Bettis Bettis RPE-Series Installation, Operation and Maintenance Manual Manuals & Guides

Installation, Operation and Maintenance Manual

Bettis RPE-Series

Rack and Pinion Pneumatic Actuators

DOC.IOM.BE.EN Rev. 9

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Table of Contents

Section 1: Before You Start

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

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

1.3 On-Site Storage ............................................................................................ 2

Section 2: Introduction

2.1 Identification ................................................................................................ 3

2.2 Intended Use ................................................................................................. 5

2.3 Specifications ................................................................................................ 5

Section 3: Configuration Code

Table of Contents

March 2019

Section 4: Installation

4.1 Before You Start ............................................................................................9

4.2 Actuator Rotation Direction .......................................................................... 9

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

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

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

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

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

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

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

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

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

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

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

Section 5: Mechanical Stroke Adjustment

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

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

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

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

Section 6: Maintenance

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

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

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

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

Table of Contents

Section 7: Decommission (Out of Service)

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

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

I

Table of Contents

March 2019

Section 8: Disassembly

Section 9: Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 10: Troubleshooting

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

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

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

Section 11: Parts List and Spare Parts Recommendations

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

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

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

C.2 Convert a Standard Actuator into a Full Stroke Adjustment Version ............ 57

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

C.3 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

II

Table of Contents

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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

Section 1: Before You Start

March 2019

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.

Before You Start

1

Section 1: Before You Start

March 2019

1.3 On-Site Storage

• All actuators should be stored in a clean, dry warehouse, free from excessive vibra-

tion and rapid temperature changes.

• Prevent moisture or dirt from entering the actuator. Plug or seal both air connec-

tion ports.

NOTICE

Failure to follow the above guidelines (Warehouse and On Site Storages) will void warranty.

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

2

Before You Start

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 2: Introduction

This section explains:

• How to identify the received product.

• The intended use of the product.

• Construction details.

• Actuator specifications.

2.1 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.

Section 2: Introduction

March 2019

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

25 ­100

150 -

600

4000

Size End cap design

5

Spring design

6

Pinion bottom /
Insert design

2

950 -

2500

SR

Maximum 12

spring cartridges

Maximum 6

loose springs

Left

Right

Left Right

Left Right

DA

SR DA

SR DA

SR DA

Maximum 12

spring cartridges

Maximum 6

loose springs

Left Right

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.

1

2

3 4

Section 2: Introduction

March 2019

Figure 1 Identification

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

4

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

2.2 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.

2.3 Specifications

Table 1. Pressure Range

Actuator Type Pressure

Double-Acting 0.2 to 8 bar (2.9 to 116 psi)

Spring-Return

Table 2. Operating Media

6 to 8 bar (87 to 116 psig), with maximum spring set
3 to 8 bar (43.5 to 116 psig), reduced spring quantity

Section 2: Introduction

March 2019

Actuator Type Operating Media

Air, dry or lubricated and inert gases
Dew point at least 10K below ambient temperature

Double-Acting and Single Acting

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

For sub-zero applications, take appropriate measures
Mentioned pressure levels are "gauge pressures".

Gauge pressure is equal to absolute pressure minus
atmospheric pressure.

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 Temperature

Standard -20°C to 80°C (-4°F to +176°F)
Option: Low Temperature -40°C to +80°C (-40°F to +176°F)
Option: High Temperature -10°C to +120°C (+14°F to +250°F)

Introduction

5

A

B

Section 2: Introduction

March 2019

Table 4. Air Volumes and Consumption

Actuator

model

RPE 0025 0.14 0.20 0.08 0.36 0.64 1.2 0.48 0.88 1.7
RPE 0040
RPE 0065 0.40 0.56 0.22 1.02 1.8 3.4 1.3 2.4 4.7
RPE 0100 0.6 0.9 0.3 1.5 2.7 5.0 2.0 3.8 7.2
RPE 0150 1.0 0.8 0.5 2.4 4.3 8.1 2.1 3.6 6.7
RPE 0200
RPE 0350
RPE 0600 3.6 3.3 2.1 9.4 17 31 8.7 15 28
RPE 0950
RPE 1600 7.9 7.3 5.4 21 37 69 20 35 64
RPE 2500 12.6 11.9 8.3 34 59 109 32 56 104
RPE 4000 21.7 19.0 13.5 57 100 187 52 89 165

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Actuator volumes:

Maximum volume (in liters) Outward Stroke Inward Stroke

Central

chamber

1

End cap

chamber

2

Displaced

3

volume

Double-Acting

and Spring-Return

2 4 8 2 4 8

0.26 0.37 0.15 0.67 1.2 2.2 0.89 1.6 3.1

1.3 1.0 0.7 3.2 5.7 11 2.8 4.9 9.1

2.1 1.9 1.2 5.5 9.8 18 5.0 8.8 16

4.9 4.6 3.2 13 23 43 12 22 40

Consumption per stoke

(in liters, pressure in barg)

Double-Acting only

Consumption per stoke

(in Cu.in., pressure in psig)

Double-Acting only

Actuator

model

Actuator volumes:

Maximum volume (Cu.in.) Outward Stroke Inward Stroke

Central

chamber

1

End cap

chamber

2

Displaced

3

volume

Double-Acting

and Spring-Return

40 80 120 40 80 120

RPE 0025 8.5 12.2 4.7 28 52 75 38 72 106
RPE 0040
RPE 0065

15.9 23 8.9 53 96 140 71 133 196
24 34 13.5 81 148 215 107 200 294

RPE 0100 36 53 19.9 118 216 314 165 310 455
RPE 0150 58 47 32 192 352 512 163 293 424
RPE 0200 76 64 44 255 466 676 220 397 573
RPE 0350 131 115 76 436 796 1157 392 709 1025
RPE 0600 222 201 129 742 1354 1967 683 1237 1790
RPE 0950 301 279 196 1025 1854 2682 966 1735 2505
RPE 1600 484 447 328 1662 2997 4331 1560 2792 4024
RPE 2500 769 728 508 2630 4751 6873 2515 4523 6530
RPE 4000 1324 1159 825 4477 8130 11782 4022 7219 10416

Notes:

1. Pistons at 90° outward position.

2. Pistons at 0° inward position.

3. Stroke is 90°.

Figure 2 Actuator air volumes

Central air chamber volume

Double-Acting and Spring-Return

6

End cap air chamber volume

Double-Acting only

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 3: Configuration Code

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

Section 3: Configuration Code

March 2019

Miscellaneous options
Internal code 1
Color / finish
Visual indicator
Temperature
Valve stem connection

Type

RPED Double Acting

RPES Spring Return

Size

0025 Size 0025 0350 Size 0350
0040 Size 0040 0600 Size 0600
0065 Size 0065 0950 Size 0950
0100 Size 0100 1600 Size 1600
0150 Size 0150 2500 Size 2500
0200 Size 0200 4000 Size 4000

Rotation angle

N 90° rotation angle

Threads

M Metric ISO 5211

U UNC/NPT/Imperial

Spring Set

00 Double Acting (no springs)
10 Spring Set 10 40 Spring Set 40
20 Spring Set 20 50 Spring Set 50
30 Spring Set 30 60 Spring Set 60

Rotation direction

CW Spring to Close/Clock Wise

CC Spring to Open/Counter Clock Wise

Pinion Material

AL High Grade Aluminium, Hard anodized
SS Stainless steel ASI 316 (+ A4-70 SS fasteners)

Valve Interface

TN Standard ISO 5211 interface
SY Small interface with center plate (DIN3337)
LY Large interface with center plate (DIN3337)

(2

Notes:
See next page.

Valve Stem Connection

Actuator

size

0025 11mm / 0.433" L11 D11 Q11

0040 &

0065

0100

0150

0200 22mm / 0.866" L22 D22 Q22

0350

0600 27mm / 1.063" L27 D27 Q27
0950 36mm / 1.417" L36 D36 Q36

1600 &

2500

4000 (355mm / 2.165" Q55 Q55 Q55

Temperature Range

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

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

L Low: -40°C to +80°C (-40°F to +176°F)

Visual Indication Code

K Standard (Knob)
N No Visual Indication

Finish

(7

B Standard coating (Bettis Orange)

Internal code 1

00 Standard
10 Stainless steel AISI316 (A4-70) end cap screws

Miceleanuous options

XX Standard
H1 1/2" High Flow plate
P1 1/2" Porting according EN 15714-3 (only sizes 950-4000)

Square

No insert 000 Not applicable

14mm / 0.551" L14 D14 Q14

17mm / 0.669" D17 Q19
19mm / 0.748" L19
17mm / 0.669" D17 Q22
19mm / 0.748" L19

22mm / 0.866" D22 Q27
27mm / 1.063" L27

46mm / 1.811" L46 D46 Q46

Aluminum Stainless Steel
Parallel
drive

Diagonal

drive

Star drive

(7

(4

Configuration Code

7

Section 3: Configuration Code

March 2019

Notes:

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

2. 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.

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

4. 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.

5. Contact you local Bettis representative for additional insert options.

6. PED Group 1 Label only available up to size 950.

7. 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.

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

8

Configuration Code

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 4: Installation

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.

4.1 Before You Start

Section 4: Installation

March 2019

SAFETY

In case of an air or electrical failure, it is important to know the behavior of the actuator.
Before mounting the actuator on a valve, consult the following sections below.

4.2 Actuator Rotation Direction

4.2.1 Valve Rotation

For the following paragraphs we assume that valves rotate as indicated in figure 3.

Figure 3 Normal valve rotation

Installation

The valve is closed after

a clockwise rotation.

The valve is open after

a counterclockwise rotation.

9

A

BA

Section 4: Installation

March 2019

4.2.2 Position After Failure

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

1. Principle of operation (see paragraph 4.3)

2. Assembly codes (see paragraph 4.4)

3. Kind of failure. Refer to the table below.

Table 5. Position After Failure

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Principle of

Operation

Assembly Code Kind of Failure Position

CW

Double-Acting

Actuator

Single-Acting

CW

(Spring-Return)

Actuator

4.3 Principles of Operation

4.3.1 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.

Pressure Not defined

Signal Closed

Supply Voltage Closed

Pressure Not defined

Signal Open

Supply Voltage Open

Pressure Closed

Signal Closed

Supply Voltage Closed

Pressure Open

Signal Open

Supply Voltage Open

10

Figure 4 Typical solenoid operation

Spring-Return Operation Double-Acting Operation

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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

Table 6. Operating Speed

Cycle time in seconds

Actuator

size

25 0.5 0.4 0.5 0.4
40 0.6 0.5 0.6 0.5

65 0.7 0.5 0.6 0.6
100 0.8 0.6 0.8 0.7
150 1.0 0.8 0.9 0.8
200 1.3 0.9 1.0 1.0
350
600 3.2 1.9 2.2 2.2
950 6.6 2.2 2.4 2.0

1600 10.6 3.5 3.6 3.3
2500 16.9 5.7 5.8 5.2
4000 29.1 9.2 9.2 9.0

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

pressurized

Spring-Return Double-Acting

A-port

1.9 1.3 1.4 1.5

Spring
stroke

Section 4: Installation

A-port

pressurized

March 2019

B-port

pressurized

Test conditions:

1. Solenoid with flow capacity: 0.6 m3/hr

2. Pipe diameter: 6mm

3. Medium: clean air

4. Supply pressure: 5.5 bar (80psi)

5. Load: with average load

6. Stroke: 90°

7. Temperature: Room temperature

4.3.2 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

A

BA

A

B

B

Section 4: Installation

March 2019

Installation, Operation and Maintenance Manual

4.3.3 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

DOC.IOM.BE.EN Rev. 9

12

Inward Stroke

Installation

Installation, Operation and Maintenance Manual

A

A

B

A

DOC.IOM.BE.EN Rev. 9

4.3.4 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

Section 4: Installation

March 2019

Installation

Inward Stroke

13

AB

A

B

A

B

A
B

Pinion and
cam position

Dot in
pinion slot

Default

pistons position

Reversed
pistons position

Pinion 90°
rotated

AB

A

B

A

BA

B

Pinion and
cam position

Dot in
pinion slot

Default

pistons position

Reversed
pistons position

Springs

Pinion 90°
rotated

Section 4: Installation

Installation, Operation and Maintenance Manual

March 2019

4.4 Actuator Assembly Codes

Figure 7 Assembly Code - Double-Acting

Assembly code: CW Assembly code: CC

= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open

= Fail-to-Close = Fail-to-Open

DOC.IOM.BE.EN Rev. 9

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 Assembly code: CC

= Standard, Clockwise-to-Close rotation = Reverse, Counterclockwise-to-Open

= Fail-to-Close = Fail-to-Open

14

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

4.5 Actuator to Valve Installation

WARNING: MOVING PARTS

Actuator must be isolated pneumatically and electrically before any (dis)assembly starts.

Stay away from moving parts to prevent serious injuries. When test cycling the actuator
and valve assembly by applying pressure to the 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.

Section 4: Installation

March 2019

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. Tool Table

Symbol Tool Symbol Tool

Wrench – All types and sizes.

Metric and Imperial

Circlip Pliers

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

2. Visually check to make sure the valve is CLOSED.

Figure 9 Valve handle removal

Allen key

Installation

15

Section 4: Installation

March 2019

3. When required, check if the insert drive (23) is mounted. If not, use a plasticmallet

Figure 10 Insert drive Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

and tap slightly until the reducer square is in the required position.

90°

90°

Parallel

square

45°

Flat head

90°

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

16

Installation

Installation, Operation and Maintenance Manual

Indicator mounting “In-line”

DOC.IOM.BE.EN Rev. 9

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

Section 4: Installation

March 2019

Actuator size ISO Pattern

25

40, 65, 100

150, 200, 350

600

950

1600, 2500

4000

F03 inner pattern M5 2.0 3.0 10-24UNC 1.5 2.2
F05 outer pattern M6 4.5 5.0 1/4"-20 3.3 3.7
F05 inner pattern M6 4.5 5.0 1/4"-20 3.3 3.7
F07 outer pattern M8 10.5 12.5 5/16"-18 7.7 9.2
F07 inner pattern M8 10.5 12.5 5/16"-18 7.7 9.2
F10 outer pattern M10 21.0 24.5 3/8"-16 15.5 18.1
F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1
F12 outer pattern M12 34.5 43.0 1/2"-13 25.4 31.7
F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1
F14 outer pattern M16 90.0 104.0 5/8"-11 66.4 76.7
F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5

F25* outer pattern 4x M16 90.0 104.0 4x 5/8"-11 66.4 76.7

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5
F25 outer pattern 8x M16 90.0 104.0 8x 5/8"-11 66.4 76.7

Torque (Nm) Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

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

Figure 12 Actuator to valve mounting

Size 12 - 350 Size 600 - 4000

26 26

90°

90°

Indicator mounting “Across Line”

90°

Installation

17

Section 4: Installation

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

4.6 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.

4.7 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

1.2 meters 4 feet 1.2 meters 4 feet

25, 40, 65 6 mm 1/4 inch 6 mm 1/4 inch

100, 150, 200,

350, 600

950, 1600, 2500,

4000

Runs up to Runs over to

6 mm 1/4 inch 8 mm 5/16 inch

6 mm 1/4 inch 10 mm 3/8 inch

18

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 5: Mechanical Stroke Adjustment

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

March 2019

80°

95°

Open

90°

Closed

Size 950 - 4000Size 25 - 600

Closed

-5°10°

90°

80°

93°

Open

-3°10°

Limit Stop 2Limit Stop 1

Mechanical Stroke Adjustment

19

Stop 1

Stop 2

Stop 1

Stop 2

Section 5: Mechanical Stroke Adjustment

March 2019

Installation, Operation and Maintenance Manual

5.1 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.

5.1.1 Double-Acting Actuators

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

2. Remove air supply.

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

DOC.IOM.BE.EN Rev. 9

Figure 14

4. 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.

5. Tighten the lock nut.

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

7. Remove air supply.

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

5.1.2 Spring-Return Actuators

20

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

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

Figure 15

Mechanical Stroke Adjustment

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

3. 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.

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

5. Check whether the actuator valve assembly is in the required position.
If not repeat steps 1 to 5.

6. Remove air supply.

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

Table 10. Limit stop dimensions

Actuator size Thread Bolt wrench size (mm) Nut wrench size (mm)

25 M6 10 10
40 M8 13 13

65 M10 17 (16)* 17 (16)*
100 M10 17 (16)* 17 (16)*
150 M10 17 (16)* 17 (16)*
200 M12 19 (18)* 17 (18)*
350 M16 24 24
600 M20
950 M 22

1600 M 24 14 36
2500 M 27 17 41
4000 M 22 12 32

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

Section 5: Mechanical Stroke Adjustment

March 2019

30
12

30
32

5.1.3 Angular Displacement

Below table identifies, per actuator size, what the angular displacement of the pinions is,
when using the limit stop screws.

— Turn the limit stop clockwise reduces the stroke.

— Turn the limit stop counteclockwise to increase the stroke.

Table 11. Angular Displacement limit stops

Actuator size

25 0.7 7.1°
40 0.8 6.3°

65 0.6 8.3°
100 0.7 7.1°
150 1.2 4.2°
200 1.0 5.0°
350 0.8 6.3°
600 0.8 6.3°
950 1.1 4.7°

1600 1.3 4.1°
2500 1.5 3.4°
4000 3.2 1.6°

NOTICE

Turns for 5° adjustment of

the pinion:

360° revolution of limit

stop screw will adjust

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

Section 6: Maintenance

March 2019

Installation, Operation and Maintenance Manual

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.

DOC.IOM.BE.EN Rev. 9

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.

22

• 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

• 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 com-

plete 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.

6.2 Inspection and Repair

Replacement of internal seals and bearings allows to you extend the normal working
life. Service kits, containing all necessary spare parts (like seals, bearings, grease and
instructions) can be obtained through authorized Emerson – Actuation Technologies
distributors.

Section 6: Maintenance

March 2019

6.2.1 Service Kits

All soft seals, bearings, and nonreusable parts are included in the recommended service
kit. The service kit is identical for both the double-acting and the spring-return models.

6.2.2 Spring-Return Actuator

For the spring-return models, we recommend a set of spare springs for each different
model in addition to the recommended spare parts kit.

On spring-return actuators, the spring cartridges can be replaced. SPRING CARTRIDGES
SHOULD ALWAYS BE REPLACED IN COMPLETE SETS. Spring kits are available through
authorized Emerson – Actuation Technologies distributors.

Maintenance

23

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)

This section explains:

• How to decommission an actuator in a safe way.

7.1 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.

24

Decommission (Out of Service)

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Section 7: Decommission (Out of Service)

7.2 Removing the actuator from the valve

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

2. Disconnect all electrical wirings of the switch box.

3. Disconnect the electrical wiring of the solenoid valve.

4. Remove the bolts and nuts from the valve flange.

5. Remove the bracket from the actuator.

6. 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

March 2019

2

4

Decommission (Out of Service)

25

Section 8: Disassembly

March 2019

Installation, Operation and Maintenance Manual

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.

DOC.IOM.BE.EN Rev. 9

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.

26

Disassembly

Installation, Operation and Maintenance Manual

2

6

8

6

11

6

5

10

8

10

11

2

DOC.IOM.BE.EN Rev. 9

Section 8: Disassembly

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

8.1 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

March 2019

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

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:

Figure 18 Spring-Return End Caps Removal

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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.

28

Disassembly

Installation, Operation and Maintenance Manual

3

1

4

5

11

2

30

5

9

11

10

2

9

10

2

6

2

11

6

8

10

8

10

2

11

DOC.IOM.BE.EN Rev. 9

Section 8: Disassembly

8.2 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.

March 2019

Figure 19 Double-Acting End Caps Removal sizes 950 to 4000

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

7

7

Section 8: Disassembly

March 2019

Figure 20 Spring-Return End Caps Removal sizes 950 to 4000

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

10

9

3

6

1

4

5

2

5

11

2

11

2

30

8.3 Removing Spring Cartridges or Springs

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

Figure 21 Removing Spring Cartridges size 25 to 600

5

10

9

30

Disassembly

Installation, Operation and Maintenance Manual

7

7

DOC.IOM.BE.EN Rev. 9

Figure 22 Removing Springs size 950 to 4000

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.

Section 8: Disassembly

March 2019

Figure 23 Limit Stop Removal

33 30

32

8.5 Removing Pistons

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

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

31

Disassembly

31

Section 8: Disassembly

March 2019

8.6 Removing Pinion

1. 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).

2. 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.

3. 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).

4. Discard all of these parts.

Figure 25 Pinion Removal

Sizes 25 to 600

23

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

19

19

27

Sizes 950, 1600, and 2500

23

27

19

Size 4000

23

27

19

21

29 25

25

18

29 19 18

24

18

21

2221

20

22

20

32

Table 12. Recommended circlip pliers according DIN 5254 (or equal) for circlips.

Actuator

size

25 - 100 22 mm 0.866" A2 1600 75 mm 2.953" A3

150 - 350 36 mm 1.417" A3 2500 95 mm 3.74" A4

600 55 mm 2.165" A3 4000 96 mm 3.78" A4
950 65mm 2.559" A3

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

8.7 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

17

14

16

15

16

17

Section 8: Disassembly

15

March 2019

Disassembly

33

Section 9: Reassembly

March 2019

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.

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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.

34

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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. Grease Instructions

Part Section of part Amount of grease

O-rings:

Housing Parts:

Piston Parts:

Piston Parts:

A Completely
B Piston bore Light film
C Top pinion bore Light film
D Bottom pinion bore Light film
E

O-ring & bearing groove
F Rack teeth Half the teeth depth full with grease
G Piston bearing Light film on outside
H Piston rack bearing strip Light film

J

Pinion bottom & O-ring groove Light film

K Pinion top & O-ring groove Light film

L Gear teeth Half the teeth depth
M Pinion top bearing Light film (inside and out)
N Pinion bottom bearing Light film (inside and out)

Section 9: Reassembly

March 2019

Light film

Light film

Reassembly

Figure 26 Grease Instructions

A

M

K

L

J

N

A

B

A

E

C

F

G

A

H

A

A

D

35

Section 9: Reassembly

Installation, Operation and Maintenance Manual

March 2019

9.2 Reassembly of the pinion

1. Grease the pinion parts according to chapter 9.1.

2. 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).

3. 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).

4. 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 Reassemble the pinion

2

Sizes 25 to 600

23

1

19

DOC.IOM.BE.EN Rev. 9

19

27

1

1

Sizes 950, 1600, and 2500

2

23

27

19

Size 4000

2

23

27

19

21

29 19

24

29 25

21

18

18

18

21

2221

20

22

20

36

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

Reassembly

Installation, Operation and Maintenance Manual

17

14

16

16

17

14

15

15

DOC.IOM.BE.EN Rev. 9

Section 9: Reassembly

March 2019

Actuator

size

25 - 100 22 mm 0.866" A2 1600 75 mm 2.953 A3

150 - 350 36 mm 1.417" A3 2500 95 mm 3.74 A4

600 55 mm 2.165" A3 4000 96 mm 3.78 A4
950 65mm 2.559" A3

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

9.3 Reassembly of the pistons

NOTICE

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

1. Grease the piston parts according to step 9.1.

2. Install the piston rack bearing strips (17) and piston O-ring seals (16) on the pis­tons (14). Ensure all these parts are kept in place during assembly.

Figure 28 Reassemble the pistons

Pinion top

diameter

Pliers according

DIN 5254

Reassembly

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.

37

90°

90°

Assembly code CW Assembly code CC

(Standard; Spring-to-Close) (Reverse; Spring-to-Open)

A

B

A

B

C

C

Section 9: Reassembly

March 2019

4. Slightly push the pinion inward to engage with the pinion.

5. When the pistons are moved 90° inwards (see figure 26), check that the pinion slot

6. If not, turn pinion to move the pistons outward until they disengage from the

7. Move the pistons outward so that just the bearing groove sticks out of the hous-

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

— Ensure that smooth movement and 90-degree operation can occur with-

out 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.

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.

pinion. Shift one tooth of the pinion, reassemble and check again.

ing. 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

38

A = Position of cam

B = Position of slot and dot in pinion.

C = Final position of pinion dot.

Reassembly

Installation, Operation and Maintenance Manual

33 30

31

32

DOC.IOM.BE.EN Rev. 9

NOTE:

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

Section 9: Reassembly

9.4 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

March 2019

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

3. Double check if the position of the slot and the cam on the pinion top is in the cor-

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

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

centerline of the housing.

rect position (see figure 26). Screw in the right hand travel stop until it comes into
contact with the pinion stop face.

centerline of the housing.

face.

— For accurate travel stop adjustment of the actuator on the valve,

see section 5.

Reassembly

39

2

6

9

6

11

6

5

10

9

10

11

2

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

9.5 Reassembly of the end caps

9.5.1 Double-Acting actuators

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

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

3. Install the end caps (6) and tighten the end cap screws (8).
Refer to Table 15 for the correct torque.

Figure 31 Double-Acting end cap assembly

DOC.IOM.BE.EN Rev. 9

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. End cap Screw Torque

Actuator

size

25 M5
40 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2

65 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2
100 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2
150 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8
200 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8
350 M8 SW 6 8.4 6.7 12.2 6.2 4.9 9.0
600 M10 SW 8 15.3 12.2 24.8 11.3 9.0 18.3
950 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7

1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7
2500 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7
4000 M14 SW12 43.5 34.8 66.4 32.1 25.7 49.0

Thread Tool Size

Allen Key

SW 4 2.0 1.6 3.0 1.5 1.2 2.2

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

40

Reassembly

Installation, Operation and Maintenance Manual

1

2 3

4

56

A

B

1

2

3

4

56

1

23

4

56

N = 10

N = 20

N = 30

1

2 3456

1

23

4

5

6

1

23

4

5

6

N = 40

N = 50

N = 60

DOC.IOM.BE.EN Rev. 9

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

Section 9: Reassembly

March 2019

Reassembly

A = Piston top view
B = Position of piston gear rack

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

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

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

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end
cap screw in small equal turns and in the sequence as per Figure 33. Refer to Table
15 for the correct torque. We recommend to use some grease on the screws for
easier fastening.

41

3

1

4

5

11

2

30

5

9

11

10

2

9

10

2

Section 9: Reassembly

March 2019

Installation, Operation and Maintenance Manual

Figure 33 Spring Return End cap assembly size 25 to 600

9.5.3 Spring-Return actuators - Size 950 to 4000

DOC.IOM.BE.EN Rev. 9

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

N = 10 N = 20 N = 30

DOC.IOM.BE.EN Rev. 9

Figure 34 Spring placement size F950 to F4000

Left RightLeftRight Left Right

B

A

1 spring 0 spring 1 spring 1 spring 2 springs1 spring

N = 40 N = 50 N = 60

Section 9: Reassembly

March 2019

Left

2 springs

Right Left RightLeft Right

2 springs 3 springs2 springs3 springs3 springs

Reassembly

43

Section 9: Reassembly

March 2019

A = Piston top view
B = Position of gear rack

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

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

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

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end

Figure 35 Spring Return end cap assembly size 950 to 4000

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

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.

10

9

3

6

1

4

5

2

5

11

2

11

2

30

5

10

9

44

Reassembly

Installation, Operation and Maintenance Manual

AB

DOC.IOM.BE.EN Rev. 9

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. Apply pressure (max. 8 bar/120 psi) to ports A and B. Use some soap suds at the
indicated points: around pinion top (1), pinion bottom (2), the end caps (3) and
limit stops (4).

2. In case of leakage around:

a. The limit stop bolts: Turn the lock nut of the bolts tighter, until the leak-

age 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.

Section 9: Reassembly

March 2019

Figure 36 Basic function and air leak test

1

4

B

A

3

2

3

Reassembly

45

Section 10: Troubleshooting

March 2019

Installation, Operation and Maintenance Manual

Section 10: Troubleshooting

10.1 Mechanical Problems

Problem Possible error Solution Where to find

Feedback position and
actual position are not
the same.

Valve is in “Closed”
position, actuator is in
“Open” position and will
not move anymore.

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

Limit stop screws are not
set correctly.

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

Readjust the limit stop
screws.

DOC.IOM.BE.EN Rev. 9

Section 4

Section 5

Valve does not reach the
completely “Closed” or
“Open” position.

Actuator rotates, valve
does not.

Actuator does not
rotate or does not rotate
smoothly.

Limit stop screws cannot
be turned out anymore.

Insert is not mounted
properly.

Pressure to low. Apply pressure as per sizing.

Sizing is wrong.

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.

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

Check valve torque data
with actuator torque data.

Re assemble actuator. Section 9

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 4.5

Appendix A.

46

Troubleshooting

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

10.2 Pneumatic Problems

Problem Possible error Solution Where to find

Actuator does not react
to electrical control
signal.

Actuator does not
react good to electrical
control signal.

Air leakage between
actuator and solenoid
valve.

There is no supply
pressure at the
actuator.

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

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

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.

Section 10: Troubleshooting

Supply the right
pressure to the
actuator.

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.

March 2019

Section 2.3
Check that the actual
supply pressure is
higher than the sizing
pressure.

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.

Leakage notice on the
actuator.

Actuator has wrong
solenoid valve
configuration.

Seals on the limit stops
screws are not air tight.

Seals on the end caps
are not air tight.

Seals on the pinion top
and bottom are not air
tight.

Mount a solenoid valve
suitable for double­acting actuators
(4/2 or 5/2 function).

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

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

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.

Instructions shipped
with the solenoid valve.

Instructions shipped
with the solenoid valve.

Section 9.6

Section 9.6 or Section 6

Section 9.6 or Section 6

Troubleshooting

47

Section 10: Troubleshooting

March 2019

Installation, Operation and Maintenance Manual

10.3 Electrical Problems

Problem Possible error Solution Where to find

Control wiring.
Power supply wiring or
feedback wiring are not

Actuator does not react
to control signals.

There are problems
with position feedback
after sending the
actuator to either the
“Open” or “Closed”
position.

right connected.
The power supply

voltage is not is not the
same as the voltage of
the applicable solenoid
valve.

The wiring of the
feedback signals may
be switched.

Connect all wiring in
the right way.

Connect the right
power supply voltage.

Connect the feedback
wiring in the right way.

DOC.IOM.BE.EN Rev. 9

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

21

19

18

6

30

33

31

32

1

16

15

14

17

19

21

3

28

2

7

11

12

8

10

5

13

9

10

Table 16. Parts List

Pos. Qty Notes Description Material

1 1 House Cast Aluminium alloy
2 2 1 B-port seal Nitrile rubber
3 1 Center plate (optional) Nylon PA6, Black
5 2 2 End cap SR (DA) Cast Aluminium alloy
6 2 2 End cap DA Cast Aluminium alloy
7 Max. 12 Spring cartridge Spring steel
8 8 End cap screw DA Stainless Steel

9 8 End cap screw SR Stainless Steel
10 8 End cap screw washer Stainless Steel
11 2 1 O-ring end cap Nitrile rubber
12 2 Warning sticker DA Polyester
13 2 Warning sticker SR Polyester
14 2 Piston Cast Aluminium alloy
15 2 1 Bearing piston PTFE 25% carbon-filled
16 2 1 O-ring piston Nitrile rubber
17 2 1 Bearing strip piston rack POM
18 2 Pinion High grade aluminium
19 2 1 Bearing pinion POM
21 2 1 O-ring pinion Nitrile rubber
23 1 1 Thrust bearing pinion POM, black UV stabilized
26 1 Indicator assembly ABS + stainless steel screw
27 1 1 Circlip Spring steel
28 1 Drive insert Aluminium
30 2 Limit stop screw Stainless steel
31 2 Limit stop nut Stainless steel
32 2 1 Limit stop washer PA66
33 2 1 O-ring limit stop 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

Installation, Operation and Maintenance Manual

March 2019

11.2 Actuator sizes RPE950 to RPE2500

26

30

31

32

33

19

1

27

23

29

21

18

16

15

DOC.IOM.BE.EN Rev. 9

6

8

10

12

9

10

5

17

14

20

22

28

4

3

2

11

7

Table 17. Parts List

Pos. Qty. Notes Description Material

1 1 House Cast Aluminium alloy

2 2 1 B-port seal Nitrile rubber

3 1 Center plate (option) Nylon PA6, Black

4 12 Thread insert Steel

5 2 End cap SR Cast Aluminium alloy

6 2 End cap DA Cast Aluminium alloy

7 Max. 6 Springs Spring steel

8 12 End cap screw DA Stainless Steel

9 12 End cap screw SR Stainless Steel
10 12 End cap screw washer Stainless Steel
11 2 1 O-ring end cap Nitrile rubber
12 2 Warning sticker DA Polyester
13 2 Warning sticker SR Polyester
14 2 Piston Cast Aluminium alloy
15 2 1 Bearing piston PTFE 25% carbon-filled
16 2 1 O-ring piston Nitrile rubber
17 2 1 Bearing strip piston rack POM
18 1 Pinion High grade aluminium
19 2 1 Bearing pinion top POM
20 1 1 Bearing pinion bottom POM
21 1 1 O-ring pinion top Nitrile rubber
22 1 1 O-ring pinion bottom Nitrile rubber
23 1 1 Thrust bearing pinion POM, black UV stabilized
26 1 Indicator assembly ABS + stainless steel screw
27 1 1 Circlip Spring steel
28 1 Drive insert Aluminium
29 1 1 Backup ring POM
30 2 Limit stop screw Stainless steel
31 2 Limit stop nut Stainless steel
32 2 1 Limit stop washer PA66
33 2 1 O-ring limit stop Nitrile rubber

Notes:

1 Included in Service Kit.

13

50

Parts List and Spare Parts

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

11.3 Actuator size RPE4000

Section 11: Parts List and Spare Parts

March 2019

26

27

23

30

25

24

31

32

17

14

133

20

22

19

29

21

18

4

3

16

15

11

2

7

Table 18. Parts List

Pos. Qty. Notes Description Material

1 1 House Cast Aluminium alloy

2 2 1 B-port seal Nitrile rubber

3 1 Center ring (option) Stainless Steel AISI 304

4 12 Thread insert Steel

5 2 End cap SR Cast Aluminium alloy

6 2 End cap DA Cast Aluminium alloy

7 Max. 6 Springs Spring steel

8 12 End cap screw DA Stainless Steel

9 12 End cap screw SR Stainless Steel
10 12 End cap screw washer Stainless Steel
11 2 1 O-ring end cap Nitrile rubber
12 2 Warning sticker DA Polyester
13 2 Warning sticker SR Polyester
14 2 Piston assembly Cast Aluminium alloy
15 2 1 Bearing piston PTFE 25% carbon-filled
16 2 1 O-ring piston Nitrile rubber
17 2 1 Bearing strip piston rack POM
18 1 Pinion High grade aluminium
19 2 1 Bearing pinion top POM
20 1 1 Bearing pinion bottom POM
21 1 1 O-ring pinion top Nitrile rubber
22 1 1 O-ring pinion bottom Nitrile rubber
23 1 1 Thrust washer pinion POM, black UV stabilized
24 1 Cam stroke adjustment Steel
25 1 1 Cam thrust washer POM, black UV stabilized
26 1 Indicator assembly ABS + stainless steel screw
27 1 1 Circlip Spring steel
29 1 1 Backup ring POM
30 2 Limit stop screw Stainless steel
31 2 Limit stop nut Stainless steel
32 2 1 Limit stop washer PA66
33 2 1 O-ring limit stop Nitrile rubber

Notes:

1 Included in Service Kit.

6

12

8

10

9

10

5

13

Parts List and Spare Parts

51

Crush / Amputaion Hazard

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

WARNING

1

2

3

4

Appendix

March 2019

Installation, Operation and Maintenance Manual

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.

DOC.IOM.BE.EN Rev. 9

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

52

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

1. Depressurize the actuator completely.

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

3. Replace one by one each end cap screw for the threaded rod kit and turn down the
adjusting nut until it touches the end cap.

4. Once all for end cap screws have been replaced, gradually turn the adjustment
nuts on threaded rod in CCW direction by turning the nuts half turn at a time.
Make sure the rod itself does not turn. Continue this until the load of springs are
relieved.

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

6. In case of an actuator/valve assembly “stuck” in mid position: The actuator now
can be disassembled from Valve, by removing the mounting studs / bolts.

Table A-1. Threaded rod dimensions in mm

Appendix

March 2019

Actuator size Thread

25 M5 140 5.5
40 M5 140 5.5

65
100 M5 140 5.5
150 M6 145 5.7
200 M6 145 5.7
350 M8 185 7.3
600 M10
950

1600 M12 498 19.6
2500 M12 498 19.6
4000 M14 600 23.6

M5 140

M12 498 19.6

Figure A-2 Spring load removal rod dimensions

Length

Thread

Washer

Threaded Rod

Threaded rod length

(mm) (inch)

5.5

185 7.3

Holding nuts

Adjusting nut

Appendix

53

Appendix

March 2019

Installation, Operation and Maintenance Manual

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

DOC.IOM.BE.EN Rev. 9

Actuator

size

25 M5
40 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2

65 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2
100 M5 SW 4 2.0 1.6 3.0 1.5 1.2 2.2
150 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8
200 M6 SW 5 3.3 2.6 5.1 2.4 1.9 3.8
350 M8 SW 6 8.4 6.7 12.2 6.2 4.9 9.0
600 M10 SW 8 15.3 12.2 24.8 11.3 9.0 18.3
950 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7

1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7
2500 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7
4000 M14 SW12 43.5 34.8 66.4 32.1 25.7 49.0

Thread Tool Size

SW 4 2.0 1.6 3.0 1.5 1.2 2.2

Allen key

Torque (Nm) Torque (lbf.ft)

Target Min. Max. Target Min. Max.

Table B-2. Bottom Flange

Actuator

size

25

40, 65, 100

150, 200, 350

600

950

1600, 2500

4000

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

ISO Pattern

F03 inner pattern M5 2.0 3.0 10-24UNC 1.5 2.2

F05 outer pattern M6 4.5 5.0 1/4"-20 3.3 3.7

F05 inner pattern M6 4.5 5.0 1/4"-20 3.3 3.7

F07 outer pattern M8 10.5 12.5 5/16"-18 7.7 9.2

F07 inner pattern M8 10.5 12.5 5/16"-18 7.7 9.2

F10 outer pattern M10 21.0 24.5 3/8"-16 15.5 18.1

F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1

F12 outer pattern M12 34.5 43.0 1/2"-13 25.4 31.7

F10 inner pattern M10 21.0 24.5 3/8"-16 15.5 18.1

F14 outer pattern M16 90.0 104.0 5/8"-11 66.4 76.7

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5

F25* outer pattern 4x M16 90.0 104.0 4x 5/8"-11 66.4 76.7

F16 inner pattern M20 170.0 204.0 3/4"-10 125.4 150.5

F25 outer pattern 8x M16 90.0 104.0 8x 5/8"-11 66.4 76.7

Metric Torque (Nm) Imperial Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

54

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

Flange

Solenoid flange screw threads M5 2.0 3.0 10-24UNC 1.5 2.2

Top flange screw threads M5 2.0 3.0 10-24UNC 1.5 2.2

Metric Torque (Nm) Imperial Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Table B-4. Limit stop screws and nuts

Actuator size Thread

25 M 6 10 10
40 M 8 13 13

65 M 10 17 (16)
100 M 10 17 (16)
150 M 10 17 (16)
200 M 12 19 (18)
350 M 16 24 24
600 M 20 30 30
950 M 22 12 32

1600 M 24 14 36
2500 M 27 17 41
4000 M 22 12 32

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

Table B-5. Recommended circlip pliers according DIN 5254 (or equal)
for shaft circlips

Appendix

March 2019

Bolt Wrench Nut wrench

size (mm) size (mm)

1

1

1

1

17 (16)
17 (16)
17 (16)
19 (18)

1

1

1

1

Actuator

size

Pinion top

diameter

Pliers

according DIN

Actuator

size

Pinion top

diameter

according DIN

25 - 100 22 mm 0.866" A2 1600 75 mm 2.953" A3

150 - 350 36 mm 1.417" A3 2500 95 mm 3.74" A4

600 55 mm 2.165" A3 4000 96 mm 3.78" A4
950 65 mm 2.559" A3

Table B-6. Angular Displacement Limit Stops

Actuator size

Turns for 5° adjustment of

the pinion:

25 0.7 7.1°
40 0.8 6.3°

65 0.6 8.3°
100 0.7 7.1°
150 1.2 4.2°
200 1 5.0°
350 0.8 6.3°
600 0.8 6.3°
950 1.1 4.7°

1600 1.3 4.1°
2500 1.5 3.4°
4000 3.2 1.6°

360° revolution of limit

stop screw will adjust

Pliers

Appendix

55

Appendix

March 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

Appendix C: Full Stroke Adjustment Option

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.

C.1 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 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

Appendix

March 2019

45 46 11

41 42 43 44

40

9 10

Table C-7 Content Full Stroke Adjustment Kit

Pos. Description Material Qty. Notes

40 End cap - Full stroke adjustment Cast Aluminium alloy 2 1
41 Full Stroke adjustment screw Stainless steel 2
42 Full Stroke adjustment Nut Stainless steel 2
43 Full Stroke adjustment washer PA66 2
44 O-Ring - Full Stroke adjustment screw Nitrile rubber 2
45 O-Ring - Thread bush Nitrile rubber 2
46 Thread bush Aluminium 2

9 End cap screw Stainless steel 8
10 Washer end cap screw Stainless steel 8
11 O-ring end cap Nitrile rubber 2
12 Warning sticker DA Full Stroke adjustment Polyester 2
13 Warning sticker SR Full Stroke adjustment Polyester 2

1. The same Full Stroke adjustment end cap is used for both double acting and spring return
actuators (flat double acting actuator end caps with Full Stroke Adjustoment options are
not available).

Appendix

57

Appendix

March 2019

C.2.1 Procedure

1. Remove the existing end caps of a standard actuator.

— Follow the instructions of Section 8 to remove both the end caps of the

— For spring return actuators; note the original positions of the spring car-

2. Mount the Full Stroke Adjustment End cap kit to the actuator.

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

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

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

positions.

6. Install the Full Stroke end cap kits and tighten the end cap screws (9,10). For

spring return units; tighten each endap screw (9,10) in small equal turns and in the
sequence as per Figure C-3. Refer to Appendix B, Table B-1 for the correct torque.

7. For Spring Return units, place the black warning sticker (13) on the end cap. For

Double Acting units, place the white warning sticker (12) on the end cap.

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

actuator.

tridges.

Figure C-27 Assembly of Full Stroke adjustment end cap kit

11

11

11

11

7

12

13

10

40

9

40

2

9

10

3

9

10

40

9

10

40

58

1

4

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BE.EN Rev. 9

C.3 Full Stroke Adjustment Setting

Note:

Standard actuators or actuators with the Full Stroke Adjustment option are shipped by
default with a rotation setting of 90° +/-0.5°.

The stroke adjustment setting procedure can be two steps:

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

2. Setting the Full Stroke Adjustment screw to the required angle.

C.3.1 Factory Setting Procedure

Appendix

March 2019

1. In order to set the Full Stroke Adjustment Screws accurately to the outward posi-

tion:

— 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.

2. 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

41

B

41

A-port

Appendix

You have now set the adjustment screw to the factory setting

Notes:

1. 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.

2. 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

Installation, Operation and Maintenance Manual

C.3.2 Setting the Full Stroke Adjustment Screw

to the Required Angle

1. Move the pistons of the actuator inwards.

— For Spring Return actuators this happens automatically when the actuator

is vented.

— For double acting actuators vent the A-port and apply pressure to

the B-port.

2. In order to set the actuator to the required angle, use next table to define the

number of revolutions which you have to turn in the Full Stroke Adjustment
Screws.

3. Turn in both the adjustment screws (41) as defined in step 2. Both the adjustment

screws should be turned in with the same length or number of revolutions.

CAUTION: DO NOT SET SCREWS UN-EQUAL

DOC.IOM.BE.EN Rev. 9

Screwing in only one adjustment screw or un-equal setting of both the screws will lead to
high point loads on the pistons and can cause premature failure of the actuator.

4. Test cycle the actuator to check if the correct rotation angle is set. If required,

repeat steps 1 to 3 to adjust the rotation angle to the required angle.

Table C-8 Actuator angle rotation per full revolution of Full Stroke adjustment screw

Actuator

size

25 15.7 0.62 1.0 x 5.5 M6 1 5.7°
40 18.8 0.74 1.2 x 6.5 M8 1.25 6.0°
65 22.0 0.87 1.2 x 6.5 M8 1.25 5.1°

100 25.1 0.99 1.2 x 6.5 M10 1.5 5.4°
150 31.4 1.24 1.2 x 6.5 M10 1.5 4.3°
200 37.7 1.48 1.2 x 6.5 M10 1.5 3.6°
350 37.7 1.48 1.2 x 6.5 M12 1.75 4.2°
600 44.0 1.73 1.2 x 6.5 M16 2 4.1°

Stroke

mm inch Thread Pitch (mm)

Flathead

screw driver

Screw

Actuator angle rotation per

full revolution of screw

60

Appendix

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