Bettis RPE-Series Owner's Manual

Bettis RPE-Series Owner's Manual

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

March 2019

Bettis RPE-Series

Rack and Pinion Pneumatic Actuators

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Table of Contents

March 2019

Table of Contents

Section 1: Before You Start

1.1

1.2

1.3

Installation, Operation and Maintenance Reference Documents ................... 1

Warehouse Storage ...................................................................................... 1

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

4.2.2

Valve Rotation .................................................................................... 9

Position After Failure ........................................................................ 10

Principles of Operation ................................................................................ 10

4.3.1

4.3.2

4.3.3

4.3.4

Solenoid Valve .................................................................................. 10

Ingress Protection (IP) rating ............................................................ 11

Double-Acting Actuators .................................................................. 12

Spring-Return Actuators ................................................................... 13

Actuator Assembly Codes ........................................................................... 14

Actuator to Valve Installation ...................................................................... 15

Mounting of control and feedback accessories ............................................ 18

Recommended Tubing Sizes ....................................................................... 18

Section 5: Mechanical Stroke Adjustment

5.1

Travel Stop Adjustment ............................................................................... 20

5.1.1

5.1.2

5.1.3

Double-Acting Actuators .................................................................. 20

Spring-Return Actuators ................................................................... 20

Angular Displacement ...................................................................... 21

Section 6: Maintenance

6.1

6.2

Normal Maintenance .................................................................................. 22

Inspection and Repair .................................................................................. 23

6.2.1

6.2.2

Service Kits ....................................................................................... 23

Spring-Return Actuator .................................................................... 23

Section 7: Decommission (Out of Service)

7.1

7.2

Before You Start .......................................................................................... 24

Removing the actuator from the valve ........................................................ 25

Table of Contents I

II

Table of Contents

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 8: Disassembly

8.1

8.2

8.3

8.4

8.5

8.6

8.7

Removing End Caps (Sizes 25 to 600) .......................................................... 27

Removing End Caps (Sizes 950 to 4000) ...................................................... 29

Removing Spring Cartridges or Springs ....................................................... 30

Removing of Limit Stop ............................................................................... 31

Removing Pistons ....................................................................................... 31

Removing Pinion ......................................................................................... 32

Cleaning the Components .......................................................................... 33

Section 9: Reassembly

9.1

9.2

9.3

9.4

9.5

9.6

Grease Instructions ..................................................................................... 35

Reassembly of the pinion ............................................................................ 36

Reassembly of the pistons ........................................................................... 37

Reassembly and settings of the limit stops .................................................. 39

Reassembly of the end caps ........................................................................ 40

9.5.1

9.5.2

9.5.3

Double-Acting actuators .................................................................. 40

Spring-Return actuators ................................................................... 41

Spring-Return actuators - Size 950 to 4000 ...................................... 42

Basic function and Air Leak Test .................................................................. 45

Section 10: Troubleshooting

10.1

10.2

10.3

Mechanical Problems .................................................................................. 46

Pneumatic Problems ................................................................................... 47

Electrical Problems ...................................................................................... 48

Section 11: Parts List and Spare Parts Recommendations

11.1

11.2

11.3

Actuator sizes RPE25 to RPE600 .................................................................. 49

Actuator sizes RPE950 to RPE2500 .............................................................. 50

Actuator size RPE4000 ................................................................................ 51

Appendix A: Spring Load Removal

A.1

Spring load relief ......................................................................................... 52

Appendix B: Tool & Torque Table

Appendix C: Full Stroke Adjustment Option

C.1

C.2

C.3

Full Stroke Adjustment Option .................................................................... 56

Convert a Standard Actuator into a Full Stroke Adjustment Version ............ 57

11.3.1 Procedure ........................................................................................ 58

Full Stroke Adjustment Setting .................................................................... 59

11.3.2 Factory Setting Procedure ................................................................ 59

11.3.3 Setting the Full Stroke Adjustment Screw to the Required Angle ...... 60

Table of Contents

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 1: Before You Start

March 2019

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 chapters in this manual.

Safety Guide (Document No. DOC.SG.BE.1).

For Safety Instrumented Systems application, read the following document:

• SIL Safety Manual Bettis RPE-Series (Document No. DOC.SILM.BE.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.

1.2 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.

1

Before You Start

Section 1: Before You Start

March 2019

1.3

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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

DOC.IOM.BE.EN Rev. 9

Section 2: Introduction

March 2019

Section 2: Introduction

2.1

This section explains:

How to identify the received product.

The intended use of the product.

Construction details.

Actuator specifications.

Identification

The Bettis™ RPE-Series Rack and Pinion actuators are available as double-acting or spring-return versions. 12 models are available, ranging from 23 Nm to 4041 Nm

(206 to 35765 lbf.in)nominal torque output.

The Bettis RPE-Series uses standardized interfaces for solenoid, switchbox or positioner mounting (VDI/VDE3845; NAMUR). The valve interface is equipped with an insert in the pinion bottom that allows both ISO5211 or DIN3337 mounting.

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 RPED150 double-acting versions have flat end caps to reduce actuator length and internal air volume.

Introduction

3

Section 2: Introduction

March 2019

Figure 1 Identification

1

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

4

2

3 4

Size End cap design

5

Spring design

6

Pinion bottom /

Insert design

2

SR DA Left Right

25 -

100

SR DA Left

Maximum 12 spring cartridges

Right

150 -

600

SR DA Left

Maximum 12 spring cartridges

Right

950 -

2500

SR DA Left

Maximum 6 loose springs

Right

4000

Maximum 6 loose springs

Notes

1. Top auxilliaries and Solenoid interface (VDI/VDE 3845; NAMUR) for size 25 to 4000.

2. Valve interface availalable according ISO5211 or DIN 3337.

Actuator sizes 25 to 2500 can be fitted with drive inserts with various inner shapes.

Actuator size 4000 is fitted with a double square; parallel and diagonal.

3. Spring-Return actuators: - with springs

4. Double-Acting actuators: - no springs

5. Actuator sizes 25 to 100 have high end caps for double-acting and spring-return models.

Actuator sizes 150 to 4000 have low end caps for double-acting models and high end caps for spring return models.

6. Actuator sizes 25 to 600 are fitted with a maximum of 12 spring cartridges.

Actuator sizes 950 to 4000 are fitted with a maximum of of 6 loose springs.

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

2.2

2.3

Section 2: Introduction

March 2019

Intended Use

The Bettis RPE 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.

Specifications

Table 1. Pressure Range

Actuator Type

Double-Acting

Spring-Return

Pressure

0.2 to 8 bar (2.9 to 116 psi)

6 to 8 bar (87 to 116 psig), with maximum spring set

3 to 8 bar (43.5 to 116 psig), reduced spring quantity

Table 2. Operating Media

Actuator Type

Double-Acting and Single Acting

Operating Media

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. Recommended air quality according ISO 8573-1 for normal operation: 7-5-4.

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. Temperature Range

Actuator Type

Standard

Option: Low Temperature

Option: High Temperature

Temperature

-20°C to 80°C (-4°F to +176°F)

-40°C to +80°C (-40°F to +176°F)

-10°C to +120°C (+14°F to +250°F)

Introduction

5

Section 2: Introduction

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Table 4.

Actuator model

RPE 0025

RPE 0040

RPE 0065

RPE 0100

RPE 0150

RPE 0200

RPE 0350

RPE 0600

RPE 0950

RPE 1600

RPE 2500

RPE 4000

Air Volumes and Consumption

Actuator volumes:

Maximum volume (in liters)

Central 1 chamber

0.14

0.26

0.40

0.6

1.0

1.3

2.1

3.6

4.9

7.9

12.6

21.7

End cap 2 chamber

0.20

0.37

0.56

0.9

0.8

1.0

1.9

3.3

4.6

7.3

11.9

19.0

Displaced 3 volume

0.08

0.15

0.22

0.3

0.5

0.7

1.2

2.1

3.2

5.4

8.3

13.5

1.5

2.4

3.2

5.5

9.4

13

Consumption per stoke

(in liters, pressure in barg)

Outward Stroke

Double-Acting

Inward Stroke

Double-Acting only

2 and Spring-Return

4 8 2 4 8

0.36

0.64

1.2

0.48

0.88

1.7

0.67

1.02

1.2

1.8

2.2

3.4

0.89

1.3

1.6

2.4

3.1

4.7

2.7

4.3

5.7

9.8

17

23

5.0

8.1

11

18

31

43

2.0

2.1

2.8

5.0

8.7

12

3.8

3.6

4.9

8.8

15

22

7.2

6.7

9.1

16

28

40

21

34

57

37

59

100

69

109

187

20

32

52

35

56

89

64

104

165

Actuator model

Actuator volumes:

Maximum volume (Cu.in.)

Central

1 chamber

End cap

2 chamber

Displaced

3 volume

RPE 0025

RPE 0040

RPE 0065

RPE 0100

RPE 0150

RPE 0200

RPE 0350

RPE 0600

RPE 0950

RPE 1600

RPE 2500

RPE 4000

8.5

15.9

24

36

58

76

131

222

301

484

769

1324

12.2

23

34

53

47

64

115

201

279

447

728

1159

Notes:

1. Pistons at 90° outward position.

2. Pistons at 0° inward position.

3. Stroke is 90°.

4.7

8.9

13.5

19.9

32

44

76

129

196

328

508

825

28

53

81

118

192

255

436

742

1025

1662

2630

4477

Consumption per stoke

(in Cu.in., pressure in psig)

Outward Stroke Inward Stroke

Double-Acting and Spring-Return

40 80 120

Double-Acting only

40 80 120

52

96

148

216

352

466

796

1354

1854

2997

4751

8130

75

140

215

314

512

676

1157

1967

2682

4331

6873

11782

38

71

107

165

163

220

392

683

966

1560

2515

4022

72

133

200

310

293

397

709

1237

1735

2792

4523

7219

106

196

294

455

424

573

1025

1790

2505

4024

6530

10416

Figure 2 Actuator air volumes

Central air chamber volume

Double-Acting and Spring-Return

End cap air chamber volume

Double-Acting only

A

6

B

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 3: Configuration Code

March 2019

Section 3: Configuration Code

Size

0025

0040

0065

0100

0150

0200

Size 0025

Size 0040

Size 0065

Size 0100

Size 0150

Size 0200

This section explains:

• How to create the configuration code for a actuator.

RPES 0150 - N U 40 CW AL TN - L19 S K A - 00 XX

Type

Size

Rotation angle

Threads

Spring set

Rotation

Pinion material

Valve interface

Miscellaneous options

Internal code 1

Color / finish

Visual indicator

Temperature

Valve stem connection

Type

RPED

RPES

Double Acting

Spring Return

Rotation angle

N

90° rotation angle

Threads

M

U

Metric ISO 5211

UNC/NPT/Imperial

0350

0600

0950

1600

2500

4000

Size 0350

Size 0600

Size 0950

Size 1600

Size 2500

Size 4000

Valve Stem Connection

Actuator size

Square

0025

0040 &

0065

No insert

11mm / 0.433"

14mm / 0.551"

0100

0150

0200

0350

0600

17mm / 0.669"

19mm / 0.748"

17mm / 0.669"

19mm / 0.748"

22mm / 0.866"

22mm / 0.866"

27mm / 1.063"

27mm / 1.063"

0950

1600 &

2500

4000 (3

36mm / 1.417"

46mm / 1.811"

55mm / 2.165"

Aluminum

Parallel drive

Diagonal drive

000

L11 D11

L14 D14

D17

L19

D17

L19

L22 D22

D22

L27

L27

L36

D27

D36

L46

Q55

D46

Q55

Stainless Steel

(4

Star drive

Not applicable

Q11

Q14

Q19

Q22

Q22

Q27

Q27

Q36

Q46

Q55

Spring Set

00

Double Acting (no springs)

10

20

30

Spring Set 10

Spring Set 20

Spring Set 30

40

50

60

Spring Set 40

Spring Set 50

Spring Set 60

Temperature Range

S

Standard: -20°C to +80°C (-4°F to +176°F)

H

L

High: -10°C to +120°C (+14°F to +250°F)

Low: -40°C to +80°C (-40°F to +176°F)

Rotation direction

CW

CC

Spring to Close/Clock Wise

Spring to Open/Counter Clock Wise

Visual Indication Code

K

Standard (Knob)

N

No Visual Indication

Pinion Material

AL

SS

High Grade Aluminium, Hard anodized (7

Stainless steel ASI 316 (+ A4-70 SS fasteners)

Finish

B

Standard coating (Bettis Orange)

Valve Interface (2

TN

Standard ISO 5211 interface

SY

LY

Small interface with center plate (DIN3337)

Large interface with center plate (DIN3337)

Notes:

See next page.

Internal code 1

00

10

Standard

Stainless steel AISI316 (A4-70) end cap screws

(7

Miceleanuous options

XX

H1

P1

Standard

1/2" High Flow plate

1/2" Porting according EN 15714-3 (only sizes 950-4000)

Configuration Code 7

Section 3: Configuration Code

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

5.

6.

7.

Notes:

1.

2.

3.

4.

The options, listed here, are all options available. Not all options apply to all configurations.

Valve Interface: Option "S"; Small Interface with Center Plate (DIN3337) is not available for size 0025, 0950 and 4000. Option "L"; Large Interface with Center

Plate (DIN3337) is not available for size 1600 and 2500.

Size 4000 does not have inserts but has two inner squares (diagonally and parallel oriented) directly in the bottom of the pinion.

Actuators with stainless steel pinions do not have inserts but have two inner squares (diagonally and parallel oriented aka "Star Drive") directly in the bottom of the pinion.

Contact you local Bettis representative for additional insert options.

PED Group 1 Label only available up to size 950.

Actuators with the default hard anodized pinions, come with stainless steel grade

A2 (AISI304) end cap screws.

Optional, the actuator is available with stainless steel grade A4-70 (AISI316) end cap screws.

Select option 10 in the "Internal code 1" segment in case stainless steel grade A4

(AISI316) end cap screws are required.

8 Configuration Code

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 4: Installation

March 2019

Section 4: Installation

4.1

This section explains:

The actuator rotation direction.

In which position the actuator will end after a failure.

Principles of operation:

Solenoid operation.

Double acting and Spring return operation.

Assembly codes.

Actuator to valve assembly.

Before You Start

4.2

4.2.1

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.

Actuator Rotation Direction

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.

The valve is open after a counterclockwise rotation.

Installation 9

Section 4: Installation

March 2019

4.2.2

4.3

4.3.1

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Position After Failure

The position of the actuator after a failure depends on the:

1.

2.

3.

Principle of operation (see paragraph 4.3)

Assembly codes (see paragraph 4.4)

Kind of failure. Refer to the table below.

Table 5. Position After Failure

Principle of

Operation

Assembly Code

Double-Acting

Actuator

Single-Acting

(Spring-Return)

Actuator

CW

CW

Kind of Failure

Pressure

Signal

Supply Voltage

Pressure

Signal

Supply Voltage

Pressure

Signal

Supply Voltage

Pressure

Signal

Supply Voltage

Position

Not defined

Closed

Closed

Not defined

Open

Open

Closed

Closed

Closed

Open

Open

Open

Principles of Operation

Solenoid Valve

All actuators can be either piped with solid or flexible tubing with the solenoid valve mounted remotely from the actuator or by mounting a VDI/VDE 3845 (NAMUR) designed solenoid valve DIRECTLY onto the NAMUR mounting pad on the side of the actuator.

Figure 4 Typical solenoid operation

Spring-Return Operation Double-Acting Operation

A A B

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4.3.2

Section 4: Installation

March 2019

The table below represents the cycle time (operating time) per different Actuator sizes:

Table 6. Operating Speed

Actuator size

25

40

65

100

150

200

350

600

950

1600

2500

4000

6.6

10.6

16.9

29.1

0.6

0.7

0.8

1.0

1.3

1.9

3.2

Cycle time in seconds

Spring-Return

A-port pressurized

0.5

Spring stroke

0.4

0.5

0.5

0.6

0.8

0.9

1.3

1.9

2.2

3.5

5.7

9.2

Double-Acting

A-port pressurized

0.5

0.6

0.6

0.8

0.9

1.0

1.4

2.2

2.4

3.6

5.8

9.2

Operating time is average with actuator under load and solenoid valve fitted.

B-port pressurized

0.4

0.5

0.6

0.7

0.8

1.0

1.5

2.2

2.0

3.3

5.2

9.0

Test conditions:

1. Solenoid with flow capacity:

2. Pipe diameter:

3. Medium:

4. Supply pressure:

5. Load:

6. Stroke:

7. Temperature:

0.6 m

3

/hr

6mm clean air

5.5 bar (80psi) with average load

90°

Room temperature

Ingress Protection (IP) rating

Bettis RPE actuators are IP66/IP67 rated. In case of IP66 or IP67 requirements, take precautions that comply with the IP66/IP67 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.

Installation 11

Section 4: Installation

March 2019

4.3.3

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Double-Acting 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 outward to the "Open" position of the valve.

Applying supply pressure to port B will move the pistons inward to the "Close" position of the valve.

For assembly codes CC, the operating principle is reversed (reverse acting).

Figure 5 Double-Acting Operation

Outward Stroke

A

A B

Inward Stroke

B

A B

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4.3.4

Section 4: Installation

March 2019

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 6 Stroke Movements

Outward Stoke

A B

Inward Stroke

A

Installation 13

Section 4: Installation

March 2019

4.4

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Actuator Assembly Codes

Figure 7 Assembly Code - Double-Acting

Assembly code: CW

= Standard, Clockwise-to-Close rotation

= Fail-to-Close

B

A Pinion and cam position

Assembly code: CC

= Reverse, Counterclockwise-to-Open

= Fail-to-Open

A

B

Pinion 90° rotated

Default

pistons position

A B

Dot in pinion slot

A B

Reversed pistons position

A = Rotation when central air chamber is pressurized.

B = Rotation when end cap air chambers are pressurized.

All views are from above. Pistons are shown in inward position.

Figure 8 Assembly Code - Spring-Return

Assembly code: CW

= Standard, Clockwise-to-Close rotation

= Fail-to-Close

B

A

Pinion and cam position

Assembly code: CC

= Reverse, Counterclockwise-to-Open

= Fail-to-Open

A

B

Pinion 90° rotated

Default

pistons position

A B

Dot in pinion slot

Springs A B

Reversed pistons position

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4.5

Section 4: Installation

March 2019

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 A or B port, 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.

Table 7.

Symbol

Tool Table

Tool

Wrench – All types and sizes.

Metric and Imperial

Symbol Tool

Allen key

Circlip Pliers

1.

2.

Figure 9

Remove handle nut, handle, lock washer, and etc. from the valve if required.

Visually check to make sure the valve is CLOSED.

Valve handle removal

Installation 15

Section 4: Installation

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

3. When required, check if the insert drive (23) is mounted. If not, use a plasticmallet and tap slightly until the reducer square is in the required position.

Figure 10 Insert drive Installation

90° 90°

Parallel square

45°

90°

Flat head

23

Diagonal square

Round with key way

4. Install the bracket to the valve flange. Tighten all bolts and nuts and apply the correct torque.

Figure 11 Bracket Installation

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Section 4: Installation

March 2019

5. Install the actuator to the bracket. Tighten all bolts and apply the correct torque

(refer to Table 8).

Table 8. Bottom flange torque values

6.

Actuator size

25

40, 65, 100

150, 200, 350

600

950

1600, 2500

4000

ISO Pattern

Torque (Nm)

Thread

F03 inner pattern

F05 outer pattern

F05 inner pattern

F07 outer pattern

F07 inner pattern

F10 outer pattern

F10 inner pattern

F12 outer pattern

M5

M6

M6

M8

M8

M10

M10

M12

F10 inner pattern

F14 outer pattern

M10

M16

F16 inner pattern M20

F25* outer pattern 4x M16

F16 inner pattern M20

F25 outer pattern 8x M16

Min.

2.0

4.5

4.5

10.5

10.5

21.0

21.0

34.5

21.0

90.0

170.0

90.0

170.0

90.0

Max.

3.0

5.0

5.0

12.5

12.5

24.5

24.5

43.0

24.5

104.0

204.0

104.0

204.0

104.0

When required, mount or adjust the visual indicator (26).

Torque (lbf.ft)

Thread

10-24UNC

1/4"-20

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

3/4"-10

8x 5/8"-11

Min.

1.5

3.3

3.3

7.7

7.7

15.5

15.5

25.4

15.5

66.4

125.4

66.4

125.4

66.4

Max.

2.2

3.7

3.7

9.2

9.2

18.1

18.1

31.7

18.1

76.7

150.5

76.7

150.5

76.7

Figure 12 Actuator to valve mounting

Size 12 - 350

Indicator mounting “In-line”

Size 600 - 4000

26 26

90°

90°

90°

Indicator mounting “Across Line”

Installation 17

Section 4: Installation

March 2019

4.6

4.7

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Mounting of control and feedback accessories

Solenoid valve and or switch boxes can now be mounted to the actuator. 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 9. Tubing Sizes

Actuator size

25, 40, 65

100, 150, 200,

350, 600

950, 1600, 2500,

4000

Runs up to

1.2 meters

6 mm

6 mm

4 feet

1/4 inch

1/4 inch

6 mm 1/4 inch

Runs over to

1.2 meters

6 mm

8 mm

4 feet

1/4 inch

5/16 inch

10 mm 3/8 inch

18 Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 5: Mechanical Stroke Adjustment

March 2019

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 RPE actuators 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 13 Factory Setting

Limit Stop 2

80°

Size 25 - 600

10°

Closed

-5°

90°

80°

Size 950 - 4000

10°

Closed

-3°

Limit Stop 1

90°

Mechanical Stroke Adjustment 19

Section 5: Mechanical Stroke Adjustment

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

5.1

5.1.1

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.

Double-Acting Actuators

1.

2.

3.

Operate valve/actuator assembly to the required "Closed" position.

Remove air supply.

Slacken locknut on the “closed” stop (2).

Figure 14

5.1.2

Stop 1

Stop 2

4.

5.

6.

7.

8.

Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out.

Tighten the lock nut.

Connect air and cycle the actuator to check that the position is correct. If not repeat from 2.

Remove air supply.

For adjusting the open position repeat steps 1 to 7, but now for the open position and “open” stop (1).

Spring-Return Actuators

1.

2.

Connect air supply to the A port. Actuator will move to the open position.

Slacken locknut (24) on the “closed” stop (2).

Figure 15

Stop 1 Stop 2

20 Mechanical Stroke Adjustment

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 5: Mechanical Stroke Adjustment

March 2019

5.1.3

3.

4.

5.

6.

7.

Turn the “closed” stop clockwise to reduce or counterclockwise to increase the travel. Consult chapter 5.1.3 (angular displacement of the pinion), to define how far the limit stop must be turned in or out.

Remove air supply. Actuator will move to the closed position.

Check whether the actuator valve assembly is in the required position.

If not repeat steps 1 to 5.

Remove air supply.

For adjusting the open position repeat steps 1 to 6, but now for the open position and "open" stop (1).

Table 10. Limit stop dimensions

Actuator size

25

40

65

100

150

200

350

600

950

1600

2500

4000

Thread

M6

M8

M10

M10

M10

M12

M16

M20

M 22

M 24

M 27

M 22

Bolt wrench size (mm)

10

13

17 (16)*

17 (16)*

17 (16)*

19 (18)*

24

30

12

14

17

12

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

Angular Displacement

Nut wrench size (mm)

10

13

17 (16)*

17 (16)*

17 (16)*

17 (18)*

24

30

32

36

41

32

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 counteclockwise to increase the stroke.

Table 11.

Actuator size

25

40

65

100

150

200

350

600

950

1600

2500

4000

Angular Displacement limit stops

Turns for 5° adjustment of the pinion:

0.7

0.8

0.6

0.7

1.2

1.0

0.8

0.8

1.1

1.3

1.5

3.2

360° revolution of limit stop screw will adjust

7.1°

6.3°

8.3°

7.1°

4.2°

5.0°

6.3°

6.3°

4.7°

4.1°

3.4°

1.6°

NOTICE

In case of air leakage over the limit stop bolts, turn the lock nut of the limit stop bolts tighter, until leakage stops.

Mechanical Stroke Adjustment 21

22

Section 6: Maintenance

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 6: Maintenance

This section explains:

When and how to do maintenance.

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 RPE actuators are designed to operate without maintenance for their normal working life. Normal working life is 500,000 cycles* for sizes up to RPE1600 and 250,000 for sizes RPE2500 and RPE4000.

For actuators with the optional low temperature silicon seals, we advise to replace these seals after 250.000 cycles*.

NOTE:

* 1 Cycle = 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:

• 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.

Maintenance

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

6.2

6.2.1

6.2.2

Section 6: Maintenance

March 2019

Inspect actuator paint work for damages to ensure continued corrosion protection.

Touch-up as required in accordance with the applicable paint specification.

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 chapters of this manual.

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.

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.

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.

Maintenance 23

24

Section 7: Decommission (Out of Service)

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 7: Decommission (Out of Service)

7.1

This section explains:

• 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)

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 7: Decommission (Out of Service)

March 2019

7.2 Removing the actuator from the valve

1.

2.

3.

4.

5.

6.

Disconnect all air supply hoses (Ports A and B or solenoid).

Disconnect all electrical wirings of the switch box.

Disconnect the electrical wiring of the solenoid valve.

Remove the bolts and nuts from the valve flange.

Remove the bracket from the actuator.

Remove the switch box and solenoid valve. Refer to the documentation of the switch box and solenoid valve for safe disassembly.

Figure 16 Removing actuator from valve

3

1

2

4

Decommission (Out of Service) 25

26

Section 8: Disassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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: PRESSURIZED ACTUATOR

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 25 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 4000 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.

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

8.1

Section 8: Disassembly

March 2019

Refer to the tables in this section or refer to Appendix B Tool and Torque tables.

Removing End Caps (Sizes 25 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 17 Double-Acting End Caps Removal

11

11

6

8

10

8

10

6

2

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 25 to 100 have high end caps for double-acting and spring-return models.

Disassembly 27

Section 8: Disassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Actuator sizes 150 to 4000 have low end caps for double-acting models and high end caps for spring return models.

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 18, to relieve the pre-load of the springs.

c. Remove the o-rings (11) and "B" port seals (2). Discard these parts.

Figure 18 Spring-Return End Caps Removal

28 Disassembly

Installation, Operation and Maintenance Manual

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8.2

Section 8: Disassembly

March 2019

30 11

3

10

9

5

2

11

2

2

1

4

Removing End Caps (Sizes 950 to 4000)

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 19

10

8

Double-Acting End Caps Removal sizes 950 to 4000

11

11

6

8

10

6

2

2

10

9

5

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 20, to relieve the pre-load of the springs.

c. Remove the o-rings (11) and "B" port seals (2). Discard these parts.

Disassembly 29

Section 8: Disassembly

March 2019

8.3

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Figure 20

10

9

2

Spring-Return End Caps Removal sizes 950 to 4000

11

5

11

6

3

2

30

2

1

5

4

Removing Spring Cartridges or Springs

3. Remove the spring cartridges or springs (7).

5

10

9

Figure 21 Removing Spring Cartridges size 25 to 600

7

7

30 Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Figure 22 Removing Springs size 950 to 4000

7

Section 8: Disassembly

March 2019

7

8.4 Removing of Limit Stop

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 23 Limit Stop Removal

33 32

31

30

8.5 Removing Pistons

1.

2.

Use a wrench and turn the pinion counterclockwise until the pistons (14) come out of the body.

Remove the piston bearings (15), piston rack bearing strips (17) and piston o-ring seals (16). Discard these parts.

Disassembly 31

Section 8: Disassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

8.6 Removing Pinion

1.

2.

3.

4.

Remove the circlip (27) and thrust bearing (23) on top of the pinion assembly.

For sizes 950 to 4000 remove also the top pinion bearing (19).

Remove the pinion (18) by pushing it downwards. For Size 4000, remove the backup ring (29), O-ring pinion top (21) the cam (24) and cam thrust washer (25) through the main bore of the housing.

Remove the pinion O-ring seals (21/22) and the pinion bearings (19/20).

For Size 950 to 2500, remove also the backup ring (29).

Discard all of these parts.

Figure 25 Pinion Removal

Sizes 25 to 600

23

19 19

27

Sizes 950, 1600, and 2500

23

27 19

Size 4000

23

27 19

21

21

18 21

22

29 19 18 20

29

25

25

24

18

20

22

32

Table 12.

Actuator size

25 - 100

150 - 350

600

950

Recommended circlip pliers according DIN 5254 (or equal) for circlips.

Pinion top diameter

22 mm

36 mm

55 mm

65mm

0.866"

1.417"

2.165"

2.559"

Pliers according

DIN 5254

A2

A3

A3

A3

Actuator size

1600

2500

4000

Pinion top diameter

75 mm

95 mm

96 mm

2.953"

3.74"

3.78"

Pliers according

DIN 5254

A3

A4

A4

Disassembly

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DOC.IOM.BE.EN Rev. 9

8.7

Section 8: Disassembly

March 2019

Cleaning the Components

In case of maintenance, use a clean dry cloth and thoroughly wipe clean and remove old grease from:

The inside and outside of the body including thread holes and crevices/grooves

The pinion gears.

The pistons.

Figure 24 Removing Pistons

14

16

15

16

14

17

17

15

Disassembly 33

34

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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 chapter 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

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

9.1 Grease Instructions

Check the product coding on the product labels and chapter 3 of this manual, to define which type of grease to use.

For standard actuators (-20°C to +80°C / -4°F to +176°F):

Castrol High Temperature grease (or equivalent).

For low temperature operation (-40°C to +80°C / -40°F to +176°F):

Castrol Tribol GR TT 1 PD (previously known as Castrol OPTITEMP TT1) or

LG2 grease (or equivalent).

— For high temperature operation (-10°C to +120°C / +14°F to +250°F):

Castrol High Temperature grease (or equivalent).

We recommend using a suitable sized paint brush to apply the required amount of grease on the parts as per Table 12 and Figure 23.

Table 13.

Part

O-rings:

Housing Parts:

Piston Parts:

Piston Parts:

M

N

K

L

H

J

F

G

C

D

E

A

B

Grease Instructions

Section of part

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

Amount of grease

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)

Figure 26 Grease Instructions

A

M

K

L

J

N

A

C

F

E

A

A

G

A

H

A

B

D

Reassembly 35

Section 9: Reassembly

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Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

9.2 Reassembly of the pinion

1.

2.

3.

4.

Grease the pinion parts according to chapter 9.1.

Install the pinion bearings (19/20) and the O-ring seals (21/22) on the pinion (18).

For Size 950 to 2500, install also the the backup ring (29).

Insert the pinion (18) in the housing. For size 4000: mount first the cam (24), cam thrust washer (25), pinion top O-ring (21) and backup ring (29) through the mainbore onto the pinion (18).

For sizes 950 to 4000 install first the top pinion bearing (19). For all sizes, install the thrust washer (23) and mount the circlip (27) on the pinion top.

— 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.

Figure 27

1

2

Reassemble the pinion

Sizes 25 to 600

23

19 19

21

18 21

1

2

27

Sizes 950, 1600, and 2500

23 21 22

1

2

27 19

Size 4000

23

27 19

29 19 18

20

22

29 25

21

24

18

20

Table 14. Recommended circlip pliers according DIN 5254 (or equal) for circlips.

36 Reassembly

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DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

9.3

Actuator size

25 - 100

150 - 350

600

950

Pinion top diameter

22 mm 0.866"

36 mm 1.417"

55 mm 2.165"

65mm 2.559"

Pliers according

DIN 5254

A2

A3

A3

A3

Actuator size

1600

2500

4000

Pinion top diameter

75 mm 2.953

95 mm 3.74

96 mm 3.78

Pliers according

DIN 5254

A3

A4

A4

Reassembly of the pistons

NOTICE

Before reassembling the pistons, check the required assembly code (see section 4.2).

1.

2.

Grease the piston parts according to step 9.1.

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 28 Reassemble the pistons

14

16

16

14

17

17

15

15

3. Align the pinion (see Figure 26) 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.

Reassembly 37

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

4.

5.

6.

7.

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 26), 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.

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.

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.

— For larger pistons, use a rubber mallet and slightly hitting the pistons inward to engage with the pinion.

Figure 29 Position of the slot and the cam on the pinion top

Assembly code CW

(Standard; Spring-to-Close)

Assembly code CC

(Reverse; Spring-to-Open)

A B

B A

90° 90°

38

A = Position of cam

B = Position of slot and dot in pinion.

C = Final position of pinion dot.

C

C

Reassembly

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DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

9.4

NOTE:

When the pistons are completely moved inwards, the pinion top will show a 5° over travel.

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 30 Install Limit Stop Bolts

33 32 31 30

4.

5.

2.

3.

Move the pistons inward until the slot in the top of the pinion is perpendicular to centerline of the housing.

Double check if the position of the slot and the cam on the pinion top is in the correct position (see figure 26). Screw in the right hand travel stop until it comes into contact with the pinion stop face.

Move the pistons outward until the slot in the top of the pinion is in line with the centerline of the housing.

Screw in the left hand travel stop until it comes into contact with the pinion stop face.

— For accurate travel stop adjustment of the actuator on the valve, see section 5.

Reassembly 39

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

9.5

9.5.1

Reassembly of the end caps

Double-Acting actuators

1.

2.

3.

Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

Install the end caps (6) and tighten the end cap screws (8).

Refer to Table 15 for the correct torque.

Figure 31 Double-Acting end cap assembly

11

11

6

9

10

9

10

6

6

2

5

2

40

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 25 to 100 have high end caps for double-acting and spring-return models.

Actuator sizes 150 to 4000 have low end caps for double-acting models and high end caps for spring return models.

Table 15.

Actuator size

25

40

65

100

150

200

350

600

950

1600

2500

4000

End cap Screw Torque

Thread

M6

M6

M8

M10

M5

M5

M5

M5

M12

M12

M12

M14

Tool

Allen Key

Size

SW 4

SW 4

SW 4

SW 4

SW 5

SW 5

SW 6

SW 8

SW10

SW10

SW10

SW12

Torque (Nm)

Target Min.

Torque (lbf.ft)

Max. Target Min.

Max.

2.0

3.3

8.4

15.3

24.3

2.0

2.0

2.0

3.3

24.3

24.3

43.5

1.6

1.6

1.6

1.6

2.6

2.6

6.7

12.2

19.4

19.4

19.4

34.8

3.0

3.0

3.0

3.0

5.1

5.1

12.2

24.8

41.6

41.6

41.6

66.4

1.5

1.5

1.5

1.5

2.4

2.4

6.2

11.3

17.9

17.9

17.9

32.1

1.2

1.2

1.2

1.2

1.9

1.9

4.9

9.0

14.3

14.3

14.3

25.7

2.2

3.8

9.0

18.3

30.7

2.2

2.2

2.2

3.8

30.7

30.7

49.0

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

9.5.2 Spring-Return actuators

Important

Bettis RPE-Series Spring return actuators are supplied with springs on each side of the actuator. Throughout the RPE-Series size range, there are two different spring designs:

— Sizes RPE25 to RPE600 have 6 springs on each side (see figure below).

— Sizes RPE950 to RPE4000 have 3 springs on each side (see chapter 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 32 Spring cartridge placement

A

B

N = 10

N = 20

N = 30

Reassembly

N = 40 N = 50

N = 60

A = Piston top view

B = Position of piston gear rack

1.

2.

3.

4.

Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

Place the spring cartridges in actuator as per required spring set (see Figure 32).

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 33. Refer to Table

15 for the correct torque. We recommend to use some grease on the screws for easier fastening.

41

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

9.5.3

Figure 33

10

9

Spring Return End cap assembly size 25 to 600

30 11

5 11

3

2

2

10

9

5

1

2

4

Spring-Return actuators - Size 950 to 4000

Important

Bettis RPE-Series Spring return actuators are supplied with springs on each side of the actuator. Throughout the RPE-Series size range, there are two different spring designs:

— Sizes RPE25 to RPE600 have 6 springs on each side (Chapter 9.5.2).

— Sizes RPE950 to RPE4000 have 3 springs on each side (see figure below).

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.

42 Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Figure 34 Spring placement size F950 to F4000

N = 10 N = 20

Section 9: Reassembly

March 2019

N = 30

B

Left Right

A

1 spring 0 spring

N = 40

Left Right

1 spring 1 spring

N = 50

Left Right

2 springs 1 spring

N = 60

Left Right

2 springs 2 springs

Left Right

3 springs 2 springs

Left Right

3 springs 3 springs

Reassembly 43

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

A = Piston top view

B = Position of gear rack

1.

2.

3.

4.

Grease the O-ring seals (11) and B port seals (2) according to step 9.1.

Ensure that O-ring seals (11) and B port seals (2) are kept in place during assembly.

Place the spring in actuator as per required spring set (see Figure 29).

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 35.

Refer to Table 15 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 35

10

9

2

Spring Return end cap assembly size 950 to 4000

11

5

11

6

3

2

30

1

5

4

2

5

10

9

44 Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

9.6 Basic function and Air Leak Test

CAUTION: MOVING PARTS

Applying pressure to the actuator will cause the actuator/valve assembly to operate.

1.

2.

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).

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 36

1

Basic function and air leak test

4

3

A B

3

A

B

2

Reassembly 45

46

Section 10: Troubleshooting

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 10: Troubleshooting

10.1 Mechanical Problems

Problem

Feedback position and actual position are not the same.

Valve is in “Closed” position, actuator is in

“Open” position and will not move anymore.

Possible error

Actuator and valve are mounted 90° rotated in relation to each other.

Solution

Limit stop screws are not set correctly.

Readjust the limit stop screws.

Where to find

Remove actuator from valve. Check assembly code of actuator. Put both valve and actuator in “Closed” position. Mount actuator on valve.

Section 4

Section 5

Valve does not reach the completely “Closed” or

“Open” position.

Insert is not mounted properly.

Pressure to low.

Mount the insert in the right position. Remark: Rotate insert to one cam = 22.5°.

Apply pressure as per sizing.

Sizing is wrong.

Check valve torque data with actuator torque data.

Actuator rotates, valve does not.

Actuator does not rotate or does not rotate smoothly.

Limit stop screws cannot be turned out anymore.

Pinion is mounted in the wrong position.

No coupling between actuator shaft and valve spindle.

Broken gearing on pistons or pinion.

Spring or Spring cartridge is broken.

Limit stop screws is bend.

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 4.5

Section 9

Section 4.5

Appendix A.

Troubleshooting

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

10.2

Section 10: Troubleshooting

March 2019

Pneumatic Problems

Problem Possible error

Actuator does not react to electrical control signal.

There is no supply pressure at the actuator.

Solution

Supply the right pressure to the actuator.

Where to find

Section 2.3

Check that the actual supply pressure is higher than the sizing pressure.

There is sufficient supply air pressure but insufficient supply air capacity.

Actuator does not react good to electrical control signal.

Supply pressure too low, causing pilot operated solenoid valve to fail.

Air leakage between actuator and solenoid valve.

Solenoid valve is not mounted properly.

Speed control throttle

(if present) blocks air flow.

Manual override

(if present) on the

Solenoid Valve is locked.

Sealing between solenoid valve and actuator is not mounted air tight.

Take care the supply air tubing has the right dimensions.

Check that supply pressure at the actuator and solenoid is sufficient to operate the actuator.

Check the solenoid valve mounting.

Turn the speed control more open.

Unlock manual override on the solenoid valve.

Reassemble solenoid valve taking care, that all seals are in place.

Section 4.6

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.

Double-acting actuator will only move to

“open” position.

Actuator has wrong solenoid valve configuration.

Mount a solenoid valve suitable for doubleacting actuators

(4/2 or 5/2 function).

Instructions shipped with the solenoid valve.

Check that conversion plate on solenoids, that have both 3/2 and 5/2 functions, is in the right position.

Instructions shipped with the solenoid valve.

Seals on the limit stops screws are not air tight.

Turn the lock nut of the bolts tighter; until the leakage stops.

Section 9.6

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.

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 47

Section 10: Troubleshooting

March 2019

10.3

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Electrical Problems

Problem

Actuator does not react to control signals.

Possible error

Control wiring.

Power supply wiring or feedback wiring are not right connected.

The power supply voltage is not is not the same as the voltage of the applicable solenoid valve.

There are problems with position feedback after sending the actuator to either the

“Open” or “Closed” position.

The wiring of the feedback signals may be switched.

Solution

Connect all wiring in the right way.

Connect the right power supply voltage.

Connect the feedback wiring in the right way.

Where to find

Instructions of the control or feedback accessories.

Instructions of the solenoid valve.

Instructions of the feedback device.

48 Troubleshooting

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 11: Parts List and Spare Parts

March 2019

Section 11: Parts List and Spare Parts

Recommendations

11.1 Actuator sizes RPE25 to RPE600

23 27 26

18 21 19

30 31 32 33 1

14

16

15

6

12

8

10

17

19

21

3

28

5

13

11 7

9

10

2

Table 16.

Pos.

1

2

30

31

32

33

23

26

27

28

17

18

19

21

13

14

15

16

8

9

10

11

12

6

7

3

5

Parts List

Qty Notes Description

1

2 1

House

B-port seal

2

2

2

2

1

1

1

1

2

2

2

2

2

2

2

2

1

2

2

Max. 12

8

2

2

8

8

1

1

1

1

1

1

2

2

1

1

1

1

Center plate (optional)

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

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 25 to 100 have high end caps for double-acting and spring-return models. Actuator sizes

150 to 4000 have low end caps for double-acting models and high end caps for spring-return models.

Parts List and Spare Parts 49

Section 11: Parts List and Spare Parts

March 2019

11.2

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Actuator sizes RPE950 to RPE2500

30 31 32 33

1 19

26

27

23

29

21

18 16 15

6

8

10

12

9

10

5

13

50

17

14

20

22

28

3 4 2 11 7

Table 17. Parts List

2

2

2

1

2

1

1

1

1

1

1

2

1

2

1

2

1

12

2

2

Max. 6

12

12

12

2

2

2

2

2

2

Pos. Qty. Notes Description

1 1 House

31

32

33

27

28

29

30

21

22

23

26

17

18

19

20

8

9

10

11

4

5

6

7

2

3

12

13

14

15

16

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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

Notes:

1 Included in Service Kit.

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

Parts List and Spare Parts

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

11.3

Section 11: Parts List and Spare Parts

March 2019

Actuator size RPE4000

30 31 32 33 1

29

21

18

26

27

23

19

16 15

6

12

8

10

25

24

9

10

5

13

17

14

20 22 3 4

Table 18. Parts List

2

2

2

1

2

1

1

1

1

1

1

1

1

1

2

2

2

2

2

12

2

2

2

2

1

12

2

2

Max. 6

12

12

Pos. Qty. Notes Description

1 1 House

31

32

33

26

27

29

30

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

6

7

8

9

4

5

2

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

B-port seal

Center ring (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 assembly

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 washer pinion

Cam stroke adjustment

Cam thrust washer

Indicator assembly

Circlip

Backup ring

Limit stop screw

Limit stop nut

Limit stop washer

O-ring limit stop

Notes:

1 Included in Service Kit.

2 11 7

Parts List and Spare Parts

Material

Cast Aluminium alloy

Nitrile rubber

Stainless Steel AISI 304

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

Steel

POM, black UV stabilized

ABS + stainless steel screw

Spring steel

POM

Stainless steel

Stainless steel

PA66

Nitrile rubber

51

52

Appendix

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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

3

1

2

4

WARNING

Crush / Amputaion Hazard

Failure to follow instructions for removal of spring loaded actuator may result in surious personal injury

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Appendix

March 2019

1.

2.

3.

4.

5.

6.

Depressurize the actuator completely.

Based on the actuator size, choose the correct threaded rod kit from Table A-1.

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.

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.

Repeat the same procedure for the end cap screws on the other size of the actuator as shown in figure A-1.

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

25

40

65

100

150

200

350

600

950

1600

2500

4000

Thread

M5

M5

M5

M5

M6

M6

M8

M10

M12

M12

M12

M14

Threaded rod length

(mm)

140

140

140

140

145

145

185

185

498

498

498

600

(inch)

5.5

5.5

5.5

5.5

5.7

5.7

7.3

7.3

19.6

19.6

19.6

23.6

Figure A-2 Spring load removal rod dimensions

Thread

Length

Washer Holding nuts

Threaded Rod Adjusting nut

Appendix 53

54

Appendix

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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 size

25

40

65

100

150

200

350

600

950

1600

2500

4000

Thread

M5

M5

M5

M5

M6

M6

M8

M10

M12

M12

M12

M14

Tool

Allen key

Size

SW 4

SW 4

SW 4

SW 4

SW 5

SW 5

SW 6

SW 8

SW10

SW10

SW10

SW12

Torque (Nm)

Target Min.

2.0

2.0

2.0

2.0

3.3

3.3

8.4

15.3

24.3

24.3

24.3

43.5

1.6

1.6

1.6

1.6

2.6

2.6

6.7

12.2

19.4

19.4

19.4

34.8

Torque (lbf.ft)

Max. Target Min.

3.0

3.0

3.0

3.0

5.1

5.1

12.2

24.8

41.6

41.6

41.6

66.4

1.5

1.5

1.5

1.5

2.4

2.4

6.2

11.3

17.9

17.9

17.9

32.1

1.9

1.9

4.9

9.0

1.2

1.2

1.2

1.2

14.3

14.3

14.3

25.7

Max.

2.2

2.2

2.2

2.2

3.8

3.8

9.0

18.3

30.7

30.7

30.7

49.0

Table B-2.

Actuator size

25

40, 65, 100

150, 200, 350

600

950

1600, 2500

4000

Bottom Flange

ISO Pattern

F03 inner pattern

F05 outer pattern

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

Metric Torque (Nm)

Thread Min.

M5

M6

M6

M8

M8

M10

M10

M12

M10

M16

M20

F25* outer pattern 4x M16

2.0

4.5

4.5

10.5

10.5

21.0

21.0

34.5

21.0

90.0

170.0

90.0

Max.

3.0

5.0

5.0

12.5

12.5

24.5

24.5

43.0

24.5

104.0

204.0

104.0

F16 inner pattern

F25 outer pattern

M20

8x M16

170.0

90.0

204.0

104.0

Imperial

Thread

10-24UNC

1/4"-20

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

3/4"-10

8x 5/8"-11

Torque (lbf.ft)

Min.

1.5

3.3

3.3

7.7

7.7

15.5

15.5

25.4

15.5

66.4

125.4

66.4

125.4

66.4

Max.

2.2

3.7

3.7

9.2

9.2

18.1

18.1

31.7

18.1

76.7

150.5

76.7

150.5

76.7

1. For actuator sizes 1600 and 2500 only 4 holes of the ISO5211 F25 drilling pattern are available.

Table B-3. NAMUR (VDE/VDI 3845) flanges

Flange

Solenoid flange screw threads

Top flange screw threads

Metric

Thread

M5

M5

Torque (Nm)

Min.

Max.

2.0

3.0

2.0

3.0

Imperial

Thread

10-24UNC

10-24UNC

Torque (lbf.ft)

Min.

Max.

1.5

2.2

1.5

2.2

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Appendix

March 2019

Table B-4. Limit stop screws and nuts

Actuator size Thread

25

40

65

100

150

200

350

600

950

1600

2500

4000

M 6

M 8

M 10

M 10

M 10

M 12

M 16

M 20

M 22

M 24

M 27

M 22

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

Bolt Wrench size (mm)

10

13

17 (16)

1

17 (16)

1

17 (16)

1

19 (18)

1

24

30

12

14

17

12

Nut wrench size (mm)

10

13

17 (16)

1

17 (16)

1

17 (16)

1

19 (18)

1

24

30

32

36

41

32

Table B-5.

Actuator size

Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips

Pinion top diameter

25 - 100 22 mm 0.866"

150 - 350 36 mm 1.417"

600

950

55 mm 2.165"

65 mm 2.559"

Pliers according DIN

A2

A3

A3

A3

Actuator size

1600

2500

4000

Pinion top diameter

75 mm

95 mm

96 mm

2.953"

3.74"

3.78"

Pliers according DIN

A3

A4

A4

Table B-6.

Actuator size

25

40

65

100

150

200

350

600

950

1600

2500

4000

Angular Displacement Limit Stops

Turns for 5° adjustment of the pinion:

0.7

0.8

0.6

0.7

1.2

1

0.8

0.8

1.1

1.3

1.5

3.2

360° revolution of limit stop screw will adjust

7.1°

6.3°

8.3°

7.1°

4.2°

5.0°

6.3°

6.3°

4.7°

4.1°

3.4°

1.6°

Appendix 55

Appendix

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Appendix C: Full Stroke Adjustment Option

C.1

This section explains:

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 25 to 600 and both the double acting kit and spring return kit use the spring return end cap.

Figure C-25 Availability formats of the full Stroke Adjustment option

56 Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

C.2

Appendix

March 2019

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-26 Full Stroke adjustment kit content

13

12

45 46 11

41 42 43 44 40 9 10

Table C-7 Content Full Stroke Adjustment Kit

Pos. Description

40 End cap - Full stroke adjustment

45

46

9

10

41

42

43

44

11

12

13

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

Material

Cast Aluminium alloy

Stainless steel

Stainless steel

PA66

Nitrile rubber

Nitrile rubber

Aluminium

Stainless steel

Stainless steel

Nitrile rubber

Polyester

Polyester

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).

Qty.

2

8

8

2

2

2

2

2

2

2

2

2

Notes

1

Appendix 57

Appendix

March 2019

C.2.1

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

2.

3.

4.

5.

Procedure

1.

6.

7.

Remove the existing end caps of a standard actuator.

— 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.

Grease the O-ring seals (11) according to section 9.1.

Ensure that O-ring seals (11) are kept in place during assembly.

For spring return actuators; place the spring cartridges (7) back in their original positions.

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.

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-27 Assembly of Full Stroke adjustment end cap kit

11

9

10

40 11

9

10

40

12

11

13

3

9

10

40

2

11

7

1

4

9

10

40

58 Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

C.3

C.3.1

Appendix

Appendix

March 2019

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.

2.

Setting the Full Stroke Adjustment screw to the 90° (factory) positon.

— This step is applicable if a standard actuator is 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-28 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.

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

59

Appendix

March 2019

C.3.2

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Setting the Full Stroke Adjustment Screw to the Required Angle

1.

2.

3.

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.

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.

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.

Table C-8

Actuator size

25

40

65

100

150

200

350

600

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.

Actuator angle rotation per full revolution of Full Stroke adjustment screw mm

15.7

18.8

22.0

25.1

31.4

37.7

37.7

44.0

Stroke inch

0.62

0.74

0.87

0.99

1.24

1.48

1.48

1.73

Flathead screw driver

1.0 x 5.5

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

1.2 x 6.5

Thread

Screw

Pitch (mm)

M6

M8

M8

M10

M10

M10

M12

M16

1

1.25

1.25

1.5

1.5

1.5

1.75

2

Actuator angle rotation per full revolution of screw

5.7°

6.0°

5.1°

5.4°

4.3°

3.6°

4.2°

4.1°

60 Appendix

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