotation.
Installation
The valve is open after
a counterclockwise rotation.
9
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.2.2
DOC.IOM.BQ.E Rev. 3
Position After Failure
The position of the actuator after a failure depends on the:
1.
Principle of operation (see paragraph 4.3)
2.
Assembly codes (see paragraph 4.4)
3.
Kind of failure. Refer to the table below.
Table 5.
Position After Failure
Principle of
Operation
Assembly Code
CW
Double-Acting
Actuator
Single-Acting
(Spring-Return)
Actuator
Table 6.
CW
Position
Pressure
Signal
Supply Voltage
Pressure
Signal
Supply Voltage
Pressure
Signal
Supply Voltage
Pressure
Signal
Supply Voltage
Not defined
Closed
Closed
Not defined
Open
Open
Closed
Closed
Closed
Open
Open
Open
Position after a failure with a Double-Acting module with
Fail-In-Last-Position Function
Principle of
Operation
Assembly Code
CW
Double-Acting
Actuator
10
Kind of Failure
Kind of Failure
Position
Pressure
Signal
Supply Voltage
Pressure
Signal
Supply Voltage
Not defined
Not defined
Closed
Not defined
Not defined
Open
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
4.3
Principles of Operation
4.3.1
Pneumatic Operation of the Base Actuator
Bettis Q-Series actuator are intended to be operated by the Q-Series Control Modules. For more
details see section 4.3.3. Below figure shows the basic pneumatic operation of the actuator.
Figure 4
Typical Pneumatic Operation
Spring-Return Operation
Double-Acting Operation
A
A
B
The table below represents the cycle time (operating time) per different Actuator sizes:
Table 7.
Operating Speed
Cycle time in seconds
Actuator
size
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
Spring-Return
Double-Acting
A-port
pressurized
Spring
stroke
A-port
pressurized
B-port
pressurized
0.6
0.7
0.8
1.0
1.3
1.9
3.2
6.6
10.6
0.5
0.5
0.6
0.8
0.9
1.3
1.9
2.2
3.5
0.6
0.6
0.8
0.9
1.0
1.4
2.2
2.4
3.6
0.5
0.6
0.7
0.8
1.0
1.5
2.2
2.0
3.3
Operating time is average with actuator under load and solenoid valve fitted.
Test conditions:
1. Solenoid with flow capacity: 0.6 m3/hr
2. Pipe diameter: 6mm
3. Medium: clean air
4. Supply pressure: 5.5 bar (80psi)
5. Load: with average load
6. Stroke: 90°
7. Temperature: Room temperature
Installation
11
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.3.2
DOC.IOM.BQ.E Rev. 3
Ingress Protection (IP) Rating
Bettis Q-Series actuators are IP66 / NEMA4 rated. In case of IP66 or NEMA4 requirements,
take precautions that comply with the IP66 / NEMA4 requirements to prevent moisture or
dust from entering the actuator through the open air exhaust port(s), either directly on the
actuator or at the exhaust ports of the connected solenoid valve.
We recommend to connect tubing to the exhaust(s) and lead this into a dry and dust free
area, or to use check valves in the exhaust.
4.3.3
Control Module Operation
The operating principle, as explained here, is applicable for actuators with assembly code
CW (direct acting).
•
The outward stroke will move the valve to the “Open” position.
•
The inward stroke will move the valve to the “Closed” position.
•
For assembly codes CC, the operating principle is reversed (reverse acting):
Figure 5
Double-Acting Operation
Outward Stroke
A-port
Option:
Throttle 1
5/2 Spool valve
Option: LMC
B-port
Option:
Throttle 2
Rb
Ps
Ra
Pilot
valve 1
12
1.
Send control signal “Open” to the Control Module.
2.
Pilot valve 1 will be activated and the 5/2spool valve will pressurize the central
air chamber.
3.
The piston will move outwards to the “Open” position.
4.
The Control Module indicates the “Open” position and activates feedback
signal “Open”.
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 6
Double-Acting Operation
Inward Stroke
A-port
Option:
Throttle 1
5/2 Spool valve
Option: LMC
B-port
Option:
Throttle 2
Rb
Ps
Ra
Pilot
valve 1
1.
Send control signal “Close” to the Control Module.
2.
Pilot valve 1 will be deactivated and the 5/2 spool valve will pressurize the end cap
air chambers.
3.
The piston will move inwards to the “Closed” position.
4.
The Control Module indicates the “Closed” position and activates feedback
signal “Closed”.
Optional Controls:
LMC Local Manual Control
SC
Speed Control throttles
Important
In case of an electric control signal failure, the actuator will move to its "Closed" position.
Installation
13
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.3.4
DOC.IOM.BQ.E Rev. 3
Double-Acting Operation with Fail-In-Last Position Function
The operating principle, as explained here, is applicable for actuators with assembly code
CW (direct acting).
•
The outward stroke will move the valve to the “Open” position.
•
The inward stroke will move the valve to the “Closed” position.
•
For assembly codes CC the operating principle is reversed (reverse acting):
Figure 7
Double-Acting Operation with Fail-In-Last Position Function
Outward Stroke
A-port
Option:
Throttle 1
5/2 Spool valve
Option: LMC 1
B-port
Option:
Throttle 2
Option:
LMC 2
Ps
Rb
Ra
Pilot valve 1
14
Pilot valve 2
1.
Send control signal “Open” to the Control Module to activate Pilot valve 1 and
de-activate Pilot valve 2.
2.
The 5/2 spool valve will pressurize the central air chamber.
3.
The piston will move outwards to the “Open” position.
4.
The Control Module indicates the “Open” position and activates feedback
signal “Open”.
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 8
Double-Acting Operation with Fail-In-Last Position Function
Inward Stroke
A-port
Option:
Throttle 1
B-port
Option:
Throttle 2
5/2 Spool valve
Option: LMC 1
Option: LMC 2
Ps
Rb
Ra
Pilot valve 1
Pilot valve 2
1.
Send control signal “Close” to the Control Module to activate Pilot valve 2 and
de-activate Pilot valve 1.
2.
The 5/2 spool valve will pressurize the end cap air chambers.
3.
The piston will move inwards to the “Closed” position.
4.
The Control Module indicates the “Closed” position and activates feedback
signal “Closed”.
Optional Controls:
LMC Local Manual Control
SC
Speed Control throttles
Installation
15
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.3.5
DOC.IOM.BQ.E Rev. 3
Spring-Return Actuators
The operating principle, as explained here, is applicable for actuators with assembly code
CW (direct acting).
•
Applying supply pressure to port A will move the pistons outwards to the "Open"
position of the valve.
•
Venting the supply pressure from port A will cause the springs to move the pistons
inwards to the "Close" position of the valve.
•
For assembly codes CC, the operating principle is reversed (reverse acting):
Figure 9
Single-Acting Operation
Outward Stoke
A-port
B-port
Option: Throttle 1
3/2 Spool valve
Option: LMC
Ps
Ra
Pilot
valve 1
16
1.
Send control signal “Open” to the Control Module.
2.
Pilot valve 1 will be activated and the 3/2 spool valve will pressurize the central
air chamber.
3.
The piston will move outwards to the “Open” position.
4.
The Control Module indicates the “Open” position and activates feedback
signal “Open”.
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 10
Single-Acting Operation
Inward Stroke
A-port
B-port
Option: Throttle 1
3/2 Spool valve
Option: LMC
Ps
Ra
Pilot
valve 1
1.
Send control signal “Close” to the Control Module.
2.
Pilot valve 1 will be deactivated and the 3/2 spool valve will vent the central
air chamber
3.
The springs will move the pistons inwards to the “Closed” position.
4.
The Control Module indicates the “Closed” position and activates feedback
signal “Closed”.
Optional Controls:
LMC Local Manual Control
SC
Speed Control throttles
Installation
17
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.3.6
DOC.IOM.BQ.E Rev. 3
Position Feedback
The Bettis Q-Series actuator (1) has a patented, contact-less position sensing system.
This system consists of a position probe (2) which is rides on a special curve (4) in the
pinion bottom.
The curve is shaped in such a way that the position probe moves linearly and proportionally
to the rotation of the actuator pinion.
The linear movement of the position probe is used, inside the control module (3) to
operated the limit switches.
CAUTION
Do not put the Control module in direct contact with magnetic material. This can cause
damage or malfunction of the position feedback.
Installation of the Bettis Q-Series Control Modules
Please refer to the Installation guides, as shipped with the product, for installation
instructions of the Control Module.
Installation Guides - Control modules
Each Control Module is shipped with an Installation Guide, which contains more
information on the pneumatic and electrical installation and operation of the Module.
Additionally, these Installation Guides can be downloaded from: www.emerson.com/bettis
Figure 11
1
3
2
18
4
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
4.4
Actuator Assembly Codes
Figure 12
Assembly Code - Double-Acting
Assembly Code: CW Assembly Code: CC
= Standard, Clockwise-to-Close rotation
= Reverse, Counterclockwise-to-Open
= Fail-to-Close = Fail-to-Open
Sizes Q40 and Q65
B
1
A
4
3
5
B
2
A
6
3
A
B
Sizes Q100 to Q1600
B
A
B
A
4
A
1
A
B
5
B
2
3
3
A
B
6
Rotation A = Central air chamber pressurized
Rotation B = End cap air chambers pressurized
1.
Limit stops location
2.
Position of cam
3.
Position of slot and dot in pinion
4.
Default pistons position
5.
Pinion 90° Rotated
6.
Reversed piston position
All views are from above. Pistons are shown in inward position.
Installation
19
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 13
Assembly Code - Spring-Return
Assembly Code: CW Assembly Code: CC
= Standard, Clockwise-to-Close rotation
= Reverse, Counterclockwise-to-Open
= Fail-to-Close = Fail-to-Open
Sizes Q40 and Q65
B
1
A
4
3
2
A
5
B
6
3
7
A
B
Sizes Q100 to Q1600
B
A
B
A
4
A
1
A
B
5
B
2
3
7
3
A
B
6
Rotation A = Central air chamber pressurized
Rotation B = Spring stroke
1.
Limit stops location
2.
Position of cam
3.
Position of slot and dot in pinion
4.
Default pistons position
5.
Pinion 90° Rotated
6.
Reversed piston position
7.
Springs
All views are from above. Pistons are shown in inward position.
20
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
4.5
Actuator to Valve Installation
WARNING: MOVING PARTS
Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.
Stay away from moving parts to prevent serious injuries. When test cycling the actuator
and valve assembly by applying pressure to the actuator, be aware that there are moving
parts like pinion top, actuator to valve coupling and the valve- blade, ball, plug, etc.
NOTICE
The actuator is designed to be installed, commissioned and maintained using generic tools
like wrenches, Allen keys and screwdrivers. For the removal of inserts, a special extractor
tool can be supplied on request.
During assembly to the valve, do not hit with hammer on pinion top. This can damage the
pinion top washer and cause premature failure.
Before mounting the actuator on the valve or valve bracket, be sure that both the
actuator and the valve are in the same closed or open position.
Refer to appendix B, Tool and Torque tables, for using the right size tool and torque.
Table 8.
Tool Table
Symbol
Tool
Symbol
Wrench – All types and sizes.
Metric and Imperial
Tool
Allen key
Circlip Pliers
1.
Remove handle nut, handle, lock washer, and etc. from the valve if required.
2.
Visually check to make sure the valve is CLOSED.
Figure 14
Installation
Valve Handle Removal
21
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
3.
When required, check if the insert drive (23) is mounted. If not, use a plastic mallet
and tap slightly until the insert is in the required position.
Be sure that the insert is mounted at 90° or 45°. It is possible to mount the insert
turned 22.5°. This way the valve will not open or close the right way.
Figure 15
Insert Drive Installation
90°
90°
Parallel
square
45°
Flat head
90°
23
Diagonal
square
4.
Install the bracket to the valve flange. Tighten all bolts and nuts and apply the
correct torque.
Figure 16
22
Round with
key way
Bracket Installation
Installation
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
DOC.IOM.BQ.E Rev. 3
5.
Install the actuator to the bracket. Tighten all bolts and apply the correct torque
(Refer to Table 9).
Table 9.
Bottom Flange Torque Values
Actuator Size
40, 65, 100
150, 200, 350
600
950
1600
6.
ISO Pattern
Torque (Nm)
Torque (lbf.ft)
Thread
Min.
Max.
Thread
Min.
Max.
F05 inner pattern
M6
F07 outer pattern
M8
F07 inner pattern
M8
F10 outer pattern
M10
F10 inner pattern
M10
F12 outer pattern
M12
F10 inner pattern
M10
F14 outer pattern
M16
F16 inner pattern
M20
F25* outer pattern 4x M16
4.5
10.5
10.5
21.0
21.0
34.5
21.0
90.0
170.0
90.0
5.0
12.5
12.5
24.5
24.5
43.0
24.5
104.0
204.0
104.0
1/4"-20
5/16"-18
5/16"-18
3/8"-16
3/8"-16
1/2"-13
3/8"-16
5/8"-11
3/4"-10
4x 5/8"-11
3.3
7.7
7.7
15.5
15.5
25.4
15.5
66.4
125.4
66.4
3.7
9.2
9.2
18.1
18.1
31.7
18.1
76.7
150.5
76.7
When required, mount or adjust the visual indicator (26).
Figure 17
Indicator Mounting
Size 40 - 600
Size 950- 1600
Indicator Mounting “In-line”
90°
90°
Indicator Mounting “Across Line”
Installation
23
Installation, Operation and Maintenance Manual
Section 4: Installation
April 2019
4.6
DOC.IOM.BQ.E Rev. 3
Mounting of Control Modules or Generic
Control and Feedback Accessories
The base Q-Series actuator can be equipped with dedicated Q-Series Control modules or
generic controls and accessories.
1.
2.
4.7
Control modules are shipped with the applicable installation guide. Please refer
to below documents when the Contorl module needs to be mounted to the base
Q-Series actuator.
——
QC41, QC42 or QC43:
Document DOC.IG.QC41.1.
——
QC40:Document DOC.IG.QC40.1.
——
QC54:Document DOC.IG.QC54.1.
Switch boxes or positioners can be mounted to the top mounting interface
(VDE/VDI3845 NAMUR).
Check the instructions as shipped with these components for installation,
operating and maintenance instructions. We recommend to test-cycle the
complete assembly to check correct operation.
Recommended Tubing Sizes
In case the solenoid valve is mounted remotely (i.e. in a central solenoid cabinet) and in
order to supply sufficient flow of air supply to the actuator, the following tubing sizes
are recommended.
Table 10.
Tubing Sizes
Actuator size
40, 65
100, 150, 200,
350, 600
950, 1600
24
Runs up to
1.2 meters
4 feet
Runs over to
1.2 meters
4 feet
6 mm
1/4 inch
6 mm
1/4 inch
6 mm
1/4 inch
8 mm
5/16 inch
6 mm
1/4 inch
10 mm
3/8 inch
Installation
Installation, Operation and Maintenance Manual
Section 5: Mechanical Stroke Adjustment
April 2019
DOC.IOM.BQ.E Rev. 3
Section 5: Mechanical Stroke Adjustment
This section explains:
•
What mechanical stroke adjustment is.
•
What the factory settings are.
•
How to adjust the travel stops.
Bettis Q-Series actuator sizes 40 to 1600 have two stroke adjustment stops for adjusting
accurately the stroke of the actuator/valve assembly in open and closed position.
The factory setting of the stroke is 90°. Most quarter-turn valve applications will not require
readjustment of these settings.
If required the stroke can be adjusted by means of two-stroke adjustment bolts.
Figure 18
Factory Setting
Limit Stop 1
Size 40 - 600
Closed
-5°
10°
Size 950 - 1600
Closed
-3°
10°
90°
90°
80°
80°
95°
Open
93°
Open
Mechanical Stroke Adjustment
Limit Stop 2
25
Section 5: Mechanical Stroke Adjustment
Installation, Operation and Maintenance Manual
April 2019
5.1
DOC.IOM.BQ.E Rev. 3
Travel Stop Adjustment
CAUTION: PRESSURIZED ACTUATOR
Do not turn out the travel stops completely when the actuator is pressurized.
When adjusting the travel stops and the actuator is still pressurized, the travel stops can be
“shot” away when completely turned out.
5.1.1
Double-Acting Actuators
1.
Operate valve/actuator assembly to the required "Closed" position.
2.
Remove air supply.
3.
Slacken locknut on the “Closed” stop (2).
Figure 19
Stop 1
Stop 2
Stop 1
Stop 2
A-port
B-port
26
4.
Turn the “closed” stop clockwise to reduce or counterclockwise to increase the
travel. Consult Section 5.1.3 (angular displacement of the pinion), to define how
far the limit stop must be turned in or out.
5.
Tighten the lock nut.
6.
Connect air and cycle the actuator to check that the position is correct.
If not repeat from 2.
7.
Remove air supply.
8.
For adjusting the open position repeat steps 1 to 7, but now for the open position
and “Open” stop (1).
Mechanical Stroke Adjustment
Installation, Operation and Maintenance Manual
Section 5: Mechanical Stroke Adjustment
April 2019
DOC.IOM.BQ.E Rev. 3
5.1.2
Spring-Return Actuators
1.
Connect air supply to the A port. Actuator will move to the open position.
2.
Slacken locknut (24) on the “Closed” stop (2).
Figure 20
Stop 1
Stop 2
Stop 1
Stop 2
A-port
B-port
3.
Turn the “Closed” stop clockwise to reduce or counterclockwise to increase the
travel. Consult Section 5.1.3 (angular displacement of the pinion), to define how
far the limit stop must be turned in or out.
4.
Remove air supply. Actuator will move to the closed position.
5.
Check whether the actuator valve assembly is in the required position.
If not repeat steps 1 to 5.
6.
Remove air supply.
7.
For adjusting the open position repeat steps 1 to 6, but now for the open position
and "Open" stop (1).
Table 11.
Limit Stop Dimensions
Actuator size
Thread
Bolt Wrench
size (mm)
Nut wrench
size (mm)
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
M8
M 10
M 10
M 10
M 12
M 16
M 20
M 22
M 24
13
17 (16)*
17 (16)*
17 (16)*
19 (18)*
24
30
12
14
13
17 (16)*
17 (16)*
17 (16)*
19 (18)*
24
30
32
36
1.
2.
Mechanical Stroke Adjustment
Default dimension according DIN933 standard.
Dimensions in brackets according ISO4017 standard.
27
Installation, Operation and Maintenance Manual
Section 5: Mechanical Stroke Adjustment
April 2019
5.1.3
DOC.IOM.BQ.E Rev. 3
Angular Displacement
Below table identifies, per actuator size, what the angular displacement of the pinions is,
when using the limit stop screws.
——
Turn the limit stop clockwise reduces the stroke.
——
Turn the limit stop counterclockwise to increase the stroke.
Table 12.
Angular Displacement Limit Stops
Actuator size Turns for 5° adjustment of the pinion: 360° revolution of limit stop screw will adjust
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
0.8
0.6
0.7
1.2
1.0
0.8
0.8
1.1
1.3
6.3°
8.3°
7.1°
4.2°
5.0°
6.3°
6.3°
4.7°
4.1°
NOTICE
In case of air leakage over the limit stop bolts, turn the lock nut of the limit stop bolts
tighter, until leakage stops.
28
Mechanical Stroke Adjustment
Installation, Operation and Maintenance Manual
Section 6: Maintenance
April 2019
DOC.IOM.BQ.E Rev. 3
Section 6: Maintenance
This section explains:
•
When and how to do maintenance to the base actuator.
——
Normal maintenance.
——
Extraordinary maintenance.
•
What to do when replacing springs.
•
What the availability is of spare parts, action conversion kits and temperature
conversion kits.
WARNING
Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.
Before mounting or (dis)assembling the actuator, consult the relevant sections of this manual.
6.1
Normal Maintenance
Bettis Q-Series actuators are designed to operate without maintenance for their normal
working life. Normal working life is 500,000 cycles* for sizes up to Q1600.
NOTE:
*Cycles = one open stroke and one close stroke.
We recommend regular inspections to make certain that the actuator / valve assembly
operates smoothly and to check that there are no visible or audible defects. We advise to
perform the following checks upon each proof test interval complying with the rules and
regulations of the country of final installation:
Maintenance
•
Visually check the entire actuator as well as the control system (where foreseen).
•
Ensure there are no leaks on the actuator parts under pressure.
•
Check pneumatic connections for leaks. Tighten tube fittings as required.
•
Check if manual override (where foreseen) is regular.
•
Check if pneumatic filter cartridge (where foreseen) is sound and filter bowl
(where foreseen) has been cleaned properly.
•
Check the setting of the relief valves (where foreseen).
•
Verify that the power fluid supply pressure value is within the required range.
•
Remove built-up dust and dirt from all actuator surfaces.
•
Inspect actuator paint work for damages to ensure continued corrosion protection.
Touch-up as required in accordance with the applicable paint specification.
29
Installation, Operation and Maintenance Manual
Section 6: Maintenance
April 2019
DOC.IOM.BQ.E Rev. 3
•
Operate the Actuator/Valve assembly for 2 complete open/close cycles with complete closing of the valve.
•
Verify the correct performing of open – close operations (e.g. check locally,
or automatically via Logic solver, the correct movement of the actuator).
All actuators are supplied with sufficient lubrication for their normal working life.
If required, see Section 9.1 (Grease instructions) for the recommended grease.
For mounting the parts of the repair kit follow the instruction of the Decommission,
Disassembly and Reassembly sections of this manual.
6.2
Inspection and Repair
Replacement of internal seals and bearings allows to you extend the normal working
life. Service kits, containing all necessary spare parts (like seals, bearings, grease and
instructions) can be obtained through authorized Emerson – Actuation Technologies
distributors.
6.2.1
Service Kits
All soft seals, bearings, and nonreusable parts are included in the recommended service
kit. The service kit is identical for both the double-acting and the spring-return models.
6.2.2
Spring-Return Actuator
For the spring-return models, we recommend a set of spare springs for each different
model in addition to the recommended spare parts kit.
On spring-return actuators, the spring cartridges can be replaced. SPRING CARTRIDGES
SHOULD ALWAYS BE REPLACED IN COMPLETE SETS. Spring kits are available through
authorized Emerson – Actuation Technologies distributors.
30
Maintenance
Installation, Operation and Maintenance Manual
Section 7: Decommission (Out of Service)
April 2019
DOC.IOM.BQ.E Rev. 3
Section 7: Decommission (Out of Service)
This section explains:
•
7.1
How to decommission an actuator in a safe way.
Before You Start
WARNING: MOVING PARTS
Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.
Before mounting or (dis)assembling the actuator consult the relevant sections of this manual.
Actuator can move when removing supply pressure and/or electrical control signal of
actuators. If not already there, a spring-return actuator will cycle to its fail position.
When removing any ball valve or plug valve assemblies from a pipe system, isolate the
piping system on which the Actuator is installed and relieve any media pressure that may
be trapped in the valve cavities before removing the actuator for maintenance.
A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a
high spring load which will cause a sudden rotation of the actuator versus the valve or
valve bracket during disassembly. This can cause serious injury to personnel or damage
to property.
Refer to Appendix A for instructions to safely remove the spring load before disassembling
the spring-return actuator from valve or bracket.
Important
Refer to the Safety Guide for Lifting Instructions.
Decommission (Out of Service)
31
Installation, Operation and Maintenance Manual
Section 7: Decommission (Out of Service)
April 2019
7.2
DOC.IOM.BQ.E Rev. 3
Removing the Actuator from the Valve
1.
Disconnect all air supply hoses from the control module.
2.
Disconnect all electrical wirings from the Control module.
3.
Remove the bolts and nuts from the valve flange.
4.
Remove the bracket from the actuator.
5.
Remove the the Control Module. Refer to the applicable installation guide of the
mounted Control module:
QC41, QC42 or QC43: Document DOC.IG.BQC41.1.
QC40: Document DOC.IG.BQC40.1.
QC54: Document DOC.IG.BQC54.1.
Figure 21
Removing Actuator from Valve
1
2
4
3
6
5
32
Decommission (Out of Service)
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
DOC.IOM.BQ.E Rev. 3
Section 8: Disassembly
This section explains:
•
How to disassemble an actuator safely.
Tip
The instructions of this section can be used for maintenance or reconfiguration like spring
set change or maintenance.
Reference numbers for components refer to the exploded view in Section 11.
In case of maintenance, discard all the used soft parts like O-ring seals, guide bands,
wear strips and circlip.
WARNING
Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.
Before mounting or (dis)assembling the actuator consult the relevant sections of this manual.
CAUTION: SPRING FORCE
Spring-return actuators contain springs in a compressed state. Follow these instructions to
release the spring force safely.
The end caps of spring-return actuators sizes 40 to 600 should be free of the spring load
after 10 full turns (crosswise relaxing) of the end cap screws. If there is still spring load on
the end cap, this might indicate a broken spring cartridge. Stop this disassembly procedure
immediately. Continuing might cause the end cap to be “shot” away causing serious injury.
Spring return actuator size 950 to 1600 have long end cap screws to release the spring load
safely.
Refer to Appendix A for instructions to safely remove the spring load before disassembling
the end cap of a spring-return actuator with a broken spring cartridge.
NOTICE
The actuator is designed to be installed, commissioned and maintained using generic tools
like wrenches, Allen keys and screwdrivers.
Refer to the tables in this section or refer to appendix B Tool and Torque tables.
Disassembly
33
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
8.1
DOC.IOM.BQ.E Rev. 3
Removing End Caps (Size 40 to 600)
1.
For Double-acting actuators, do the following:
a.
Remove the screws (8) and washers (10) of the end caps (6).
b.
Remove the o-ring (11) and "B" port seal (2). Discard these parts.
Figure 22
Double-Acting End Caps Removal
11
6
11
8
10
8
10
2
6
6
2
5
Double-Acting end caps (6) are fitted with a white warning sticker. Spring-Return end
caps (5) are fitted with a black warning sticker.
Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models.
Actuator sizes 150 to 1600 have low end caps for double-acting models and high end
caps for spring-return models.
34
Disassembly
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
DOC.IOM.BQ.E Rev. 3
2.
For Spring-return actuators, do the following:
a.
Tip: For actuators with assembly code CW, turn back the right hand limit
stop screw (30) 2 full turns.
For actuators with assembly code CC, turn back the left hand limit stop
screw (30) 2 full turns.
This will lower the spring force on the end cap and reduces the screw out
length of the end cap screws.
b.
Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a
time, in sequence, as per Figure 23, to relieve the pre-load of the springs.
c.
Remove the o-rings (11) and "B" port seals (2). Discard these parts.
Figure 23
Spring-Return End Caps Removal
5
30
11
10
9
10
5
9
11
3
2
2
2
1
4
Disassembly
35
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
8.2
DOC.IOM.BQ.E Rev. 3
Removing End Caps (Size 950 to 1600)
1.
For Double-acting actuators, do the following:
a.
Remove the screws (8) and washers (10) of the end caps (6).
b.
Remove the o-ring (11) and "B" port seal (2). Discard these parts.
Figure 24
Double-Acting End Caps Removal Size 950 to 1600
11
6
11
10
8
8
10
6
2
2
2.
For Spring-return actuators, do the following:
a.
Tip: For actuators with assembly code CW, turn back the right hand limit
stop screw (30) 2 full turns.
For actuators with assembly code CC, turn back the left hand limit stop
screw (30) 2 full turns.
This will lower the spring force on the end cap and reduces the screw out
length of the end cap screws.
b.
Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a
time, in sequence, as per Figure 25, to relieve the pre-load of the springs.
c.
Remove the o-rings (11) and "B" port seals (2). Discard these parts.
Figure 25
Spring-Return End Caps Removal Size 950 to 1600
5
10
11
5
11
9
10
3
9
2
6
30
5
1
4
36
2
2
Disassembly
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
DOC.IOM.BQ.E Rev. 3
8.3
Removing Spring Cartridges or Springs
1.
Remove the spring cartridges or springs (7).
Figure 26
Removing Spring Cartridges Size 40 to 600
7
7
Figure 27
Removing Springs Size 950 to 1600
7
7
Disassembly
37
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
8.4
DOC.IOM.BQ.E Rev. 3
Removing of Limit Stop Screws
1.
Remove the limit stop screws (30), limit stop nuts (31), limit stop washers (32) and
limit stop o-rings (33). Discard the o-rings.
Figure 28
Limit Stop Removal
33
8.5
32
31 30
Removing Pistons
1.
Use a wrench and turn the pinion counterclockwise until the pistons (14) come out
of the body.
2.
Remove the piston bearings (15), piston rack bearing strips (17) and piston o-ring
seals (16). Discard these parts.
Figure 29
Removing Pistons
14
16
17
15
16
15
14
17
38
Disassembly
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
DOC.IOM.BQ.E Rev. 3
8.6
Removing Pinion
1.
Remove the circlip (27) and thrust bearing (23) on top of the pinion assembly.
For sizes 950 to 1600 remove also the top pinion bearing (19).
2.
Remove the pinion (18) by pushing it downwards.
3.
Remove the pinion O-ring seals (21/22) and the pinion bearings (19/20).
For Size 950 to 1600, remove also the backup ring (29).
4.
Discard all of these parts.
Figure 30
Pinion Removal
Sizes 40 to 600
19
19
27
21
23
21
18
Sizes 950 and 1600
23
27 19
Table 13.
Actuator
size
40 - 100
150 - 350
600
Disassembly
22
21
29
18
19
20
Recommended circlip pliers according DIN 5254 (or equal) for shaft circlip
Pinion top
diameter
22 mm
36 mm
55 mm
0.866"
1.417"
2.165"
Pliers according Actuator
DIN 5254
size
A2
A3
A3
950
1600
Pinion top
diameter
65 mm
75 mm
2.559"
2.953"
Pliers according
DIN 5254
A3
A3
39
Installation, Operation and Maintenance Manual
Section 8: Disassembly
April 2019
8.7
DOC.IOM.BQ.E Rev. 3
Cleaning the Components
In case of maintenance, use a clean dry cloth and thoroughly wipe clean and remove old
grease from:
40
•
The inside and outside of the body including thread holes and crevices/grooves.
•
The pinion gears.
•
The pistons.
Disassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
Section 9: Reassembly
This section explains:
•
Which parts and how to grease them.
•
How to reassemble a complete actuator.
•
How to set the stroke adjustment bolts after reassembly.
•
How to do a basic function and air leak test.
Tip
The instructions of this section can be used for maintenance or reconfiguration like spring
set change or maintenance.
Reference numbers for components refer to the exploded view in Section 11.
In case of maintenance, discard all used soft parts like O-ring seals, guide bands and wear
strips and circlip and replace them with the parts as supplied in the repair kit.
In case of reconfiguration replace the parts as supplied in the conversion kit
(see also Section 6).
Refer to the Safety Guide for Lifting Instructions.
NOTICE
The actuator is designed to be installed, commissioned and maintained using generic tools
like wrenches, Allen keys and screwdrivers.
Refer to the tables in this section or refer to Appendix B Tool and Torque tables.
Reassembly
41
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.1
DOC.IOM.BQ.E Rev. 3
Grease Instructions
Check the product coding on the product labels and Section 3 of this manual, to define
which type of grease to use.
Table 14.
Recommended greases
Standard temperature:
-20°C to +80°C / -4°F to +176°F
- Castrol High Temperature -Formerly called Castrol LMX
- Rocol Sapphire Premier - Formerly called Sapphire HI-TEMP 2
- Castrol Spheerol EPL 2 - Formerly called BP Energrease LS-EP2
- Total Ceran XM 220
- Formerly called Total Ceran WR2
We recommend using a suitable sized paint brush to apply the required amount of grease
on the parts as per Table 15 and Figure 31.
Table 15.
Grease Instruction
Part
O-rings:
A
B
C
D
E
F
G
H
J
K
L
M
N
Housing Parts:
Piston Parts:
Piston Parts:
Figure 31
Section of part
Amount of grease
Completely
Piston bore
Top pinion bore
Bottom pinion bore
O-ring & bearing groove
Rack teeth
Piston bearing
Piston rack bearing strip
Pinion bottom & O-ring groove
Pinion top & O-ring groove
Gear teeth
Pinion top bearing
Pinion bottom bearing
Light film
Light film
Light film
Light film
Light film
Half the teeth depth full with grease
Light film on outside
Light film
Light film
Light film
Half the teeth depth
Light film (inside and out)
Light film (inside and out)
Grease Instructions
A
C
G
A
E
A
E
F
H
A
G
H
D
F B
M
A
A
K
L
J
42
N
A
Reassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
9.2
Reassembly of the Pinion
1.
Grease the pinion parts according to Section 9.1.
2.
Install the pinion bearings (19/20) and the O-ring seals (21/22) on the pinion (18).
For Size 950 to 1600, install also the the backup ring (29).
3.
Insert the pinion (18) in the housing.
4.
For sizes 950 to 1600 install first the top pinion bearing (19). For all sizes, install
the thrust washer (23) and mount the circlip (27) on the pinion top.
——
Figure 32
Install the new circlip onto its mating groove on the top shaft extension
and with the non-sharp edge (2) towards the housing and the sharp edge
(1) towards the top of the shaft.
Reassemble the Pinion
Sizes 40 to 600
1
19
2
19
23
27
21
21
18
Sizes 950 and 1600
1
2
23
29
19
Table 16.
Actuator
size
40 - 100
150 - 350
600
Reassembly
22
21
18
19
20
Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips
Pinion top
diameter
22 mm
36 mm
55 mm
0.866"
1.417"
2.165"
Pliers according Actuator
DIN 5254
size
A2
A3
A3
950
1600
Pinion top
diameter
65 mm
75 mm
2.559"
2.953"
Pliers according
DIN 5254
A3
A3
43
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.3
DOC.IOM.BQ.E Rev. 3
Reassembly of the Pistons
NOTICE
Before reassembling the pistons, check the required assembly code (see Section 4.4).
1.
Grease the piston parts according to step 9.1.
2.
Install the piston rack bearing strips (17) and piston O-ring seals (16) on the
pistons (14). Ensure all these parts are kept in place during assembly.
Figure 33
Reassemble the Pistons
14
16
17
16
14
17
15
15
3.
4.
5.
Before aligning the pinion and pistons, verify the actuator size and the location
of the limit stop screws (D), see Figure 34. Align the pinion so that the teeth on
the pinion will pick up the pistons rack teeth when turning the pinion. Note the
position of the pinion top slot and the cam on the pinion top:
——
For standard or Spring-to-Close: Assembly Code CW.
——
For reverse or Spring-to-Open: Assembly Code CC.
Slightly push the pinion inward to engage with the pinion.
——
Ensure that smooth movement and 90-degree operation can occur without moving the pistons out of the actuator body.
——
For larger pistons, use a rubber mallet and slightly hitting the pistons
inward to engage with the pinion.
When the pistons are moved 90° inwards (see Figure 34), check that the pinion
slot on the pinion top is:
——
Perpendicular to the length centre line of the house for assembly code CW.
——
In line to the length centre line of the house for assembly code CC.
6.
If not, turn pinion to move the pistons outward until they disengage from the
pinion. Shift one tooth of the pinion, reassemble and check again.
7.
Move the pistons outward so that just the bearing groove sticks out of the
housing. Fold the piston bearings (15) around the piston and hold the bearing
ends in place while moving the pistons inwards.
——
44
For larger pistons, use a rubber mallet and slightly hitting the pistons
inward to engage with the pinion.
Reassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
Figure 34
Position of the Slot and the Cam on the Pinion Top
Assembly code CW
(Standard; Spring-to-Close)
Sizes Q40 to Q100
Assembly code CC
(Reverse; Spring-to-Open)
D
D
90°
A
B
B
A
90°
C
C
Sizes Q150 to Q1600
A
B
A
B
D
D
90°
90°
C
C
A = Position of cam
C = Final position of pinion dot
B = Position of slot and dot in pinion
D = Position of limit stop screws
NOTE:
When the pistons are completely moved inwards, the pinion top will show a 5° over travel.
Reassembly
45
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.4
DOC.IOM.BQ.E Rev. 3
Reassembly and Settings of the Limit Stops
1.
Install the limit stop screws (30), limit stop nuts (31), limit stop washers (32) and
limit stop O-rings (33).
Figure 35
Install Limit Stop Bolts
33
31 30
2.
Move the pistons inward until the slot in the top of the pinion is pendicular to
centerline of the housing.
3.
Double check if the position of the slot and the cam on the pinion top is in the
correct position (see Figure 34). Screw in the right hand travel stop until it comes
into contact with the pinion stop face.
4.
Move the pistons outward until the slot in the top of the pinion is in line with the
centerline of the housing.
5.
Screw in the left hand travel stop until it comes into contact with the pinion
stop face.
——
46
32
For accurate travel stop adjustment of the actuator on the valve,
see Section 5.
Reassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
9.5
Reassembly of the End Caps
9.5.1
Double-Acting Actuators
1.
Grease the O-ring seals (11) and B port seals (2) according to step 9.1.
2.
Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.
3.
Install the end caps (6) and tighten the end cap screws (8).
Refer to Table 17 for the correct torque.
Figure 36
Double-Acting End Cap Assembly
11
6
11
8
10
8
10
2
6
2
6
5
Double acting end caps (6) are fitted with a white warning sticker. Spring return end
caps (5) are fitted with a black warning sticker.
Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models.
Actuator sizes 150 to 1600 have low end caps for double-acting models and high end
caps for spring return models.
Table 17.
End Cap Screw Torque
Actuator
Thread
size
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
Reassembly
M5
M5
M5
M6
M6
M8
M10
M12
M12
Tool
Size
Allen Key
SW 4
SW 4
SW 4
SW 5
SW 5
SW 6
SW 8
SW10
SW10
Torque (Nm)
Torque (lbf.ft)
Target Min. Max. Target Min. Max.
2.0
2.0
2.0
3.3
3.3
8.4
15.3
24.3
24.3
1.6
1.6
1.6
2.6
2.6
6.7
12.2
19.4
19.4
3.0
3.0
3.0
5.1
5.1
12.2
24.8
41.6
41.6
1.5
1.5
1.5
2.4
2.4
6.2
11.3
17.9
17.9
1.2
1.2
1.2
1.9
1.9
4.9
9.0
14.3
14.3
2.2
2.2
2.2
3.8
3.8
9.0
18.3
30.7
30.7
47
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.5.2
DOC.IOM.BQ.E Rev. 3
Spring-Return Actuators (Size 40 to 600)
Important
Bettis Q-Series Spring return actuators are supplied with springs on each side of the
actuator. Throughout the Q-Series size range, there are three different spring designs:
——
Sizes Q40 to Q600 have 6 springs on each side (see Figure 37).
——
Sizes Q950 to Q1600 have 3 springs on each side (see Section 9.5.3).
Check below figures to see where to place the spring cartridges in case of spring set conversion.
When replacing spring cartridges in a spring-return actuator, ensure that the cartridges are
replaced in their identical position from where they were removed.
Before assembling the spring cartridges and end caps, make sure that the pistons are
completely inwards.
Figure 37
Spring Placement Size 40 to 600
6
2
5
3
6
1
4
3
6
N = 20
5
1
2
5
6
N = 10
4
3
6
2
3
1
4
3
A
N = 30
4
N = 60
5
1
N = 50
2
4
6
5
1
2
N = 40
5
2
1
4
3
B
A = Piston top view
B = Position of piston gear rack
48
Reassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
1.
Grease the O-ring seals (11) and B port seals (2) according to step 9.1.
2.
Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.
3.
Place the spring cartridges in actuator as per required spring set (see Figure 37).
4.
Put the end cap screw washer (10) on the end cap screw (9) and tighten each end
cap screw in small equal turns and in the sequence as per Figure 38. Refer to Table
17 for the correct torque. We recommend to use some grease on the screws for
easier fastening.
Figure 38
Spring-Return End Cap Assembly Size 40 to 600
30
10
5
11
5
10
9
11
9
3
2
2
2
1
4
Reassembly
49
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.5.3
DOC.IOM.BQ.E Rev. 3
Spring-Return Actuators (Size 950 to 1600)
Important
Bettis Q-Series Spring return actuators are supplied with springs on each side of the
actuator. Throughout the Q-Series size range, there are three different spring designs:
——
Sizes 40 to 600 have 6 springs on each side (Section 9.5.2).
——
Sizes 950 to 1600 have 3 springs on each side (see Figure 39).
Check below figures to see where to place the springs in case of spring set conversion.
When replacing springs in a spring-return actuator, ensure that the springs are replaced in
their identical position from where they were removed.
Before assembling the springs and end caps, make sure that the pistons are completely inwards.
Figure 39
Spring Placement Size 950 and 1600
N = 10
N = 20
N = 30
Left
Right
Left
Right
Left
1 spring
0 spring
1 spring
1 spring
2 springs
Right
B
A
N = 40
Left
Right
2 springs
2 springs
N = 50
Left
3 springs
Right
2 springs
1 spring
N = 60
Left
Right
3 springs
3 springs
A = Piston top view
B = Position of piston gear rack
50
Reassembly
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
DOC.IOM.BQ.E Rev. 3
1.
Grease the O-ring seals (11) and B port seals (2) according to step 9.1.
2.
Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.
3.
Place the spring in actuator as per required spring set (see Figure 39).
4.
Put the end cap screw washer (10) on the end cap screw (9) and tighten each end
cap screw in small equal turns and in the sequence as per Figure 40.
Refer to Table 17 for the correct torque. We recommend to use some grease on
the screws for easier fastening.
Figure 40
Spring-Return End Cap Assembly Size 950 to 1600
5
10
11
5
11
9
10
3
9
2
6
30
5
1
4
Reassembly
2
2
51
Installation, Operation and Maintenance Manual
Section 9: Reassembly
April 2019
9.6
DOC.IOM.BQ.E Rev. 3
Basic Function and Air Leak Test
CAUTION: MOVING PARTS
Applying pressure to the actuator will cause the actuator/valve assembly to operate.
1.
Apply pressure (max. 8 bar/120 psi) to ports A and B. Use some soap suds at the
indicated points: around pinion top (1), pinion bottom (2), the end caps (3) and
limit stops (4).
2.
In case of leakage around:
a.
The limit stop bolts: Turn the lock nut of the bolts tighter,
until the leakage stops.
b.
The end caps: Disassemble the end caps, replace o-rings and reassemble.
c.
The pinion top or bottom and A- or B- port: Disassemble the complete
actuator, replace o-rings and reassemble.
Figure 41
Basic Function and Air Leak Test
1
4
3
3
A
B
A
B
2
52
Reassembly
Installation, Operation and Maintenance Manual
Section 10: Troubleshooting
April 2019
DOC.IOM.BQ.E Rev. 3
Section 10:
10.1
Troubleshooting
Mechanical Problems
Problem
Possible error
Feedback position and
actual position are not
the same.
Actuator and valve are
mounted 90° rotated in
Valve is in “Closed”
relation to each other.
position, actuator is in
“Open” position and will
not move anymore.
Limit stop screws are not
set correctly.
Insert is not mounted
properly.
Valve does not reach the
completely “Closed” or
“Open” position.
Pressure to low.
Sizing is wrong.
Actuator rotates, valve
does not.
Pinion is mounted in the
wrong position.
No coupling between
actuator shaft and valve
spindle.
Broken gearing on
pistons or pinion.
Actuator does not
rotate or does not rotate
smoothly.
Spring or Spring
cartridge is broken.
Limit stop screws cannot Limit stop screws is
be turned out anymore. bend.
Troubleshooting
Solution
Where to find
Remove actuator from
valve. Check assembly code
of actuator. Put both valve
Section 4
and actuator in “Closed”
position. Mount actuator on
valve.
Readjust the limit stop
screws.
Section 5
Mount the insert in the right
position. Remark: Rotate
Section 4.5
insert to one cam = 22.5°.
Apply pressure as per sizing.
Check valve torque data
with actuator torque data.
Re assemble actuator.
Install a coupling between
actuator shaft and valve
spindle.
Contact nearest Bettis
representative to replace
actuator.
Contact nearest Bettis
representative to replace
actuator.
Contact nearest Bettis
representative to replace
actuator.
Section 9
Section 4.5
Appendix A.
53
Section 10: Troubleshooting
Installation, Operation and Maintenance Manual
April 2019
10.2
DOC.IOM.BQ.E Rev. 3
Pneumatic Problems
Problem
Possible error
Actuator does not react There is no supply
to electrical control
pressure at the
signal.
actuator.
There is sufficient
supply air pressure but
insufficient supply air
capacity.
Solution
Where to find
Supply the right
pressure to the
actuator.
Section 2.3
Check that the actual
supply pressure is
higher than the sizing
pressure.
Take care the supply
air tubing has the right
dimensions.
Section 4.6
Check that supply
Supply pressure too
pressure at the
low, causing pilot
actuator and solenoid
operated solenoid valve
is sufficient to operate
to fail.
Actuator does not
the actuator.
react good to electrical
Solenoid valve is not
Check the solenoid
control signal.
mounted properly.
valve mounting.
Speed control throttle Turn the speed control
(if present) blocks air
more open.
flow.
Manual override
Unlock manual override
(if present) on the
on the solenoid valve.
Solenoid Valve is
locked.
Air leakage between
Sealing between
Reassemble solenoid
actuator and solenoid solenoid valve and
valve taking care, that
valve.
actuator is not
all seals are in place.
mounted air tight.
Double-acting actuator Actuator has wrong
will only move to
solenoid valve
“open” position.
configuration.
Section 2.3
Check that the actual
supply pressure is
higher than the sizing
pressure.
Instructions shipped
with the solenoid valve.
Instructions shipped
with the speed control
valve.
Instructions shipped
with the manual
override.
Instructions shipped
with the solenoid valve.
Mount a solenoid valve
suitable for doubleInstructions shipped
acting actuators
with the solenoid valve.
(4/2 or 5/2 function).
Check that conversion
plate on solenoids, that
Instructions shipped
have both 3/2 and 5/2
with the solenoid valve.
functions, is in the right
position.
Turn the lock nut of the
Seals on the limit stops
bolts tighter; until the Section 9.6
screws are not air tight.
leakage stops.
Leakage notice on the
actuator.
Seals on the end caps
are not air tight.
Seals on the pinion top
and bottom are not air
tight.
54
Disassemble the end
caps, replace O-rings
and reassemble.
Consider to replace
all O-ring seals and
bearings.
Disassemble the
complete actuator,
replace O-rings and
reassemble. Consider
to replace all O-ring
seals and bearings.
Section 9.6 or Section 6
Section 9.6 or Section 6
Troubleshooting
Installation, Operation and Maintenance Manual
Section 10: Troubleshooting
April 2019
DOC.IOM.BQ.E Rev. 3
10.3
Electrical Problems
Problem
Possible error
Control wiring. Power
supply wiring or
feedback wiring are not
right connected.
Actuator does not react
The power supply
to control signals.
voltage is not is not the
same as the voltage of
the applicable solenoid
valve.
There are problems
with position feedback
The wiring of the
after sending the
feedback signals may
actuator to either the
be switched.
“Open” or “Closed”
position.
Troubleshooting
Solution
Where to find
Connect all wiring in
the right way.
Instructions of the
control or feedback
accessories.
Connect the right
power supply voltage.
Instructions of the
solenoid valve.
Connect the feedback
wiring in the right way.
Instructions of the
feedback device.
55
Section 11: Parts List and Spare Parts
Installation, Operation and Maintenance Manual
April 2019
DOC.IOM.BQ.E Rev. 3
Section 11: Parts List and Spare Parts Recommendations
11.1
Actuator Size Q40 to Q600
23 27 26
18 19 21
6
12
29 30 31 32
14 16 15
1
8
10
5
17
19
13
21
9
10
3
2
28
Pos.
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
23
26
27
28
30
31
32
33
Qty
1
2
1
2
2
Max. 12
8
8
8
2
2
2
2
2
2
2
2
2
2
1
1
1
1
2
2
2
2
Notes Description
1
2
2
1
1
1
1
1
1
1
1
1
1
House
B-port seal
Center plate (option)
End cap SR (DA)
End cap DA
Spring cartridge
End cap screw DA
End cap screw SR
End cap screw washer
O-ring end cap
Warning sticker DA
Warning sticker SR
Piston
Bearing piston
O-ring piston
Bearing strip piston rack
Pinion
Bearing pinion
O-ring pinion
Thrust bearing pinion
Indicator assembly
Circlip
Drive insert
Limit stop screw
Limit stop nut
Limit stop washer
O-ring limit stop
11
7
Material
Cast Aluminium alloy
Nitrile rubber
Nylon PA6, Black
Cast Aluminium alloy
Cast Aluminium alloy
Spring steel
Stainless Steel
Stainless Steel
Stainless Steel
Nitrile rubber
Polyester
Polyester
Cast Aluminium alloy
PTFE 25% carbon-filled
Nitrile rubber
POM
High grade aluminium
POM
Nitrile rubber
POM, black UV stabilized
ABS + stainless steel screw
Spring steel
Aluminium
Stainless steel
Stainless steel
PA66
Nitrile rubber
Notes:
1 Included in Service Kit.
2 Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models. Actuator sizes
150 to 1600 have low end caps for double-acting models and high end caps for spring-return models.
56
Parts List and Spare Parts
Installation, Operation and Maintenance Manual
Section 11: Parts List and Spare Parts
April 2019
DOC.IOM.BQ.E Rev. 3
11.2
Actuator Size Q950 to Q1600
19
26
6
27
1
8
23
32
33
29
31
12
21
30
15
18
9
10
5
13
3
4
28
Pos. Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
26
27
28
29
30
31
32
33
1
2
1
12
2
2
Max. 6
12
12
12
2
2
2
2
2
2
2
1
2
1
1
1
1
1
1
1
1
2
2
2
2
2
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
House
B-port seal
Center plate (option)
Thread insert
End cap SR
End cap DA
Springs
End cap screw DA
End cap screw SR
End cap screw washer
O-ring end cap
Warning sticker DA
Warning sticker SR
Piston
Bearing piston
O-ring piston
Bearing strip piston rack
Pinion
Bearing pinion top
Bearing pinion bottom
O-ring pinion top
O-ring pinion bottom
Thrust bearing pinion
Indicator assembly
Circlip
Drive insert
Backup ring
Limit stop screw
Limit stop nut
Limit stop washer
O-ring limit stop
11
7
Material
Cast Aluminium alloy
Nitrile rubber
Nylon PA6, Black
Steel
Cast Aluminium alloy
Cast Aluminium alloy
Spring steel
Stainless Steel
Stainless Steel
Stainless Steel
Nitrile rubber
Polyester
Polyester
Cast Aluminium alloy
PTFE 25% carbon-filled
Nitrile rubber
POM
High grade aluminium
POM
POM
Nitrile rubber
Nitrile rubber
POM, black UV stabilized
ABS + stainless steel screw
Spring steel
Aluminium
POM
Stainless steel
Stainless steel
PA66
Nitrile rubber
Notes:
1 Included in Service Kit.
Parts List and Spare Parts
57
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
Appendix A: Spring Load Removal
This section explains:
•
How to remove the spring load safely of spring-return actuators in case:
——
The valve gets “stuck” in mid position.
——
One of the spring cartridges is broken.
WARNING: MOVING PARTS
A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high
spring load which will cause a sudden rotation of the actuator versus the valve during
disassembly. This can cause serious injury to personnel or damage to material.
On spring-return actuators with a broken spring cartridge, the end cap can be “shot” away
during disassembly of the actuator. This can cause serious injury to personnel or damage
to material.
A.1
Spring Load Relief
CAUTION: ROTATING ACTUATOR
In case of an actuator/valve assembly “stuck” in mid position, leave the actuator on the
valve and/or mounting bracket during this procedure.
Figure A-1
Spring Load Removal
WARNING
3
Crush / Amputaion Hazard
2
Failure to follow instructions
for removal of spring loaded
actuator may result in
surious personal injury
1
4
58
Appendix
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
1.
Depressurize the actuator completely.
2.
Based on the actuator size, choose the correct threaded rod kit from Table A-1.
3.
Replace one by one each end cap screw for the threaded rod kit and turn down the
adjusting nut until it touches the end cap.
4.
Once all for end cap screws have been replaced, gradually turn the adjustment nuts
on threaded rod in CCW direction by turning the nuts half turn at a time. Make sure
the rod itself does not turn. Continue this until the load of springs are relieved.
5.
Repeat the same procedure for the end cap screws on the other size of the
actuator as shown in Figure A-1.
6.
In case of an actuator/valve assembly “stuck” in mid position: The actuator now
can be disassembled from Valve, by removing the mounting studs/bolts.
Table A-1.
Threaded Rod Dimensions in mm
Actuator Size
Thread
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
M5
M5
M5
M6
M6
M8
M10
M12
M12
Figure A-2
Threaded rod length
(mm)
(inch)
140
140
140
145
145
185
185
498
498
5.5
5.5
5.5
5.7
5.7
7.3
7.3
19.6
19.6
Spring Load Removal Rod Dimensions
Length
Thread
Washer
Threaded Rod
Appendix
Holding nuts
Adjusting nut
59
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
Appendix B: Tool & Torque Table
This section explains:
•
Which tools to use for the indicated fasteners.
•
The recommended amount of torque to apply on the indicated fasteners.
Table B-1.
End Cap Bolts
Actuator
Thread
size
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
M5
M5
M5
M6
M6
M8
M10
M12
M12
Table B-2.
Actuator
size
40, 65, 100
150, 200, 350
600
950
1600
Tool
Size
Allen Key
SW 4
SW 4
SW 4
SW 5
SW 5
SW 6
SW 8
SW10
SW10
Torque (Nm)
Torque (lbf.ft)
Target Min. Max. Target Min. Max.
2.0
2.0
2.0
3.3
3.3
8.4
15.3
24.3
24.3
1.6
1.6
1.6
2.6
2.6
6.7
12.2
19.4
19.4
3.0
3.0
3.0
5.1
5.1
12.2
24.8
41.6
41.6
1.5
1.5
1.5
2.4
2.4
6.2
11.3
17.9
17.9
1.2
1.2
1.2
1.9
1.9
4.9
9.0
14.3
14.3
2.2
2.2
2.2
3.8
3.8
9.0
18.3
30.7
30.7
Bottom Flange, Metric Units
ISO Pattern
Metric
Thread
F05 inner pattern
F07 outer pattern
F07 inner pattern
F10 outer pattern
F10 inner pattern
F12 outer pattern
F10 inner pattern
F14 outer pattern
F16 inner pattern
F25* outer pattern
M6
M8
M8
M10
M10
M12
M10
M16
M20
4x M16
Torque (Nm)
Min.
Max.
Imperial
Thread
Torque (lbf.ft)
Min.
Max.
4.5
10.5
10.5
21.0
21.0
34.5
21.0
90.0
170.0
90.0
1/4"-20
5/16"-18
5/16"-18
3/8"-16
3/8"-16
1/2"-13
3/8"-16
5/8"-11
3/4"-10
4x 5/8"-11
3.3
7.7
7.7
15.5
15.5
25.4
15.5
66.4
125.4
66.4
5.0
12.5
12.5
24.5
24.5
43.0
24.5
104.0
204.0
104.0
3.7
9.2
9.2
18.1
18.1
31.7
18.1
76.7
150.5
76.7
1. Actuator size 1600 has only 4 holes of the ISO5211 F25 drilling pattern are available.
Table B-3.
Adaptation Plate
Metric
Thread
Flange
Torque (Nm)
Min.
Max.
Imperial
Thread
Torque (lbf.ft)
Min.
Max.
Solenoid flange screw threads
M5
2.0
3.0
10-24UNC
1.5
2.2
Top flange screw threads
M5
2.0
3.0
10-24UNC
1.5
2.2
Table B-4.
Limit Stop Screws
Actuator size
Thread
Bolt Wrench
size (mm)
Nut wrench
size (mm)
40
65
100
150
200
350
600
950
1600
M8
M 10
M 10
M 10
M 12
M 16
M 20
M 22
M 24
13
17 (16)1
17 (16)1
17 (16)1
19 (18)1
24
30
12
14
13
17 (16)1
17 (16)1
17 (16)1
19 (18)1
24
30
32
36
1. Default dimension according DIN933 standard
2. Dimensions in brackets according ISO4017 standard
60
Appendix
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
Table B-5.
Recommended circlip pliers according DIN 5254 (or equal)
for shaft circlips
Actuator size
Q40 - Q100
Q150 - Q350
Q600
Q 950
Q 1600
Table B-6.
Appendix
Pinion top diameter
22 mm
36 mm
55 mm
65 mm
75 mm
Pliers
according DIN
0.866"
1.417"
2.165"
2.559"
2.953"
A2
A3
A3
A3
A3
Angular Displacement Limit Stops
Actuator size
Turns for 5°
adjustment of the pinion:
360° revolution of
limit stop screw will adjust
Q 40
Q 65
Q 100
Q 150
Q 200
Q 350
Q 600
Q 950
Q 1600
0.8
0.6
0.7
1.2
1
0.8
0.8
1.1
1.3
6.3°
8.3°
7.1°
4.2°
5.0°
6.3°
6.3°
4.7°
4.1°
61
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
Appendix C: Full Stroke Adjustment Option
This section explains:
C.1
•
How to mount the Full Stroke Adjustment option to an actuator.
•
How to adjust the Full Stroke Adjustment option to a required rotation angle.
Full Stroke Adjustment Option
The Full Stroke Adjustment option is available as a complete actuator or as an end cap
conversion kit in order to upgrade a standard actuator into a Full Stroke Ajdustment version.
The option is available for sizes 40 to 600 and both the double acting kit and spring return
kit use the spring return end cap.
Figure C-1
Availability Formats of the Full Stroke Adjustment Option
Spring-Return Full
Stroke Adjustment Kit
Complete Spring-Return
or Double-Acting actuator
Double-Acting Full
Stroke Adjustment Kit
62
Appendix
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
C.2
Convert a Standard Actuator into a Full Stroke
Adjustment Version
Before starting to assemble the Full Stroke adjustment kit, please check the kit for
completeness. See Figure C-2.
Figure C-2
Full Stroke Adjustment Kit Content
13
12
45 46
11
41 42
Table C-1
1.
43 44
40
9 10
Content Full Stroke Adjustment kit
Pos.
Description
Material
Qty.
Notes
40
41
42
43
44
45
46
9
10
11
12
13
End cap - Full stroke adjustment
Full Stroke adjustment screw
Full Stroke adjustment Nut
Full Stroke adjustment washer
O-Ring - Full Stroke adjustment screw
O-Ring - Thread bush
Thread bush
End cap screw
Washer end cap screw
O-ring end cap
Warning sticker DA Full Stroke adjustment
Warning sticker SR Full Stroke adjustment
Cast Aluminium alloy
Stainless steel
Stainless steel
PA66
Nitrile rubber
Nitrile rubber
Aluminium
Stainless steel
Stainless steel
Nitrile rubber
Polyester
Polyester
2
2
2
2
2
2
2
8
8
2
2
2
1
The same Full Stroke adjustment end cap is used for both double acting and spring return actuators
(flat double acting actuator end caps with Full Stroke Adjustoment options are not available).
Appendix
63
Installation, Operation and Maintenance Manual
Appendix
April 2019
C.2.1
DOC.IOM.BQ.E Rev. 3
Procedure
1.
Remove the existing end caps of a standard actuator.
2.
——
Follow the instructions of Section 8 to remove both the end caps of
the actuator.
——
For spring return actuators; note the original positions of the
spring cartridges.
Mount the Full Stroke Adjustment End cap kit to the actuator.
——
The stroke adjustment screw (41) is factory set at the 90° position.
3.
Grease the O-ring seals (11) and B port seals (2) according to Section 9.1.
4.
Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.
5.
For spring return actuators; place the spring cartridges (7) back in their original
positions.
6.
Install the Full Stroke end cap kits and tighten the end cap screws (9,10). For spring
return units; tighten each endap screw (9,10) in small equal turns and in the sequence as per Figure C-3. Refer to Appendix B, Table B-1 for the correct torque.
7.
For Spring Return units, place the black warning sticker (13) on the end cap.
For Double Acting units, place the white warning sticker (12) on the end cap.
Figure C-3
Assembly of Full Stroke Adjustment End Cap Kit
11
9
40
9
11
10
10
40
12
11
9
11
40
9
10
10
3
7
2
40
13
1
4
64
Appendix
Installation, Operation and Maintenance Manual
Appendix
April 2019
DOC.IOM.BQ.E Rev. 3
C.3
Full Stroke Adjustment Setting
NOTE:
Standard actuators or actuators with the Full Stroke Adjustment option are shipped by
default with a rotation setting of 90° +/-0.5°.
The stroke adjustment setting procedure can be two steps:
1.
Setting the Full Stroke Adjustment screw to the 90° (factory) poisiton.
——
2.
C.3.1
This step can be applicable if a standard actuator needs to be converted
with a Full Stroke Adjustment end cap kit or if the position of the Full
Stroke Adjustment screw is somehow lost.
Setting the Full Stroke Adjustment screw to the required angle.
Factory Setting Procedure
1.
2.
In order to set the Full Stroke Adjustment Screws accurately to the outward position:
——
Do not change the setting of the DSA limit stop screws (A and B) located
above the air connection interface.
——
Move the pistons of the actuator outwards by applying pressure to the
A-port.
Screw in both the Full Stroke Adjustment Screws (41) until the screws touch the
pistons. You will feel an obstruction.
Important: Do not overtighten the screws.
Figure C-4
DSA Limit Stop Screw Setting
A
B
41
41
A-port
You have now set the adjustment screw to the factory setting
Notes:
1.
2.
Appendix
Only the outward stroke can be adjusted with the Full Stroke Adjustment screws.
——
In case of assembly code CW, the left side limit stop (A) is redundant.
——
In case of assembly code CC, the right side limit stop (B) is redundant.
For the inward stroke the standard limit stops can be used:
——
The right side limit stop (B) for assembly code CW
——
The left side limit stop (A) for assembly code CC
65
Installation, Operation and Maintenance Manual
Appendix
April 2019
C.3.2
DOC.IOM.BQ.E Rev. 3
Setting the Full Stroke Adjustment Screw to the
Required Angle
1.
Move the pistons of the actuator inwards.
——
For Spring Return actuators this happens automatically when the actuator
is vented.
——
For double acting actuators vent the A-port and apply pressure to the
B-port.
2.
In order to set the actuator to the required angle, use next table to define the
number of revolutions which you have to turn in the Full Stroke
Adjustment Screws.
3.
Turn in both the adjustment screws (41) as defined in step 2. Both the adjustment
screws should be turned in with the same length or number of revolutions.
CAUTION: DO NOT SET SCREWS UN-EQUAL
Screwing in only one adjustment screw or un-equal setting of both the screws will lead to
high point loads on the pistons and can cause premature failure of the actuator.
4.
Test cycle the actuator to check if the correct rotation angle is set. If required,
repeat steps 1 to 3 to adjust the rotation angle to the required angle.
Table C-2
66
Actuator angle rotation per full revolution of Full Stroke adjustment screw
Stroke
Actuator
size
mm
40
65
100
150
200
350
600
18.8
22.0
25.1
31.4
37.7
37.7
44.0
Screw
inch
Flathead
screw driver
Thread
Pitch (mm)
Actuator angle rotation per
full revolution of screw
0.74
0.87
0.99
1.24
1.48
1.48
1.73
1.2 x 6.5
1.2 x 6.5
1.2 x 6.5
1.2 x 6.5
1.2 x 6.5
1.2 x 6.5
1.2 x 6.5
M8
M8
M10
M10
M10
M12
M16
1.25
1.25
1.5
1.5
1.5
1.75
2
6.0°
5.1°
5.4°
4.3°
3.6°
4.2°
4.1°
Appendix
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