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Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
May 2020
Bettis M Series
Stainless Steel Scotch Yoke Actuators
Notes
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
This page intentionally left blank
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Table of Contents
May 2020
Table of Contents
Section 1: Introduction
1.1
1.2
1.3
Section 2: Maintenance
Section 3: Jackscrew Override
3.1
3.2
3.3
3.4
Section 4: Manual Handpump Hydraulic Override
4.1
4.2
Remote Mounting the Handpump .............................................................. 10
Section 5: Integral Proximity Switch Mounting
Section 6: Spring Conversion to change Operating Pressure
Spring Conversion to change Operating Pressure .................................................. 12
Section 7: Failure Mode Change – Spring-Return
Section 8: Removal of Actuator from Valve
Section 9: Disassembly
9.1
Disassembly of Symmetric Yoke Actuators .................................................. 15
9.2
Disassembly of Canted Yoke Actuators ........................................................ 17
Table of Contents i
ii
Table of Contents
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 10: Assembly
10.1
Assembly of Symmetric Yoke Actuators ...................................................... 18
10.2
10.3
Assembly of Canted Yoke Actuators ............................................................ 22
Section 11: Operating Instructions
Section 12: Important Safeguards
Section 13: Additional Safety Instructions for Actuators used in a Potentially Explosive Atmosphere under ATEX 2014/34/EU
13.1
13.2
13.3
13.4
Section 14: Additional Safety Instructions for Actuators used in Emergency Shut-down Service or IEC 61508 safety integrity level (SIL) Compliant Installations
Additional Safety Instructions for Actuators used in Emergency Shut-down
Service or IEC 61508 safety integrity level (SIL) Compliant Installations ................. 26
Table of Contents
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 1: Introduction
May 2020
Section 1: Introduction
1.1
1.2
General Application
Actuators are designed for "ON-OFF" or modulating control of any quarter-turn ball, butterfly, rotary plug or damper style valve application.
Technical Data
Supply Pressure
Supply Medium
Temperature Rating
Angular Rotation
40 - 160 psig, see product nameplate
Any pneumatic fluid compatible with materials of construction
Standard Range: -20 °F to 210 °F
Optional Range: -65 °F to 300 °F
90 degrees ± 8 degrees
NOTE:
Language translations of the safety related portions of this document are available at www.emerson.com
Introduction 1
2
Section 1: Introduction
May 2020
1.3
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Installation
The actuator can be mounted parallel or perpendicular to pipeline. The actuator can be installed in any convenient position including vertical, horizontal or upside down.
A.
B.
C.
D.
E.
Begin by bolting the mounting bracket to actuator only hand tight.
Install coupling on valve. Remove or disable any stops on the valve.
Use only the actuator position stops!
Install the actuator and bracket to valve being sure to leave all fastener connections hand tight. If possible, stroke valve and actuator to a half open position and physically shift actuator back and forth until coupling and all fasteners are centered then tighten all bolts and nuts. This procedure will accurately align valve stem to actuator output shaft and prolong valve stem seal life. Lift the actuator at a balance point near the center housing. Do not lift the weight of the valve, see Figure 1.
Cycle valve / actuator assembly and confirm smooth operation.
Adjust the actuator travel stops for perfect valve alignment in both open and closed positions.
NOTE:
If the valve disk is torque seated (E.G. Vanessa butterfly), close the valve against the actuator stop, then unscrew the stop until turns freely, then screw the stop back in until it stops, then turn the stop with a wrench one additional turn and lock into place.
F. Tubing Connections – some models utilize two pistons for added power. Spring return (single acting) dual cylinders designs require one "jumper" to make the supply port common on both pistons. Double acting (air to air) dual cylinder designs require two "jumpers." See Figure 2 for typical arrangement.
!
CAUTION
Use correct length mounting bolts! Mounting bolts used in actuator mounting pad may interfere with the actuator rotary mechanism. Select bolts that will not extend more than two threads above the back of the mounting pad.
Introduction
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 2: Maintenance
May 2020
Section 2: Maintenance
Actuators are factory lubricated and in general do not require periodic lubrication or maintenance while in service. Actuators should be visually inspected periodically for corrosion damage and promptly repaired. Actuators should be operated at least annually to assure proper operation.
Figure 1
Maintenance
Figure 2
SINGLE ACTING ACTUATOR
ONE CYLINDER
SOLENOID
OR
POSITIONER
SINGLE ACTING ACTUATOR
TWO CYLINDERS WITH JUMPER
SOLENOID
OR
POSITIONER
DOUBLE ACTING ACTUATOR
ONE CYLINDER
SOLENOID
OR
POSITIONER
SHUT
DOUBLE ACTING ACTUATOR
TWO CYLINDERS WITH JUMPER
SOLENOID
OR
POSITIONER
3
4
Section 3: Jackscrew Override
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 3: Jackscrew Override
3.1
The jackscrew option is intended for infrequent or emergency on-site operation of the automated valve.
Jackscrew Operating Instructions
3.2
1.
2.
Disengage power supply and vent air from actuator.
Operate the handwheel to drive the actuator into the desired position. Valve position can be verified by checking the actuator position indicator. For models
006 through 270, the jackscrew must be returned to the fully retracted position before actuator can resume normal operation. Back the jackscrew out until it stops. Air will leak from the jackscrew unless it has been fully retracted against its internal seal.
Actuator Stroke Adjustment
3.3
The jackscrew has a built-in actuator stroke adjustment, see Figure 3 and 4.
Models 006 through 270
See Figure 3:
1.
2.
3.
Retract the jackscrew override completely by rotating counter clockwise.
Loosen the lock nut and turn the brass adjusting screw to the desired position.
The handwheel will rotate with the adjusting screw. Never make stroke adjustments by turning the handwheel only.
Tighten lock nut.
Figure 3 Jackscrew Override - Models 006 through 270
Actuator stroke adjusting screw
Note: Air escapes unless jackscrew is fully retracted
Stroke adjusting screw
Jackscrew
JACKSCREW FULLY RETRACTED
Lock nut
Seal
Jackscrew seal
JACKSCREW EXTENDED
Jackscrew Override
SHUT
SHUT
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
3.4
Section 3: Jackscrew Override
May 2020
Models 370, 740 and 575
See Figure 4:
1.
2.
3.
4.
Retract the jackscrew override completely by rotating clockwise.
Loosen the stroke adjusting screw and lock nut.
Using the handwheel, turn the jackscrew to adjust the actuator to the desired position.
Screw the adjusting screw until it stops and tighten lock nut.
Figure 4 Jackscrew Override - Models 370, 575 and 740
Handwheel
Lock nut
Stroke adjusting screw
Sealed jackscrew assembly
SHUT
SHUT
Lock nut
Stroke adjusting screw
Jackscrew Override 5
Section 3: Jackscrew Override
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Single-Acting Spring-Return Two Pistons
Models: 012, 046, 058, 059, 072, 100, 144, 270, 344, 345, 420, 740, 944, 945, 1150,
1480, 1929, 1930, 2380
38 27 46 4 26 2 13
14 15 17 21 8a
53 55 56 49 50 54 51
37 1 14 15 17 21
Single-Acting Spring-Return One Piston
8a
Models: 006, 015, 023, 036, 050, 135, 210, 370 and 575
38 27 46 4 26 2 13 53 55
33 34
56 49
52
50 54
57
51
37 1 33 34 52 57
38 27 46 4 26 2
38 27 46 4 26 2
53 55 56 49 50 54 51
23
53 55 56 49 50 54 51
23
6
6
6
1
3
3
5
12
5 8
43
28
41 24
39
32 18 19 20 31 35 25
16 7 29 30
36
A
43
11
28
10
11
8 10
9
42
41 24
42
39
48
32 18 19 20 31 35 25
A
A
16 7 29 30
8a
5
12
48
A
8a
1
1
5
12
3
36
8
13
13c
8
13
13c
22
6b
2
22
5 12b 2
6b
9
3
5 12b
Jackscrew Override
4
4 12 8
12 8
A
4a
55 56 35 55 56
A
A
4a
55 56 35 55 56
1
20
19
1
20
19
18
12
18
42
12
42
42
43
42
2
43
2
24
14
15
24
13
14
15
13
5
5
22
32 4b 6 9
20
19
A
18
15
12a
12b
31 35 31 25 41
13
11
31 35 31 25 41 5
22
32 4b 6
1
20
19
9
18
15
12a
12b
13
11
15b
15a
36
15b
15a
22
1 3
6a
2
5
5 22
22
6b 10
5
22
3
6a
42
2
5
22
6b 10
22
42
MAN-02-01-39-0704-EN Rev. 1
38 27 46 4
1
26 2 13
14 15 17 21 8a
53 55 56 49 50 54 51
33 34
Section 3: Jackscrew Override
May 2020
Double-Acting Air to Air Two Pistons
Models: 012, 059, 072, 100, 144, 270, 345, 420, 740, 945, 1150, 1480, 1930, 2380
38 27 46 4 26 2 53 55 56 49 50 54 51
23
4 12 8
A
4a
55 56 35 55 56
43 41 24 32 18 19 20 31 35 25
28 39 16 7
Double-Acting Air to Air One Piston
A
Models: 006, 015, 023, 036, 050, 135, 210, 370, 575
29 30
36
A
6
12
1
3
6
1
3
12
5
11
42
10
11
42 10
1
9
48
5
12
48
9
8
3
5 8
A
8
13
13c
8a
22
6b
2
20
19
1 5
18
12
1
42
8
13
13c
22
6b
2
2
13
5 12b
3
12 42
5 12b
14
15
22
5
20
19
5
22
1
18 42
12
42
43 24
13
5
22
32 4b 6
20
19
9
18
15
12a
12b
31 35 31 25 41
13
11
36
15b
15a
5
1 22
2
14
15
5
22
3
6a
2
6b
42
10
5
22
Jackscrew Override 7
Section 3: Jackscrew Override
May 2020
8
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Table 1. Materials of Construction
50
51
52
53
Item
Material
003-100 135-1150
3
4
1
2
5
Housing
Yoke
Output shaft
Piston rod
Bushing - output shaft
316 SS
17-4 PH
17-4 SS
316 SS
Teflon
35
36
37
38
32
33
34
25
26
27
28
29
30
31
39
41
42
43
45
46
47
48
49
16
17
18
19
20
21
22
23
24
7
8
6a
6b
Yoke pin
Key - yoke -
18-8 SS
Bushing - piston rod Teflon
Retaining ring - output shaft 15-7 MO
9
10
Thrust pin
Roller bearing
11 Retaining ring - pin
12 Seal, thrust plate
12a Set screw
12b Retaining ring - lower bearing
13 Pointer adaptor
13a Position indicator
13b Thrust plate
13c Gasket, thrust plate
14
15
Hex head bolt
Lock washer
-
-
-
-
-
440C SS
440C SS
15-7 MO
18-8 SS
304 SS
18-8 SS
18-8 SS
Pointer
Round head screw
Cover - housing
Hex head bolt
Lock washer
Pointer washer
Thrust washer
Gasket - cover
Cylinder
Soft PVC
18-8 SS
316 SS
18-8 SS
18-8 SS
-
18-8 SS
Fiber
316 SS
Piston
Adaptor
End cap
Rod cover
Seal - piston rod
Seal - piston bolt
Seal- piston
Gasket - housing
Piston bolt
Lock washer
Bearing - piston
Thread seal
Travel stop bolt
Jam nut
Socket head cap screw
Tie rod
Seal - output shaft
Lock washer
Stato-seal
Cylinder gasket or O-ring
Label - nameplate
Seal - output shaft bushing
Cylinder - spring side
316 SS
316 SS
316 SS
316 SS
BUNA-N
BUNA-N
BUNA-N
Fiber
18-8 SS
18-8 SS
Teflon
SS/EPDM
18-8 SS
18-8 SS
18-8 SS
18-8 SS
-
18-8 SS
BUNA-N
-
18-8 SS
18-8 SS
18-8 SS
BUNA-N
TFE or BUNA-N BUNA-N
MYLAR MYLAR
-
316 SS
-
316 SS
316 SS
316 SS
316 SS
316 SS
BUNA-N
BUNA-N
BUNA-N
Fiber
18-8 SS
18-8 SS
Teflon
SS/EPDM
18-8 SS
18-8 SS
-
Nylon
316 SS
Fiber
18-8 SS
18-8 SS
Soft PVC
18-8 SS
316 SS
18-8 SS
18-8 SS
18-8 SS
18-8 SS
Fiber
316 SS
316 SS
17-4 PH
17-4 SS
316 SS
Teflon com posite
-
17-4 PH
Teflon
15-7 MO
440C SS
440C SS
15-7 MO
-
BUNA-N
18-8 SS
Tie rod - spring side
Hex head bolt
Travel stop bolt
Flat washer
316 SS
18-8 SS
18-8 SS
18-8 SS
316 SS
18-8 SS
18-8 SS
18-8 SS
3
4
1
2
5
Item
Housing
Yoke
Piston rod
Bearing - yoke
7
8
6a
6b
9
10
11
12
12a
12b
Bushing - piston rod
Thrust pin
Slide Block
Retaining ring - pin
Plug - thrust pin access
49
50
51
52
Pointer adaptor
Drive bar
Screw - accessory deive
Pointer
Round head screw
Cover - housing
Hex head bolt - cover
Lock washer - cover
Pointer washer
Vent Valve
Cylinder
Piston
Adaptor
End cap
Rod cover
Seal - piston rod
Seal - piston bolt
Seal- piston
Gasket - housing
Hex head bolt - piston
Lock washer - piston
Bearing - piston
Thread seal
Travel stop bolt
Jam nut
Socket head cap screw
Tie rod
Seal - yoke
Lock washer
Hex head bolt
Stato-seal
Cylinder O-ring
Label - Nameplate
Seal - Outpuut shaft bushing
Cylinder - spring side
Tie rod - spring side
Hex head bolt
Travel stop bolt
35
36
37
38
32
33
34
25
26
27
28
29
30
31
16
17
18
19
20
21
22
23
24
13
13a
13b
13c
14
15
39
41
42
43
44
45
46
47
48
Material
1480-2380
316 SS
17-4 PH
316 SS
Teflon Com posite
Bronze
440C SS
Bronze
15-7 MO
18-8 SS
Nylon
18-8SS
18-8 SS
BUNA- N
18-8 SS
18-8 SS
BUNA-N
BUNA-N
MYLAR
BUNA-N
316 SS
316 SS
316 SS
316 SS
316 SS
BUNA-N
BUNA-N
BUNA-N
Fiber
18-8 SS
18-8 SS
Teflon
SS/EPDM
18-8SS
18-8SS
316 SS
316 SS
18-8 SS
18-8 SS
Steel
Steel
Soft PVC
18-8 SS
316 SS
18-8 SS
18-8 SS
18-8 SS
Brass
Jackscrew Override
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 4: Manual Handpump Hydraulic Override
May 2020
Section 4: Manual Handpump
Hydraulic Override
SHUT
SHUT
See Figure 5:
A.
B.
C.
Maintain fluid level to fill line using ISO-22 hydraulic fluid. Use Chevron
"Hydraulic Oil AW" or equal.
The selector control valve is set in center position for remote operation. Select left or right positions for manual open or manual close as shown on pump label.
Store and lock handle to keep pump plunger closed. Do not remotely operate actuator with handle on plunger.
Figure 5 Hydraulic Override
Reservoir
Handle
Selector valve
Manual Handpump Specifications:
1.
2.
3.
4.
Maximum reservoir fill volume = 75 cu. in.
Pump relief pressure = 1500 psi
Pump volume/stroke = 0.66 cu. in.
Handle length = 24 in.
Manual Handpump Hydraulic Override 9
Section 4: Manual Handpump Hydraulic Override
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
4.1
4.2
Hydraulic Fluid Level
The fluid level in the handpump reservoir changes when the actuator is operated.
The fluid level is high when the hydraulic cylinder piston rod is retracted into the hydraulic cylinder. The fluid level is low when the hydraulic cylinder piston rod is extended out of the hydraulic cylinder. Measure the fluid level in the low position, using a dip stick, and maintain this level as shown on the sticker (1 inch above the pump base). Operate the actuator open and closed and view the fluid level to verify where the low position is.
Be sure to tighten the fill port plug securely.
!
CAUTION
Do not exceed this fluid level or fluid may squirt out of the relief valve.
Remote Mounting the Handpump
The handpump is normally installed on the actuator with the fill port on top.
When installed on a valve in a pipeline, the fill port must remain on top regardless of the angle of the valve in the pipeline. This may require the handpump to be reinstalled in the field. The handpump can be remote mounted on an adjacent structure.
The optimum position is close to and above the actuator. If the handpump is located below the actuator, both speed control valves must be completely closed before removing the reservoir fill plug to check the fluid level. This will prevent hydraulic fluid from draining out of the actuator. Reset both speed controls after the fill plug is reinstalled.
NOTE:
Handpump must not be located more than 33" lower than the actuator.
10 Manual Handpump Hydraulic Override
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 5: Integral Proximity Switch Mounting
May 2020
Section 5: Integral Proximity
Switch Mounting
(Only with Prox Prep Factory Ordered Option)
A.
B.
C.
D.
Remove plastic plugs from proximity ports located on the back of the actuator housing.
Insert switch and turn clockwise until switch touches ferrous activator on yoke, then back off approximately 1/16 in.
Test switch by stroking actuator and verifying make and break of switch.
Repeat procedure for second switch if required.
Integral Proximity Switch Mounting 11
12
Section 6: Spring Conversion to change Operating Pressure
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 6: Spring Conversion to change
Operating Pressure
All spring packs except the 40 psi consist of an inner and outer spring. The 40 psi spring pack uses an outer spring only. Various spring packages are available as shown in the
Bettis catalog.
!
CAUTION
Before attempting spring conversions always be sure that spring is in the "failed" or extended position. Remove any accessory equipment that may cause the spring to be cocked (e.g.: declutchable override, jackscrew override, etc.).
A. Back off adjustable travel stop on end of actuator opposite spring end. This will allow maximum spring extension inside the actuator.
(Models 003)
B.
C.
Remove tie rod bolts (41). Back off piston bolt (33) until spring is fully relaxed and piston (25) is free.
Remove 80 psi spring package and replace with desired spring package.
D. Re-assemble piston, cylinder, endcap and tie rods, being sure to follow the tie rod tightening sequence (Figure 6A). Do not over tighten bolts. Refer to Assembly
Torque Requirements Chart (Table 2).
(All models except 003)
A.
B.
C.
D.
Alternately and uniformly remove bolts (51) from hollow tie rods. Back off each bolt approximately 1/4 in. following the tie rod sequence (Figure 6A). Repeat the sequence until spring(s) is/are totally relaxed and endcap is free.
Remove 80 psi spring package and replace with desired spring package.
Re-assembly endcap with bolts (51). Use reverse procedure as shown in step B, being sure to follow the tie rod tightening sequence (Figure 6A). Be sure each hollow tie rod slides into the counterbore in endcap. Do not over tighten bolts.
Refer to Assembly Torque Requirement Chart (Table 2).
Remove nameplate from actuator and stamp or etch correct spring pressure rating accordingly.
Spring Conversion to change Operating Pressure
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 7: Failure Mode Change
May 2020
Section 7: Failure Mode Change –
Spring-Return
(Models 003-100) Symmetric Yoke Actuators Only
Conversion from "fail close" to "fail open" is accomplished by flipping the actuator over (i.e. left to right). The top and bottom of the center housing have identical mounting flanges and output shaft dimensions. Remove the vinyl pointer and indicator plate and mount them on opposite side of actuator.
(Models 023-2380) Canted and Symmetric Yoke Actuators (Except Noted Above)
Conversion requires removal of the spring cylinder assembly and reinstallation on the other side of the housing. It is recommended that fail open and fail closed be ordered from the factory.
Failure Mode Change 13
14
Section 8: Removal of Actuator from Valve
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 8: Removal of Actuator from Valve
!
CAUTION
Do not attempt to remove mounting bolts between actuator and valve until supply pressure has been disconnected and vented. If spring return, be sure that valve is completely in failed position. If valve is frozen in a position causing the spring to be cocked, removal of bracket bolts would allow spring to stroke, resulting in the actuator rotating over bracket causing possible injury or damage.
A.
B.
C.
Loosen bracket to actuator bolts to hand tight position.
Physically shift actuator back and forth to be sure there is no strain (or shear stress) on the bracket bolts. Once it has been determined that there is no pressure or spring coil remaining in the actuator, remove bolts and remove actuator and coupling from valve.
In the event the valve is frozen or locked in place, resulting in spring energy remaining in the actuator, replace adjusting screw (37) on end of actuator opposite spring end with length of "all thread" rod of sufficient length and turn clockwise until it contacts the piston. This procedure will safely secure the piston and spring assembly and allow actuator removal. Be sure to remove "all thread" rod prior to actuator disassembly.
Figure 6
Figure 7
Figure 8
Removal of Actuator from Valve
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 9: Disassembly
May 2020
Section 9: Disassembly
9.1 Disassembly of Symmetric Yoke Actuators
H.
I.
J.
K.
L.
M.
N.
A.
B.
C.
Remove endcap(s) (27); tie rods (41) and cylinder (24). Remove rod cover (28) if applicable.
Remove piston bolts (33) and pistons (25) and springs if applicable (55 and 56).
Remove adaptor (26) and piston rod seals (29).
Note: 003 one piece cast housing / adaptor.
D. Remove housing cover (18), pointer (16) and position indicator (where applicable) (13).
(Models 003-100)
E.
F.
G.
Disengage yoke (2) from roller bearing assembly by pulling piston rod to extreme right, as in Figure 6, and swing yoke mechanism clear of roller bearing as in Figure 7.
Rotate piston rod 90° to allow access to retaining ring (11) as shown in Figure 8.
Remove retaining ring and bearing (10). Then rotate piston rod (4) 180° and remove the bearing and thrust pin assembly.
H.
I.
J.
Remove piston rod (4) and piston rod bushings (7).
Remove plug (12) from back of housing.
Using a punch or suitable dowel pin, insert through clearance hole and press yoke pin (6) out.
Remove retaining ring (8) from output shaft. Remove output shaft and yoke.
K.
L. Remove bushings (5) from housing.
(Models 135, 270-1150)
E.
F.
G.
Disengage yoke (2) from roller bearing assembly by pulling piston rod (4) to extreme right, as in Figure 6, and swing yoke (2) clear of roller bearing (10) assembly. See Figure 7.
Rotate piston rod (4) 90° to allow access to retaining ring (11) as shown in Figure 8.
Remove the thrust pin retaining rings (11) and withdraw the roller bearings (10), and thrust pin (9).
Remove piston rod (4) and piston rod bushings (7).
Remove retaining rings (8) and (12b) on both ends of output shaft.
Remove thrust plate (13b) and thrust washers (22) from the output shaft (3).
Position the yoke (2) in the fully clockwise position (viewed from the thrust plate
(13b) side).
Using a soft hammer, drive output shaft (3) out through top of housing (1).
Withdraw yoke (2) from housing (1).
Remove the output shaft bushings (5) from the housing (1).
Disassembly 15
Section 9: Disassembly
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
(Models 1480, 1929, 1930, 2380)
E.
F.
G.
H.
I.
J.
Remove the pointer (16) and accessory drive (13) from the actuator by removing the screw (14) from inside the yoke (2) bore.
Remove all cover bolts (19). Three of these bolts occupy "jack bolts" holes and are threaded into the cover (18). Screw three long cover bolts into these "jack bolt" holes and turn them sequentially 1/2 turn at a time to pry the cover off. See Figure 7A.
Remove the thrust pin access plug (12). (Figure 6A)
Push the yoke (2) using the piston rod (4) until the thrust pin (9) is centered over the thrust pin access hole (See Figure 6A). Remove the upper thrust pin retaining ring (11) from the thrust pin (9) (Figure 8A).
Push the thrust pin (9) and lower retaining ring (11) out through the thrust pin access hole allowing the slide blocks (10) to fall free. Remove the slide blocks (10).
Remove the piston rod (4), piston rod bushings (7), yoke (2). Remove yoke bearings (5), and yoke seals (48) from the housing (1) and cover (18).
Remove the upper and lower vent valves (22) from the back of the housing.
Figure 6A
Figure 7A
Jack bolts
Thrust pin access
Figure 8A
Yoke Slide block and thrust pin
16 Disassembly
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
9.2
Section 9: Disassembly
May 2020
Disassembly of Canted Yoke Actuators
Canted yoke actuators are disassembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models:
(Models 023-100)
These actuators are disassembled using the same procedure as the symmetric actuators.
However, the thrust pin (9) is removed from the housing (1) via access plugs on the upper and lower housing mounting flanges.
(Models 135-1150)
A.
B.
C.
D.
E.
F.
G.
Remove the pointer (16), pointer adaptor (13) and pry out the thrust plate seal
(12) (if fitted).
Remove the thrust plate (13b) and thrust washers (22) from the output shaft (3).
Position the yoke (2) in the fully clockwise position (viewed from the thrust plate
(13b) side).
Using a soft hammer, drive output shaft (3) out through the thrust plate side of the housing (1). This will drive out the upper output shaft bushing (5) and yoke key (6b).
Remove the piston rod bushings (7) from the housing (1).
Shift the yoke (2) around in the housing (1) so that the thrust pin (9) and roller bearing (10) assembly can be moved out of the yoke slot. Remove the thrust pin retaining rings (11) and withdraw the roller bearings (10), thrust pin (9), piston rod
(4) and yoke (2).
Remove the lower output shaft bushing retaining ring (12b) and lower output shaft bushing (5).
Figure 8C
1.
2.
Curved arm of yoke
Canted Yoke Actuator
Open Position - Top view
Symmetric Yoke Actuator
Open Position - Top view
The canted yoke piston rod is not symmetrical, it must be positioned as shown.
The symmetrical yoke piston rod can be installed either way.
Canted yoke must be installed oriented as shown.
Disassembly 17
18
Section 10: Assembly
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 10: Assembly
10.1 Assembly of Symmetric Yoke Actuators
(Models 003-100)
A.
B.
C.
Insert piston rod bushings (7) and output shaft bushings (5) in housing.
(On models B-006 through 100 lube output shaft bushings O-rings (48) with
"Dow Corning #112" lubricant. Push one O-ring halfway on each bushing and install bushings in housing.)
Place yoke (2) in position in housing. Lubricate with "WD-40" or similar lubricant and install output shaft (3). (On models B-006 through 100, lube output shaft
O-rings (42) with "Dow Corning #112" lubricant. Install one O-ring on one end of output shaft and insert through housing and yoke. Install second O-ring on opposite end of output shaft and push output shaft back into housing.)
Secure output shaft with retaining rings (8).
Lubricate and press yoke pin (6) into yoke and output shaft assembly from open side of housing. Be sure pin is pressed flush in yoke to prevent interference with piston rod (4).
(Models 135, 270-1150)
A.
B.
Insert yoke key (6b) into output shaft (3).
Install yoke (2) in housing (1). Slide output shaft (3) through top of housing (1) into the yoke (2). Install lubricated upper and lower bearings (5a).
C. Install lower thrust washer (22), thrust plate (13), upper thrust washer (22) retaining ring (8) and thrust plate seal (12) (if fitted). Install lower bearing retaining ring (12b).
(Models 003-1150)
D.
E.
F.
G.
H.
I.
Lubricate with "WD40" and install piston rod (4) being careful not to scratch sealing surfaces when sliding through yoke assembly.
Swing yoke clear toward left side of housing as shown in Figure 8.
Sub-assemble thrust pin (9) with one roller bearing (10) and one retaining ring (11). Pre-lubricate sub-assembly with high temperature grease such as
"Whitmore’s Omnitemp II".
Install roller bearing sub-assembly per Figure 8. Rotate piston rod 180° and assemble second roller bearing and retaining ring. Place ample amount of high temperature grease on roller bearing and inside wear area of yoke.
Engage roller bearing in yoke assembly as shown in Figure 8, 7, and 6.
Install plug (12) in back of housing if applicable. Use "Loctite 222 Thread Locker".
Assembly
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 10: Assembly
May 2020
(Models 1480-2380)
A.
B.
C.
Install yoke seals (42) using o-ring lube and yoke bearings (5) using WD-40 into the cover (18) and housing (1).
Inspect the housing upper and lower vent passages and clear any blockage. Install new vent valves (22).
Lubricate the bearing surfaces of the yoke (2) with WD-40 and install the yoke
(2) in the housing (1). Install the yoke with the marking and the pointer drive bar visible through the cover hole.
Install the piston rod bushings (7) and the piston rod (4).
D.
E.
F.
Install the lower retaining ring (11) on the thrust pin (9) and lubricate the pin with
Whitmore grease. Lubricate the slide blocks (10) with Whitmore grease inside and out and position them in the yoke (2) slots. Insert the thrust pin (9) through the thrust pin access hole (Figure 6) and slide it through the lower slide block (10), piston rod (4), and upper slide block (10). Install the upper retaining ring (11) on the thrust pin (9).
Place joint compound on the sealing surface of the cover (18), install the cover on the housing (1), and torque the cover bolts (19) to 30 ft-lb. Install the short cover bolts (19) into the jack bolt holes of the cover (18).
G.
H.
Insert a bead of Dow Corning 732 silicone sealant on the cover (18) sealing surface and install the cover (18) on the housing (1) torquing the bolts to 15 in-lb.
Install the cap seal (12a) and cap (15).
(Cylinder and Rod Cover Assembly-All Models)
Assemble bolt (33) on end of piston rod before installing rod cover when rod cover is required.
A.
B.
C.
Install rod cover (28) if applicable. Actuators utilizing one piston only require a rod cover. Bolt rod cover and gasket in place with socket head screws (39).
Use "Locktite 222 Thread Locker."
For models 1485 – 3072 install the piston rod spacer plate.
Assemble piston rod o-ring (29) on piston rod. Lubricate o-ring with "Dow Corning
#112" lubricant.
Assembly 19
Section 10: Assembly
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Figure 9
1
TIe Rod Tightening Sequence
3
5
1
4
20
4 2
3
2
6
C.
D.
E.
Table 2.
A.
B.
F.
G.
H.
Assembly Torque Requirements (ft/lb)
Model No.
003
S-006, 012
023 thru 100
135, 270
344
345
210, 420
370, 575 thru 7114
Adaptor Bolt (44) Piston Bolt (33)
N/A
15
30
150
150
150
150
250
15
15
40
150
150
150
150
250
Tie Rod (41)
10
15
30
150
250
150
250
250
Tie Rod Bolt
Spring Side (51)
N/A
10
25
100
100
250
250
250
Assemble adaptor (26) to housing using gasket (32) between adaptor and housing. If actuator is spring return model be sure to insert long tie rod bolts (51) with washer into adaptor prior to bolting adaptor to housing. Secure the adaptor
(26) using hex head bolts (44) with stato-seals (45). Use "Locktite 222 Removable
Thread Locker" on the bolts. Uniformly tighten referring to Assembly Torque
Requirement (Figure 9 and Table 2) for proper bolt torque.
Lubricate piston bolt o-ring (30) with "Dow Corning #112" lubricant and put on piston rod. Assemble piston (25) to piston rod with bolt (33) and lock washer (34).
Use "Locktite 262 Permanent Thread Locker"on bolt threads. Rotate piston before tightening piston bolt to ensure proper seating of o-ring.
Install cylinder gasket or lubricated o-ring (46) in adaptor groove.
Lubricate piston seal (31) with "Dow Corning #112" lubricant and install on piston.
Lubricate piston bearing (35) and cylinder (24) with "Dow Corning #112" lubricant.
Hold piston bearing (35) in place on piston (25) and slide cylinder (24) over piston and bearing until cylinder is in contact with gasket / o-ring (46) in adaptor groove.
On spring return models substitute one cylinder (24) with cylinder (49) on spring side.
Assemble tie rods (41) on adaptor.
Insert cylinder gasket / o-ring (46) in endcap (27) groove and place endcap over tie rods (41) and on cylinder (24).
Assemble lock washers (43) and hex nuts (HP Models) on tie rods and uniformly tighten. Do not exceed torque values shown in Assembly Torque Requirement
Table (Figure 9 and Table 2).
Assembly
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
10.2
Section 10: Assembly
May 2020
Spring-Return Only
(Models 003)
L.
M.
Place cylinder gasket / O-ring (46) in endcap (54).
Place springs in adaptor, being sure to nest in contours. Mount piston (25) over springs and fasten with piston bolt (33) and lock washer (34). Do not over tighten bolts. Refer to Assembly torque requirements chart (Table 2).
All Models (except 003)
N.
O.
On spring return models; hollow tie rods (50) must be screwed onto long bolts
(51) protruding from adaptor (26).
Place cylinder gasket / o-ring (46) in endcap (54). Insert long bolts (51) with flat washer (53) in endcap.
P. Place spring(s) in cylinder, being sure to nest in piston contours. Mount endcap over extended spring(s) and fasten to hollow tie rods (50) with bolts (51).
To prevent galling, lubricate bolts (51) with "Whitmore’s Omnitemp II" grease or equal. Alternately and uniformly tighten bolts (51) in hollow tie rods. Tighten each bolt approximately 1/4" – 1/2" following the sequence shown in Tie Rod Tightening
Sequence (Figure 9) until spring is completely compressed. Be sure that each hollow tie rod slides into the counterbore in the endcap. Do not over tighten bolts.
Refer to Assembly Torque Requirements Table (Figure 9 and Table 2).
All Models
Q.
R.
Install position indicator (13) and pointer (16), where applicable. Assemble adjusting screws (37), thread seals (36) and jam nuts (38). Lubricate the rubber face of the thread seal with Dow Corning #112 lubricant and install finger tight against the endcap. Tighten the seal approximately one turn so that the rubber begins to bulge beyond the metal portion of the seal.
Stoke actuator with rated supply air and check for leaks. The thread seal may be tightened up to one additional turn if there is any leakage at the adjusting bolt.
Assembly 21
Section 10: Assembly
May 2020
10.3
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Assembly of Canted Yoke Actuators
Canted yoke actuators are assembled the same way as the symmetric yoke actuators except for the following additional instructions for specific models.
Canted yoke actuators have a non-symmetrical piston rod as well as a non-symmetrical yoke. It is important to orient the piston rod with the longer dimension in relation to the yoke as shown in Figure 8C. Note that the finished housing assembly is used for both fail open and fail closed actuators.
I.
J.
(Models 135-1150)
A.
B.
C.
D.
E.
F.
G.
H.
Insert the yoke (2) into the housing (1) and position the yoke in the fully clockwise position (viewed from the thrust plate (13b) side).
Insert the piston rod (4) correctly oriented with the longer dimension as shown in
Figure 8C.
Install the thrust pin (9) and roller bearings (10) using generous amounts of
Whitmore Omnitemp grease and install both pin retaining rings (11).
Shift the yoke (2) and piston rod (4) so that the thrust pin (11) and roller bearing
(10) assembly can be inserted into the yoke slot. The absence of the piston rod bushings (7) and output shaft bushings (5) allows just enough room for this process.
Insert the lower output shaft bushing (5) and retaining ring (12b). This bushing must have a press fit. The integral seal o-ring must be oriented toward the yoke.
Insert the yoke key (6b) into the output shaft (3), then insert the output shaft into the housing (1) and yoke(2) and lower output shaft bushing (5).
Install the upper output shaft bushing (5) over the output shaft and into the housing (5). The bearing must have a press fit. The integral seal o-ring must be oriented toward the yoke.
Install output shaft thrust washer (22), thrust plate gasket(13b) thrust plate (13b), thrust washer (22) and retaining ring (8).
Install Pointer adaptor (13) using two socket head cap screws.
Install the thrust plate seal (12), pointer (16) and pointer washer (21).
22 Assembly
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 11: Operating Instructions
May 2020
Section 11: Operating Instructions
Operate the actuator in accordance with the pressure and temperature limits specified on the nameplate. See the appropriate Bettis Catalog for technical information.
Operating Instructions 23
24
Section 12: Important Safeguards
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 12: Important Safeguards
!
CAUTION
To reduce the risk of injury:
• Read the entire Operation and maintenance Instruction manual before installing, operating, or servicing this actuator.
• Inspect the actuator regularly for signs of corrosion and repair immediately.
• Always remove pressure and disconnect power supply before servicing the actuator.
• Keep hands and feet clear of an actuator that is in service.
• Do not disassemble the actuator without reviewing the disassembly procedure in this manual first. This is particularly important that the proper procedure be followed to avoid injury from internal spring power.
• Before attempting to remove an actuator from the equipment it is assembled to, always be sure that spring is in the "failed" or extended position. Remove any accessory equipment that may cause the spring to be cocked. If there is any doubt that the actuator is in the "failed" position, remove the air pressure from the actuator and install a long threaded bolt (a bolt that exceeds the length of the cylinder) in place of both travel stops. Once the actuator has been removed from the equipment the long bolts must be removed first before the actuator can be disassembled.
• Repair or replace a damaged actuator immediately.
• Inspect the vent valves on models 1480 – 2380 during regular maintenance periods.
The valves should allow leaking fluids to escape but prevent contaminates from the surrounding atmosphere from entering the actuator. Fluid leaking from the lower valve indicates a valve stem seal leak. Fluid leaking from the upper valve indicates a leaking cylinder seal. If leakage is observed from either valve disassemble and repair the source immediately. Never replace the vent valves with plugs.
• Operate the actuators within the pressure and temperature ranges specified on the nameplate. Otherwise the actuator life may be reduced or serious safety hazards may develop.
Important Safeguards
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 13: Additional Safety Instructions
May 2020
Section 13: Additional Safety Instructions for Actuators used in a
Potentially Explosive Atmosphere under ATEX 2014/34/EU
13.1
13.2
13.3
13.4
Marking
• ATEX 2014/34/EU, Ex II 2G Ex h IIc T4 Gb
Selection
•
•
Ensure that the equipment is marked with the correct equipment group, category and type of atmosphere for the application and that the safety instructions are followed for each item of the equipment.
In particular, all items included in an actuator package, including valve, actuator and all accessories should be CE marked to ATEX in the appropriate and / or requested category.
Installation
•
•
•
•
•
•
•
The installer must only use tooling appropriate to the working area, see EN 1127-1 Annex A.
Installation must be carried out at ambient temperature.
During installation ensure that no metallic shocks / impacts are made to the equipment or the adjacent piping.
Ensure that the equipment is suitably earthed (grounded) through the pipe or individually.
The installer should thoroughly follow the operating and safety instructions provided for each individual item of equipment.
When the valve is to handle hot fluids or fluids where exothermic reactions may take place, the end user must take al the necessary measures to ensure that the hot surface of the valve cannot provide a source of ignition to the surrounding gas, vapour, mist or dust atmosphere.
Before putting into use or during operation with a dangerous fluid, ensure that no release of the fluid to atmosphere can take place.
Maintenance
•
•
•
•
The operator shall ensure that maintenance and testing activities are carried out by competent personnel.
The operator must ensure that only personnel qualified to work in a potentially hazardous area are allowed to carry out maintenance appropriate to the category of the equipment in use.
The end user must ensure that only tooling appropriate to the working area is used, see EN 1127-1 Annex A.
All equipment must only be fitted with manufacturer’s original spare parts.
Additional Safety Instructions 25
26
Section 14: Additional Safety Instructions
May 2020
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
Section 14: Additional Safety Instructions for Actuators used in
Emergency Shut-down Service or IEC 61508 safety integrity level (SIL) Compliant Installations
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
The actuator will move a valve to the designated safe position per the actuator design within the specified safety time.
The actuator has met the systematic requirements for SIL-3.
The actuator is a Type A device with a hardware fault tolerance (HFT) = 0.
If the automated partial valve stroke test (PVST) diagnostics is used, the diagnostics time is the PVST test interval.
Customer is required to confirm the actuator is operated within the listed temperature limitations shown on page 1.
Customers may voluntarily register their actuator by contacting Bettis Actuator sales department.
Actuators should be inspected for proper functioning and signs of deterioration every 100,000 cycles or annually (whichever comes first) under normal operating conditions. Inspect more frequently under severe operating conditions. Defects should be repaired promptly.
Normal operating conditions are: Air Quality within ANSI/ISA-7.0.01 standards; operating temperature and pressures consistent with the actuator nameplate and catalog limits; environment free from excessive particulates; operating environment consistent with the actuator materials of construction. Under these conditions, actuator life can exceed a million cycles.
The recommended minimum operating interval is six months and a partial stroke is acceptable to confirm that the installation is functioning.
When an actuator has been repaired or any maintenance is performed, check the actuator for proper function (proof testing). Any failures effecting functional safety should be reported to the Pelham facility.
IEC 61508 (SIL) installations should consult the Emerson factory to obtain the assessment and FMEDA report, which include failure data, PFDAVG, and other associated statistical data to establish or satisfy SIL level or requirements. This information is available in report MOR 12\04-064 R001 V1 R1 FMEDA.
Proof testing of the actuator shall be performed on the interval determined per
IEC 61508 / IEC 61511 requirements. A suggested proof test is included in report
MOR 12\04-064 R001 V1 R1 FMEDA. No special tools are needed. The report includes the achieved proof test coverage.
Service and maintenance on actuators shall only be performed by personnel trained in Safety Integrity Systems (SIS) operations and in the repair and maintenance procedure for Bettis actuators.
Additional Safety Instructions
Installation, Operation and Maintenance Manual
MAN-02-01-39-0704-EN Rev. 1
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Notes
May 2020
World Area Configuration Centers (WACC) offer sales support, service, inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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1616 Modderfontein Extension 5
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T +27 11 451 3700
EUROPE
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29017 Fiorenzuola d’Arda (PC)
Italy
T +39 0523 944 411
For complete list of sales and manufacturing sites, please visit www.emerson.com/actuationtechnologieslocations or contact us at [email protected]
www.emerson.com/bettis
VCIOM-13941-EN ©2020 Emerson. All rights reserved.
The Emerson logo is a trademark and service mark of Emerson Electric Co.
Bettis TM is a mark of one of the Emerson family of companies.
All other marks are property of their respective owners.
The contents of this publication are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.
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