Bettis Installation, Operation and Maintenance Q-Series - Release 2 - 2019 Manuals & Guides

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Installation, Operation and Maintenance Manual

Bettis Q-Series

Pneumatic Actuators with Integrated Controls

DOC.IOM.BQ.E Rev. 3

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Table of Contents

Section 1: Before You Start

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

1.2 Warehouse Storage ....................................................................................... 2

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

Section 2: Introduction

2.1 Identication ................................................................................................. 3

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

2.3 Specications ................................................................................................ 5

Section 3: Configuration Code

Table of Contents

April 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 ................................................................................ 11

4.3.1 Pneumatic Operation of the Base Actuator ....................................... 11

4.3.2 Ingress Protection (IP) Rating ........................................................... 12

4.3.3 Control Module Operation................................................................12

4.3.4 Double-Acting Operation with Fail-In-Last Position Function ............ 14

4.3.5 Spring-Return Actuators ................................................................... 16

4.3.6 Position Feedback ............................................................................ 18

4.4 Actuator Assembly Codes ........................................................................... 19

4.5 Actuator to Valve Installation ...................................................................... 21

4.6 Mounting of Control Modules or Generic Control and Feedback Accessories .... 24

4.7 Recommended Tubing Sizes ........................................................................ 24

Section 5: Mechanical Stroke Adjustment

5.1 Travel Stop Adjustment ............................................................................... 26

5.1.1 Double-Acting Actuators .................................................................. 26

5.1.2 Spring-Return Actuators ................................................................... 27

5.1.3 Angular Displacement ...................................................................... 28

Section 6: Maintenance

6.1 Normal Maintenance ................................................................................... 29

6.2 Inspection and Repair .................................................................................. 30

6.2.1 Service Kits ....................................................................................... 30

6.2.2 Spring-Return Actuator .................................................................... 30

Section 7: Decommission (Out of Service)

7.1 Before You Start .......................................................................................... 31

7.2 Removing the Actuator from the Valve ........................................................ 32

ITable of Contents

Table of Contents

April 2019

Section 8: Disassembly

Section 9: Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

8.1 Removing End Caps (Size 40 to 600)............................................................ 34

8.2 Removing End Caps (Size 950 to 1600) ....................................................... 36

8.3 Removing Spring Cartridges or Springs ....................................................... 37

8.4 Removing of Limit Stop Screws ................................................................... 38

8.5 Removing Pistons ........................................................................................38

8.6 Removing Pinion ......................................................................................... 39

8.7 Cleaning the Components .......................................................................... 40

9.1 Grease Instructions ..................................................................................... 42

9.2 Reassembly of the Pinion ............................................................................. 43

9.3 Reassembly of the Pistons ........................................................................... 44

9.4 Reassembly and Settings of the Limit Stops ................................................. 46

9.5 Reassembly of the End Caps ........................................................................ 47

9.5.1 Double-Acting Actuators .................................................................. 47

9.5.2 Spring-Return Actuators (Size 40 to 600) ..........................................48

9.5.3 Spring-Return Actuators (Size 950 to 1600) ......................................50

9.6 Basic Function and Air Leak Test .................................................................. 52

Section 10: Troubleshooting

10.1 Mechanical Problems .................................................................................. 53

10.2 Pneumatic Problems ................................................................................... 54

10.3 Electrical Problems ...................................................................................... 55

Section 11: Parts List and Spare Parts Recommendations

11.1 Actuator Size Q40 to Q600 .......................................................................... 56

11.2 Actuator Size Q950 to Q1600 ...................................................................... 57

Appendix A: Spring Load Removal

A.1 Spring Load Relief ........................................................................................ 58

Appendix B: Tool & Torque Table

Appendix C: Full Stroke Adjustment Option

C.1 Full Stroke Adjustment Option .................................................................... 62

C.2 Convert a Standard Actuator into a Full Stroke Adjustment Version ............. 63

11.2.1 Procedure ........................................................................................64

C.3 Full Stroke Adjustment Setting .................................................................... 65

11.2.2 Factory Setting Procedure ................................................................ 65

11.2.3 Setting the Full Stroke Adjustment Screw to the Required Angle....... 66

Table of Contents

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 1: Before You Start

This section explains:

• Base safety procedures.

• Where to nd detailed information relating safety.

• Storage guidelines.

Installation, adjustment, putting into service, use, assembly, disassembly and maintenance

of the pneumatic actuator must be performed by qualied personnel.

NOTICE

Failure to follow the above guidelines will void warranty.

WARNING

Section 1: Before You Start

April 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 Sections in this manual.

• Safety Guide (Document No. DOC.SG.BQ.EN).

Mounted Control modules are shipped with the applicable installation guide:

QC41, QC42 or QC43: Document DOC.IG.BQC41.1.

QC40: Document DOC.IG.BQC40.1.

QC54: Document DOC.IG.BQC54.1.

For Safety Instrumented Systems application, read the following document:

• SIL Safety Manual Bettis Q-Series (Document No. DOC.SILM.BQ.EN).

Before You Start

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.

Section 1: Before You Start

April 2019

Installation, Operation and Maintenance Manual

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 oor surface - it must be placed in

racks/shelves or use a pallet.

1.3 On-Site Storage

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

vibration and rapid temperature changes.

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

connection ports.

NOTICE

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

DOC.IOM.BQ.E Rev. 3

Before You Start2

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 2: Introduction

This section explains:

• How to identify the received product.

• The intended use of the product.

• Construction details.

• Actuator specications.

2.1 Identification

The Bettis Q-Series Rack and Pinion actuators are available as double-acting or springreturn versions. 9 models are available, ranging from 40 Nm to 1600 Nm (354 to 14161 lbf. in) nominal torque output.

The Bettis Q-Series package consists of an actuator with a module for control and position feed back and forms an integrated concept for “On/Off” valve automation.

Section 2: Introduction

April 2019

1. Basic Actuators

The basic actuator supplies the torque, required to open and close valves and is available in various sizes (rated 47 to 1676Nm at 5.5barg or 413 to 14874 In.lb. at 80pisg).

Double acting and spring return executions are available. The spring return execution can be equipped with multiple spring sets to cover a pressure range from 2 to 8 barg (30 to 120 psig).

The springs in the spring-return version allow a fail action in case of loss of air supply pressure (Fail-to-Close or Fail-to-Open). As from size FD150 double-acting versions have

at end caps to reduce actuator length and internal air volume.

The springs in the spring-return version allow a fail action in case of loss of air supply pressure (Fail-to-Close or Fail-to-Open).

As from size 150 double-acting versions have at end caps to reduce actuator length and

internal air volume.

2. Control Modules

The Control Modules contain, next to the components for feedback switches, also all the pneumatic control components.

Its compact and robust construction incorporates basic control and feedback functionality and is suitable for indoor and outdoor use.

Introduction

Section 2: Introduction

April 2019

Figure 1 Identification

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

3 4

Size End cap design

SR DA

Spring design

Left

Right

Pinion bottom / Insert design

40 100

Maximum 12

spring cartridges

SR Left RightDA

150 -

600

Maximum 12

spring cartridges

Left RightSR DA

950 -

1600

Notes:

1. Top auxilliaries according (VDI/VDE 3845; NAMUR). Bettis Q-Series comes with a proprietary pneumatic interface for direct mounting of the Control modules.

2. Valve interface available according ISO5211 or DIN 3337. Actuator sizes 40 to 1600 can be fitted with driv inserts with various inner shapes.

3. Spring-Return actuators: - with springs

4. Double-Acting actuators: - no springs

5. Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models. Actuator sizes 150 to 1600 have low end caps for double-acting models and high end caps for spring-return models.

6. Actuator sizes 40 to 600 are fitted with a maximum of 12 spring cartridges. Actuator sizes 950 and 1600 are fitted with a maximum of 6 loose springs.

Maximum 6

loose springs

Introduction4

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

2.2 Intended Use

The Bettis Q-Series Rack and Pinion actuators are intended for the automation and

operation of quarter-turn valves like Buttery, Ball and Plug valves.

Rack and Pinion actuators can also be used to operate dampers or any other quarter-turn applications.

2.3 Specifications

Table 1. Pressure Range

Actuator Type Pressure

Double-Acting 0.2 to 8.3 barg (2.9 to 120 psig)

Spring-Return

6 to 8.3 barg (87 to 120 psig), with maximum spring set 3 to 8.3 barg (43.5 to 120 psig), reduced spring quantity

Section 2: Introduction

April 2019

Table 2. Operating Media

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. For the base actuator the recommended air quality for normal operation (according ISO 8573-1) is: 7-5-4.

2. In case Q-Series Control Modules are used, the operating media specication as mentioned in the Installation Guide (shipped with each control module) are applicable. QC41, QC42 or QC43: Document DOC.IG.BQC41.1. QC40: Document DOC.IG.BQC40.1. QC54: Document DOC.IG.BQC54.1.

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 lters, 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

Introduction

Actuator Type Temperature

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

1. In case Q-Series Control Modules are used, the temperature range as mentioned in the Installation Guide (shipped with each control module) are applicable. QC41, QC42 or QC43: Document DOC.IG.BQC41.1. QC40: Document DOC.IG.BQC40.1. QC54: Document DOC.IG.BQC54.1.

Section 2: Introduction

April 2019

Table 4. Air Volumes and Consumption

Actuator

model

Q 0040 0.26 0.37 0.15 0.67 1.2 2.2 0.89 1.6 3.1 Q 0065 0.40 0.56 0.22 1.02 1.8 3.4 1.3 2.4 4.7 Q 0100 0.6 0.9 0.3 1.5 2.7 5.0 2.0 3.8 7.2 Q 0150 1.0 0.8 0.5 2.4 4.3 8.1 2.1 3.6 6.7 Q 0200 1.3 1.0 0.7 3.2 5.7 11 2.8 4.9 9.1 Q 0350 2.1 1.9 1.2 5.5 9.8 18 5.0 8.8 16 Q 0600 3.6 3.3 2.1 9.4 17 31 8.7 15 28 Q 0950 4.9 4.6 3.2 13 23 43 12 22 40 Q 1600 7.9 7.3 5.4 21 37 69 20 35 64

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Actuator volumes:

Maximum volume (in liters) Outward Stroke Inward Stroke

Double-Acting

and Spring-Return

2.0 barg 4.0 barg 8.0 barg 2.0 barg 4.0 barg 8.0 barg

Central

chamber

End cap

chamber

Displaced

volume

Consumption per stoke

(in liters, pressure in barg)

Double-Acting only

Actuator volumes:

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

Actuator

model

Q 0040 15.9 23 8.9 53 96 140 71 133 196 Q 0065 24 34 13.5 81 148 215 107 200 294 Q 0100 36 53 19.9 118 216 314 165 310 455 Q 0150 58 47 32 192 352 512 163 293 424 Q 0200 76 64 44 255 466 676 220 397 573 Q 0350 131 115 76 436 796 1157 392 709 1025 Q 0600 222 201 129 742 1354 1967 683 1237 1790 Q 0950 301 279 196 1025 1854 2682 966 1735 2505 Q 1600 484 447 328 1662 2997 4331 1560 2792 4024

Central

chamber

End cap

chamber

Displaced

volume

Double-Acting

and Spring-Return

40 psig 80 psig 120 psig 40 psig 80 psig 120 psig

Consumption per stoke

(in Cu.in., pressure in psig)

Double-Acting only

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

End cap air chamber volume

Double-Acting only

Introduction

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 3: Conguration Code

This section explains:

• How to create or read the conguration code for a actuator.

QS 0150 - N U 40 CW AL TN - L17 S K B - 00 XX

Section 3: Configuration Code

April 2019

Miscellaneous options Internal code 1

Color / nish

Visual indicator Temperature Valve stem connection Valve interface Pinion material Rotation Spring set Threads Rotation angle Size Typ e

Typ e

FD Double Acting

FS Spring Return

Size

0040 Size 0040 0350 Size 0350 0065 Size 0065 0600 Size 0600 0100 Size 0100 0950 Size 0950 0150 Size 0150 1600 Size 1600 0200 Size 0200

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

Valve Stem Connection, Note 3

Actuator Size

No insert 000

0040 & 0065 14mm / 0.551" L14 D14

0100

0150

0200 22mm / 0.866" L22 D22

0350

0600 27mm / 1.063" L22 D22

0350

0600 27mm / 1.063" L27 D27 0950 36mm / 1.417" L36 D36 1600 46mm / 1.811" L46 D46

Temperature Range

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

Visual Indication Code

K Standard (Knob)

N No Visual Indication

Finish

B Standard coating (Bettis Orange)

Square

Dimensions

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

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

Parallel Drive

Diagonal

Drive

Pinion Material

AL High Grade Aluminium, Hard anodized

Valve Interface, Note 2

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

LY Large interface with center plate (DIN3337)

Notes: See next page.

Conguration Code

Internal Code 1

00 Standard

Miscellaneous Options

XX Standard: Suitable for Control module mounting

FS Full stroke adjustement (only sizes 40 to 600)

Section 3: Configuration Code

April 2019

Notes:

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

congurations. Check the actuator size page for valid congurations.

2. Valve Interface:

— Option "S"; Small Interface with Center Plate (DIN3337)

— Option "L"; Large Interface with Center Plate (DIN33337)

3. Contact your local Bettis Q-Series representative for additional insert options.

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

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

is not available for sizes 0950.

is not available for sizes 1600.

Conguration Code

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 4: Installation

This section explains:

• The actuator rotation direction.

• In which position the actuator will end after a failure.

• Principles of operation:

— Pneumatic operation.

— Double acting and Spring return operation.

• Assembly codes.

• Actuator to valve assembly.

4.1 Before You Start

Section 4: Installation

April 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.

Section 4: Installation

April 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.BQ.E Rev. 3

Principle of

Operation

Double-Acting

Actuator

Single-Acting

(Spring-Return)

Actuator

Assembly Code Kind of Failure Position

Pressure Not dened

Signal Closed

Supply Voltage Closed

Pressure Not dened

Signal Open

Supply Voltage Open

Pressure Closed

Signal Closed

Supply Voltage Closed

Pressure Open

Signal Open

Supply Voltage Open

Table 6. Position after a failure with a Double-Acting module with Fail-In-Last-Position Function

Principle of

Operation

Double-Acting

Actuator

Assembly Code Kind of Failure Position

Pressure Not dened

Signal Not dened

Supply Voltage Closed

Pressure Not dened

Signal Not dened

Supply Voltage Open

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

4.3 Principles of Operation

4.3.1 Pneumatic Operation of the Base Actuator

Bettis Q-Series actuator are intended to be operated by the Q-Series Control Modules. For more

details see section 4.3.3. Below gure shows the basic pneumatic operation of the actuator.

Figure 4 Typical Pneumatic Operation

Spring-Return Operation Double-Acting Operation

Section 4: Installation

April 2019

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

Table 7. Operating Speed

Cycle time in seconds

Actuator

size

Q 40 0.6 0.5 0.6 0.5

Q 65 0.7 0.5 0.6 0.6 Q 100 0.8 0.6 0.8 0.7 Q 150 1.0 0.8 0.9 0.8 Q 200 1.3 0.9 1.0 1.0 Q 350 1.9 1.3 1.4 1.5 Q 600 Q 950 6.6 2.2 2.4 2.0

Q 1600 10.6 3.5 3.6 3.3

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

Test conditions:

1. Solenoid with ow 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

pressurized

Spring-Return Double-Acting

A-port

3.2 1.9 2.2 2.2

Spring

stroke

A-port

pressurized

B-port

Installation

Section 4: Installation

Installation, Operation and Maintenance Manual

April 2019

4.3.2 Ingress Protection (IP) Rating

Bettis Q-Series actuators are IP66 / NEMA4 rated. In case of IP66 or NEMA4 requirements, take precautions that comply with the IP66 / NEMA4 requirements to prevent moisture or dust from entering the actuator through the open air exhaust port(s), either directly on the actuator or at the exhaust ports of the connected solenoid valve.

We recommend to connect tubing to the exhaust(s) and lead this into a dry and dust free area, or to use check valves in the exhaust.

4.3.3 Control Module Operation

The operating principle, as explained here, is applicable for actuators with assembly code CW (direct acting).

• The outward stroke will move the valve to the “Open” position.

• The inward stroke will move the valve to the “Closed” position.

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

DOC.IOM.BQ.E Rev. 3

Figure 5 Double-Acting Operation

Outward Stroke

A-port

Option: Throttle 1

5/2 Spool valve

Option: LMC

Pilot valve 1

B-port

Option: Throttle 2

1. Send control signal “Open” to the Control Module.

2. Pilot valve 1 will be activated and the 5/2spool valve will pressurize the central air chamber.

3. The piston will move outwards to the “Open” position.

4. The Control Module indicates the “Open” position and activates feedback signal “Open”.

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Figure 6 Double-Acting Operation

Inward Stroke

Section 4: Installation

April 2019

A-port

Option:

5/2 Spool valve

Option: LMC

Pilot valve 1

Throttle 1

B-port

Option: Throttle 2

1. Send control signal “Close” to the Control Module.

2. Pilot valve 1 will be deactivated and the 5/2 spool valve will pressurize the end cap air chambers.

3. The piston will move inwards to the “Closed” position.

4. The Control Module indicates the “Closed” position and activates feedback signal “Closed”.

Optional Controls:

LMC Local Manual Control SC Speed Control throttles

Important

In case of an electric control signal failure, the actuator will move to its "Closed" position.

Installation

Section 4: Installation

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

4.3.4 Double-Acting Operation with Fail-In-Last Position Function

The operating principle, as explained here, is applicable for actuators with assembly code CW (direct acting).

• The outward stroke will move the valve to the “Open” position.

• The inward stroke will move the valve to the “Closed” position.

• For assembly codes CC the operating principle is reversed (reverse acting):

Figure 7 Double-Acting Operation with Fail-In-Last Position Function

Outward Stroke

B-port

Option: Throttle 2

Pilot valve 2

Option: LMC 2

Option: LMC 1

Pilot valve 1

A-port

Option: Throttle 1

5/2 Spool valve

1. Send control signal “Open” to the Control Module to activate Pilot valve 1 and de-activate Pilot valve 2.

2. The 5/2 spool valve will pressurize the central air chamber.

3. The piston will move outwards to the “Open” position.

4. The Control Module indicates the “Open” position and activates feedback signal “Open”.

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Figure 8 Double-Acting Operation with Fail-In-Last Position Function

Inward Stroke

Section 4: Installation

April 2019

A-port

Option: Throttle 1

5/2 Spool valve

Option: LMC 1 Option: LMC 2

Pilot valve 1

B-port

Option: Throttle 2

Pilot valve 2

1. Send control signal “Close” to the Control Module to activate Pilot valve 2 and de-activate Pilot valve 1.

2. The 5/2 spool valve will pressurize the end cap air chambers.

3. The piston will move inwards to the “Closed” position.

4. The Control Module indicates the “Closed” position and activates feedback signal “Closed”.

Optional Controls:

LMC Local Manual Control SC Speed Control throttles

Installation

Section 4: Installation

Installation, Operation and Maintenance Manual

April 2019

4.3.5 Spring-Return Actuators

The operating principle, as explained here, is applicable for actuators with assembly code CW (direct acting).

• Applying supply pressure to port A will move the pistons outwards to the "Open"

position of the valve.

• Venting the supply pressure from port A will cause the springs to move the pistons

inwards to the "Close" position of the valve.

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

Figure 9 Single-Acting Operation

Outward Stoke

DOC.IOM.BQ.E Rev. 3

A-port

Option: Throttle 1

3/2 Spool valve

Option: LMC

Pilot valve 1

B-port

1. Send control signal “Open” to the Control Module.

2. Pilot valve 1 will be activated and the 3/2 spool valve will pressurize the central air chamber.

3. The piston will move outwards to the “Open” position.

4. The Control Module indicates the “Open” position and activates feedback signal “Open”.

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Figure 10 Single-Acting Operation

Inward Stroke

Section 4: Installation

April 2019

A-port

Option: Throttle 1

3/2 Spool valve

Option: LMC

Pilot valve 1

B-port

1. Send control signal “Close” to the Control Module.

2. Pilot valve 1 will be deactivated and the 3/2 spool valve will vent the central air chamber

3. The springs will move the pistons inwards to the “Closed” position.

4. The Control Module indicates the “Closed” position and activates feedback signal “Closed”.

Optional Controls:

LMC Local Manual Control SC Speed Control throttles

Installation

Section 4: Installation

April 2019

4.3.6 Position Feedback

The Bettis Q-Series actuator (1) has a patented, contact-less position sensing system. This system consists of a position probe (2) which is rides on a special curve (4) in the pinion bottom.

The curve is shaped in such a way that the position probe moves linearly and proportionally to the rotation of the actuator pinion.

The linear movement of the position probe is used, inside the control module (3) to operated the limit switches.

CAUTION

Do not put the Control module in direct contact with magnetic material. This can cause damage or malfunction of the position feedback.

Installation of the Bettis Q-Series Control Modules

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Please refer to the Installation guides, as shipped with the product, for installation instructions of the Control Module.

Installation Guides - Control modules

Each Control Module is shipped with an Installation Guide, which contains more information on the pneumatic and electrical installation and operation of the Module. Additionally, these Installation Guides can be downloaded from: www.emerson.com/bettis

Figure 11

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

4.4 Actuator Assembly Codes

Figure 12 Assembly Code - Double-Acting

Assembly Code: CW Assembly Code: CC

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

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

zes Q40 and Q65

Section 4: Installation

April 2019

A B

zes Q100 to Q1600

B A

Rotation A = Central air chamber pressurized

Rotation B = End cap air chambers pressurized

1. Limit stops location

2. Position of cam

3. Position of slot and dot in pinion

4. Default pistons position

5. Pinion 90° Rotated

6. Reversed piston position

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

Installation

Section 4: Installation

April 2019

Figure 13 Assembly Code - Spring-Return

Assembly Code: CW Assembly Code: CC

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

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

Sizes Q40 and Q65

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

A B

Sizes Q100 to Q1600

B A

Rotation A = Central air chamber pressurized

Rotation B = Spring stroke

1. Limit stops location

2. Position of cam

3. Position of slot and dot in pinion

4. Default pistons position

5. Pinion 90° Rotated

6. Reversed piston position

7. Springs

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

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

4.5 Actuator to Valve Installation

WARNING: MOVING PARTS

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

Stay away from moving parts to prevent serious injuries. When test cycling the actuator and valve assembly by applying pressure to the actuator, be aware that there are moving parts like pinion top, actuator to valve coupling and the valve- blade, ball, plug, etc.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers. For the removal of inserts, a special extractor tool can be supplied on request.

During assembly to the valve, do not hit with hammer on pinion top. This can damage the pinion top washer and cause premature failure.

Section 4: Installation

April 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 and torque.

Table 8. Tool Table

Symbol Tool Symbol Too l

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 14 Valve Handle Removal

Allen key

Installation

Section 4: Installation

April 2019

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

Figure 15 Insert Drive Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

and tap slightly until the insert is in the required position. Be sure that the insert is mounted at 90° or 45°. It is possible to mount the insert turned 22.5°. This way the valve will not open or close the right way.

90°

Parallel

square

45°

90°

Flat head

90°

Diagonal

square

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

Figure 16 Bracket Installation

Round with

key way

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

5. Install the actuator to the bracket. Tighten all bolts and apply the correct torque (Refer to Table 9).

Table 9. Bottom Flange Torque Values

Section 4: Installation

April 2019

Actuator Size ISO Pattern

40, 65, 100

150, 200, 350

600

950

1600

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

Torque (Nm) Torque (lbf.ft)

Thread Min. Max. Thread Min. Max.

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

Figure 17 Indicator Mounting

Size 950- 1600

Indicator Mounting “In-line”Size 40 - 600

90°

Indicator Mounting “Across Line”

Installation

Section 4: Installation

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

4.6 Mounting of Control Modules or Generic Control and Feedback Accessories

The base Q-Series actuator can be equipped with dedicated Q-Series Control modules or generic controls and accessories.

1. Control modules are shipped with the applicable installation guide. Please refer

to below documents when the Contorl module needs to be mounted to the base Q-Series actuator.

— QC41, QC42 or QC43: Document DOC.IG.QC41.1.

— QC40: Document DOC.IG.QC40.1.

— QC54: Document DOC.IG.QC54.1.

2. Switch boxes or positioners can be mounted to the top mounting interface

(VDE/VDI3845 NAMUR). Check the instructions as shipped with these components for installation, operating and maintenance instructions. We recommend to test-cycle the complete assembly to check correct operation.

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 sufcient ow of air supply to the actuator, the following tubing sizes are recommended.

Table 10. Tubing Sizes

Actuator size

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

100, 150, 200,

350, 600

950, 1600 6 mm 1/4 inch 10 mm 3/8 inch

1.2 meters 4 feet 1.2 meters 4 feet

Runs up to Runs over to

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

Installation

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 5: Mechanical Stroke Adjustment

This section explains:

• What mechanical stroke adjustment is.

• What the factory settings are.

• How to adjust the travel stops.

Bettis Q-Series actuator sizes 40 to 1600 have two stroke adjustment stops for adjusting accurately the stroke of the actuator/valve assembly in open and closed position.

The factory setting of the stroke is 90°. Most quarter-turn valve applications will not require readjustment of these settings.

If required the stroke can be adjusted by means of two-stroke adjustment bolts.

Figure 18 Factory Setting

April 2019

80°

95°

Open

Size 40 - 600

Closed

10°

90°

-5°

Size 950 - 1600

10°

90°

80°

93°

Open

Limit Stop 2Limit Stop 1

Closed

-3°

Mechanical Stroke Adjustment

Section 5: Mechanical Stroke Adjustment

April 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.BQ.E Rev. 3

Figure 19

Stop 1

4. Turn the “closed” stop clockwise to reduce or counterclockwise to increase the

travel. Consult Section 5.1.3 (angular displacement of the pinion), to dene 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).

Stop 2

A-port

B-port

Stop

top 2

Mechanical Stroke Adjustment

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

5.1.2 Spring-Return Actuators

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

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

Figure 20

Section 5: Mechanical Stroke Adjustment

April 2019

Stop 1

Stop 2

Stop

top 2

A-port

B-port

3. Turn the “Closed” stop clockwise to reduce or counterclockwise to increase the

travel. Consult Section 5.1.3 (angular displacement of the pinion), to dene how

far the limit stop must be turned in or out.

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

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

If not repeat steps 1 to 5.

6. Remove air supply.

7. For adjusting the open position repeat steps 1 to 6, but now for the open position

and "Open" stop (1).

Table 11. Limit Stop Dimensions

Actuator size Thread

Q 40 M 8 13 13

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

Q 1600 M 24 14 36

1. Default dimension according DIN933 standard.

2. Dimensions in brackets according ISO4017 standard.

Bolt Wrench Nut wrench

size (mm) size (mm)

Mechanical Stroke Adjustment

Section 5: Mechanical Stroke Adjustment

April 2019

5.1.3 Angular Displacement

Below table identies, per actuator size, what the angular displacement of the pinions is,

when using the limit stop screws.

— Turn the limit stop clockwise reduces the stroke.

— Turn the limit stop counterclockwise to increase the stroke.

Table 12. Angular Displacement Limit Stops

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Actuator size

Q 40 0.8 6.3°

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

Q 1600 1.3 4.1°

Turns for 5° adjustment of the pinion: 360° revolution of limit stop screw will adjust

NOTICE

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

Mechanical Stroke Adjustment

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 6: Maintenance

This section explains:

• When and how to do maintenance to the base actuator.

— Normal maintenance.

— Extraordinary maintenance.

• What to do when replacing springs.

• What the availability is of spare parts, action conversion kits and temperature

conversion kits.

WARNING

Actuator must be isolated pneumatically and electrically before any (dis)assembly starts. Before mounting or (dis)assembling the actuator, consult the relevant sections of this manual.

Section 6: Maintenance

April 2019

6.1 Normal Maintenance

Bettis Q-Series actuators are designed to operate without maintenance for their normal working life. Normal working life is 500,000 cycles* for sizes up to Q1600.

NOTE:

*Cycles = one open stroke and one close stroke.

We recommend regular inspections to make certain that the actuator / valve assembly operates smoothly and to check that there are no visible or audible defects. We advise to perform the following checks upon each proof test interval complying with the rules and

regulations of the country of nal 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 ttings as required.

• Check if manual override (where foreseen) is regular.

• Check if pneumatic lter cartridge (where foreseen) is sound and lter bowl

(where foreseen) has been cleaned properly.

Maintenance

• Check the setting of the relief valves (where foreseen).

• Verify that the power uid supply pressure value is within the required range.

• Remove built-up dust and dirt from all actuator surfaces.

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

Touch-up as required in accordance with the applicable paint specication.

Section 6: Maintenance

April 2019

• 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 sufcient lubrication for their normal working life. If required, see Section 9.1 (Grease instructions) for the recommended grease.

For mounting the parts of the repair kit follow the instruction of the Decommission, Disassembly and Reassembly sections of this manual.

Installation, Operation and Maintenance 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.

DOC.IOM.BQ.E Rev. 3

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

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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.

April 2019

A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high spring load which will cause a sudden rotation of the actuator versus the valve or valve bracket during disassembly. This can cause serious injury to personnel or damage to property.

Refer to Appendix A for instructions to safely remove the spring load before disassembling the spring-return actuator from valve or bracket.

Important

Refer to the Safety Guide for Lifting Instructions.

Decommission (Out of Service)

Section 7: Decommission (Out of Service)

April 2019

Installation, Operation and Maintenance Manual

7.2 Removing the Actuator from the Valve

1. Disconnect all air supply hoses from the control module.

2. Disconnect all electrical wirings from the Control module.

3. Remove the bolts and nuts from the valve ange.

4. Remove the bracket from the actuator.

5. Remove the the Control Module. Refer to the applicable installation guide of the mounted Control module: QC41, QC42 or QC43: Document DOC.IG.BQC41.1. QC40: Document DOC.IG.BQC40.1. QC54: Document DOC.IG.BQC54.1.

Figure 21 Removing Actuator from Valve

DOC.IOM.BQ.E Rev. 3

Decommission (Out of Service)

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 8: Disassembly

This section explains:

• How to disassemble an actuator safely.

Tip

The instructions of this section can be used for maintenance or reconguration 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.

Section 8: Disassembly

April 2019

Before mounting or (dis)assembling the actuator consult the relevant sections of this manual.

CAUTION: SPRING FORCE

Spring-return actuators contain springs in a compressed state. Follow these instructions to release the spring force safely.

The end caps of spring-return actuators sizes 40 to 600 should be free of the spring load after 10 full turns (crosswise relaxing) of the end cap screws. If there is still spring load on the end cap, this might indicate a broken spring cartridge. Stop this disassembly procedure immediately. Continuing might cause the end cap to be “shot” away causing serious injury.

Spring return actuator size 950 to 1600 have long end cap screws to release the spring load safely.

Refer to Appendix A for instructions to safely remove the spring load before disassembling the end cap of a spring-return actuator with a broken spring cartridge.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers.

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

Disassembly

Section 8: Disassembly

April 2019

Installation, Operation and Maintenance Manual

8.1 Removing End Caps (Size 40 to 600)

1. For Double-acting actuators, do the following:

a. Remove the screws (8) and washers (10) of the end caps (6).

b. Remove the o-ring (11) and "B" port seal (2). Discard these parts.

Figure 22 Double-Acting End Caps Removal

DOC.IOM.BQ.E Rev. 3

Double-Acting end caps (6) are fitted with a white warning sticker. Spring-Return end caps (5) are fitted with a black warning sticker.

Actuator sizes 40 to 100 have high end caps for double-acting and spring-return models.

Actuator sizes 150 to 1600 have low end caps for double-acting models and high end caps for spring-return models.

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

2. For Spring-return actuators, do the following:

a. Tip: For actuators with assembly code CW, turn back the right hand limit

stop screw (30) 2 full turns. For actuators with assembly code CC, turn back the left hand limit stop screw (30) 2 full turns. This will lower the spring force on the end cap and reduces the screw out length of the end cap screws.

b. Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a

time, in sequence, as per Figure 23, to relieve the pre-load of the springs.

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

Figure 23 Spring-Return End Caps Removal

Section 8: Disassembly

April 2019

Disassembly

Section 8: Disassembly

April 2019

Installation, Operation and Maintenance Manual

8.2 Removing End Caps (Size 950 to 1600)

1. For Double-acting actuators, do the following:

a. Remove the screws (8) and washers (10) of the end caps (6).

b. Remove the o-ring (11) and "B" port seal (2). Discard these parts.

Figure 24 Double-Acting End Caps Removal Size 950 to 1600

DOC.IOM.BQ.E Rev. 3

2. For Spring-return actuators, do the following:

a. Tip: For actuators with assembly code CW, turn back the right hand limit

b. Uniformly loosen the screws (9) of the end caps (5) 1/4-1/2 turns at a

time, in sequence, as per Figure 25, to relieve the pre-load of the springs.

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

Figure 25 Spring-Return End Caps Removal Size 950 to 1600

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 8: Disassembly

8.3 Removing Spring Cartridges or Springs

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

Figure 26 Removing Spring Cartridges Size 40 to 600

April 2019

Figure 27 Removing Springs Size 950 to 1600

Disassembly

Section 8: Disassembly

April 2019

Installation, Operation and Maintenance Manual

8.4 Removing of Limit Stop Screws

1. Remove the limit stop screws (30), limit stop nuts (31), limit stop washers (32) and limit stop o-rings (33). Discard the o-rings.

Figure 28 Limit Stop Removal

DOC.IOM.BQ.E Rev. 3

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.

Figure 29 Removing Pistons

Disassembly

Sizes 950 and 1600

Sizes 40 to 600

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

8.6 Removing Pinion

1. Remove the circlip (27) and thrust bearing (23) on top of the pinion assembly. For sizes 950 to 1600 remove also the top pinion bearing (19).

2. Remove the pinion (18) by pushing it downwards.

3. Remove the pinion O-ring seals (21/22) and the pinion bearings (19/20). For Size 950 to 1600, remove also the backup ring (29).

4. Discard all of these parts.

Figure 30 Pinion Removal

Section 8: Disassembly

April 2019

Disassembly

Table 13. Recommended circlip pliers according DIN 5254 (or equal) for shaft circlip

Actuator

size

40 - 100 22 mm 0.866" A2 950 65 mm 2.559" A3

150 - 350 36 mm 1.417" A3 1600 75 mm 2.953" A3

600 55 mm 2.165" A3

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

Section 8: Disassembly

April 2019

Installation, Operation and Maintenance Manual

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.

DOC.IOM.BQ.E Rev. 3

Disassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 9: Reassembly

This section explains:

• Which parts and how to grease them.

• How to reassemble a complete actuator.

• How to set the stroke adjustment bolts after reassembly.

• How to do a basic function and air leak test.

Tip

The instructions of this section can be used for maintenance or reconguration 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.

Section 9: Reassembly

April 2019

In case of reconguration replace the parts as supplied in the conversion kit (see also Section 6).

Refer to the Safety Guide for Lifting Instructions.

NOTICE

The actuator is designed to be installed, commissioned and maintained using generic tools like wrenches, Allen keys and screwdrivers.

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

Reassembly

Section 9: Reassembly

April 2019

Installation, Operation and Maintenance Manual

9.1 Grease Instructions

Check the product coding on the product labels and Section 3 of this manual, to dene

which type of grease to use.

Table 14. Recommended greases

Standard temperature:

-20°C to +80°C / -4°F to +176°F

- Castrol High Temperature - Formerly called Castrol LMX

- Rocol Sapphire Premier - Formerly called Sapphire HI-TEMP 2

- Castrol Spheerol EPL 2 - Formerly called BP Energrease LS-EP2

- Total Ceran XM 220 - Formerly called Total Ceran WR2

We recommend using a suitable sized paint brush to apply the required amount of grease on the parts as per Table 15 and Figure 31.

Table 15. Grease Instruction

Part Section of part Amount of grease

O-rings: A Completely Light lm

B Piston bore Light lm

Housing Parts:

Piston Parts:

C Top pinion bore Light lm D Bottom pinion bore Light lm

E O-ring & bearing groove Light lm

F Rack teeth Half the teeth depth full with grease G Piston bearing Light lm on outside H Piston rack bearing strip Light lm

J Pinion bottom & O-ring groove Light lm

K Pinion top & O-ring groove Light lm

L Gear teeth Half the teeth depth

M Pinion top bearing Light lm (inside and out) N Pinion bottom bearing Light lm (inside and out)

DOC.IOM.BQ.E Rev. 3

Figure 31 Grease Instructions

N A

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

9.2 Reassembly of the Pinion

1. Grease the pinion parts according to Section 9.1.

2. Install the pinion bearings (19/20) and the O-ring seals (21/22) on the pinion (18). For Size 950 to 1600, install also the the backup ring (29).

3. Insert the pinion (18) in the housing.

4. For sizes 950 to 1600 install rst 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 32 Reassemble the Pinion

Sizes 40 to 600

Section 9: Reassembly

April 2019

Sizes 950 and 1600

Table 16. Recommended circlip pliers according DIN 5254 (or equal) for shaft circlips

Actuator

size

40 - 100 22 mm 0.866" A2 950 65 mm 2.559" A3

150 - 350 36 mm 1.417" A3 1600 75 mm 2.953" A3

600 55 mm 2.165" A3

Pinion top

diameter

Pliers according

DIN 5254

Actuator

size

Pinion top

diameter

Pliers according

DIN 5254

Reassembly

Section 9: Reassembly

April 2019

Installation, Operation and Maintenance Manual

9.3 Reassembly of the Pistons

NOTICE

Before reassembling the pistons, check the required assembly code (see Section 4.4).

1. Grease the piston parts according to step 9.1.

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

Figure 33 Reassemble the Pistons

DOC.IOM.BQ.E Rev. 3

3. Before aligning the pinion and pistons, verify the actuator size and the location of the limit stop screws (D), see Figure 34. Align the pinion so that the teeth on the pinion will pick up the pistons rack teeth when turning the pinion. Note the position of the pinion top slot and the cam on the pinion top:

— For standard or Spring-to-Close: Assembly Code CW.

— For reverse or Spring-to-Open: Assembly Code CC.

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

— 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.

5. When the pistons are moved 90° inwards (see Figure 34), check that the pinion slot on the pinion top is:

— Perpendicular to the length centre line of the house for assembly code CW.

— In line to the length centre line of the house for assembly code CC.

6. If not, turn pinion to move the pistons outward until they disengage from the pinion. Shift one tooth of the pinion, reassemble and check again.

7. Move the pistons outward so that just the bearing groove sticks out of the housing. Fold the piston bearings (15) around the piston and hold the bearing ends in place while moving the pistons inwards.

— For larger pistons, use a rubber mallet and slightly hitting the pistons

inward to engage with the pinion.

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Figure 34 Position of the Slot and the Cam on the Pinion Top

Assembly code CW Assembly code CC

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

Section 9: Reassembly

April 2019

Sizes Q40 to Q100

Sizes Q150 to Q1600

90°

Reassembly

90°

A = Position of cam C = Final position of pinion dot

B = Position of slot and dot in pinion D = Position of limit stop screws

NOTE:

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

Section 9: Reassembly

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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 35 Install Limit Stop Bolts

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

3. Double check if the position of the slot and the cam on the pinion top is in the correct position (see Figure 34). Screw in the right hand travel stop until it comes into contact with the pinion stop face.

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

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

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

see Section 5.

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

9.5 Reassembly of the End Caps

9.5.1 Double-Acting Actuators

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

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

3. Install the end caps (6) and tighten the end cap screws (8). Refer to Table 17 for the correct torque.

Figure 36 Double-Acting End Cap Assembly

Section 9: Reassembly

April 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 40 to 100 have high end caps for double-acting and spring-return models.

Actuator sizes 150 to 1600 have low end caps for double-acting models and high end caps for spring return models.

Reassembly

Table 17. End Cap Screw Torque

Actuator

size

Q 40 M5

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

Q 1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7

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.

2 3

N = 10 N = 20

N = 30

2 3456

N = 40

N = 50

N = 60

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

Section 9: Reassembly

Installation, Operation and Maintenance Manual

April 2019

9.5.2 Spring-Return Actuators (Size 40 to 600)

Important

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

— Sizes Q40 to Q600 have 6 springs on each side (see Figure 37).

— Sizes Q950 to Q1600 have 3 springs on each side (see Section 9.5.3).

Check below gures to see where to place the spring cartridges in case of spring set conversion.

When replacing spring cartridges in a spring-return actuator, ensure that the cartridges are replaced in their identical position from where they were removed.

Before assembling the spring cartridges and end caps, make sure that the pistons are completely inwards.

Figure 37 Spring Placement Size 40 to 600

DOC.IOM.BQ.E Rev. 3

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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

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

3. Place the spring cartridges in actuator as per required spring set (see Figure 37).

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end cap screw in small equal turns and in the sequence as per Figure 38. Refer to Table 17 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 38 Spring-Return End Cap Assembly Size 40 to 600

Section 9: Reassembly

April 2019

Reassembly

N = 10 N = 20 N = 30

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

Section 9: Reassembly

April 2019

Installation, Operation and Maintenance Manual

9.5.3 Spring-Return Actuators (Size 950 to 1600)

Important

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

— Sizes 40 to 600 have 6 springs on each side (Section 9.5.2).

— Sizes 950 to 1600 have 3 springs on each side (see Figure 39).

Check below gures to see where to place the springs in case of spring set conversion.

When replacing springs in a spring-return actuator, ensure that the springs are replaced in their identical position from where they were removed.

Before assembling the springs and end caps, make sure that the pistons are completely inwards.

Figure 39 Spring Placement Size 950 and 1600

DOC.IOM.BQ.E Rev. 3

Left RightLeftRight Left Right

1 spring 0 spring 1 spring 1 spring 2 springs1 spring

N = 40 N = 50 N = 60

Left

2 springs

Right Left RightLeftRight

2 springs 3 springs2 springs3 springs3 springs

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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

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

3. Place the spring in actuator as per required spring set (see Figure 39).

4. Put the end cap screw washer (10) on the end cap screw (9) and tighten each end cap screw in small equal turns and in the sequence as per Figure 40. Refer to Table 17 for the correct torque. We recommend to use some grease on the screws for easier fastening.

Figure 40 Spring-Return End Cap Assembly Size 950 to 1600

Section 9: Reassembly

April 2019

Reassembly

Section 9: Reassembly

April 2019

Installation, Operation and Maintenance Manual

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 leakage stops.

b. The end caps: Disassemble the end caps, replace o-rings and reassemble.

c. The pinion top or bottom and A- or B- port: Disassemble the complete

actuator, replace o-rings and reassemble.

DOC.IOM.BQ.E Rev. 3

Figure 41 Basic Function and Air Leak Test

Reassembly

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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.

Section 10: Troubleshooting

April 2019

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.

Section 4.5

Appendix A.

Troubleshooting

Section 10: Troubleshooting

April 2019

Installation, Operation and Maintenance Manual

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 sufcient

supply air pressure but

insufcient 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

ow.

Manual override (if present) on the Solenoid Valve is locked.

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

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 sufcient 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.

DOC.IOM.BQ.E Rev. 3

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

conguration.

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.

Section 9.6

Section 9.6 or Section 6

Troubleshooting

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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.

Section 10: Troubleshooting

Connect all wiring in the right way.

Connect the right power supply voltage.

Connect the feedback wiring in the right way.

April 2019

Instructions of the control or feedback accessories.

Instructions of the solenoid valve.

Instructions of the feedback device.

Troubleshooting

Section 11: Parts List and Spare Parts

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Section 11: Parts List and Spare Parts

Recommendations

11.1 Actuator Size Q40 to Q600

2118

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 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-lled 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 40 to 100 have high end caps for double-acting and spring-return models. Actuator sizes

150 to 1600 have low end caps for double-acting models and high end caps for spring-return models.

Parts List and Spare Parts

Installation, Operation and Maintenance Manual

Section 11: Parts List and Spare Parts

DOC.IOM.BQ.E Rev. 3

11.2 Actuator Size Q950 to Q1600

April 2019

11 72

Pos. Qty. 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-lled 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.

Parts List and Spare Parts

Appendix

April 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.BQ.E Rev. 3

A.1 Spring Load Relief

CAUTION: ROTATING ACTUATOR

In case of an actuator/valve assembly “stuck” in mid position, leave the actuator on the valve and/or mounting bracket during this procedure.

Figure A-1 Spring Load Removal

WARNING

Crush / Amputaion Hazard

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

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

1. Depressurize the actuator completely.

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

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

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

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

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

Table A-1. Threaded Rod Dimensions in mm

Appendix

April 2019

Actuator Size Thread

Q 40 M5 140 5.5

Q 65 M5 140 5.5 Q 100 M5 140 5.5 Q 150 M6 145 5.7 Q 200 M6 145 5.7 Q 350 M8 185 7.3 Q 600 M10 185 7.3 Q 950 M12 498 19.6

Q 1600 M12 498 19.6

Figure A-2 Spring Load Removal Rod Dimensions

Length

Thread

Washer

Threaded Rod

Threaded rod length

(mm) (inch)

Holding nuts

Adjusting nut

Appendix

Installation, Operation and Maintenance Manual

April 2019

Appendix B: Tool & Torque Table

This section explains:

• Which tools to use for the indicated fasteners.

• The recommended amount of torque to apply on the indicated fasteners.

Table B-1. End Cap Bolts

Actuator

size

Q 40 M5

Q 1600 M12 SW10 24.3 19.4 41.6 17.9 14.3 30.7

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.

DOC.IOM.BQ.E Rev. 3

Table B-2. Bottom Flange, Metric Units

Actuator

size

40, 65, 100

150, 200, 350

600

950

1600

ISO Pattern

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

1. Actuator size 1600 has only 4 holes of the ISO5211 F25 drilling pattern are available.

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

Thread Min. Max. Thread Min. Max.

Table B-3. Adaptation Plate

Flange

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

Top ange 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.

Table B-4. Limit Stop Screws

Actuator size Thread

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

1. Default dimension according DIN933 standard

2. Dimensions in brackets according ISO4017 standard

Bolt Wrench Nut wrench

size (mm) size (mm)

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

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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

Actuator size Pinion top diameter

Q40 - Q100 22 mm 0.866" A2

Q150 - Q350 36 mm 1.417" A3

Q600 55 mm 2.165" A3

Q 950 65 mm 2.559" A3

Q 1600 75 mm 2.953" A3

Table B-6. Angular Displacement Limit Stops

Actuator size

Q 40 0.8 6.3°

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

Q 1600 1.3 4.1°

adjustment of the pinion:

Turns for 5°

Appendix

April 2019

Pliers

according DIN

360° revolution of

limit stop screw will adjust

Appendix

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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

Figure C-1 Availability Formats of the Full Stroke Adjustment Option

Complete Spring-Return or Double-Acting actuator

Spring-Return Full Stroke Adjustment Kit

Double-Acting Full Stroke Adjustment Kit

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

Appendix

April 2019

C.2 Convert a Standard Actuator into a Full Stroke

Adjustment Version

Before starting to assemble the Full Stroke adjustment kit, please check the kit for completeness. See Figure C-2.

Figure C-2 Full Stroke Adjustment Kit Content

40 9 10

Table C-1 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

(at double acting actuator end caps with Full Stroke Adjustoment options are not available).

Appendix

April 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

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

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

— The stroke adjustment screw (41) is factory set at the 90° position.

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

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

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

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

7. For Spring Return units, place the black warning sticker (13) on the end cap. For Double Acting units, place the white warning sticker (12) on the end cap.

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

the actuator.

spring cartridges.

Figure C-3 Assembly of Full Stroke Adjustment End Cap Kit

Appendix

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

C.3 Full Stroke Adjustment Setting

NOTE:

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

The stroke adjustment setting procedure can be two steps:

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

— This step can be applicable if a standard actuator needs to be converted

with a Full Stroke Adjustment end cap kit or if the position of the Full Stroke Adjustment screw is somehow lost.

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

C.3.1 Factory Setting Procedure

Appendix

April 2019

1. In order to set the Full Stroke Adjustment Screws accurately to the outward position:

— Do not change the setting of the DSA limit stop screws (A and B) located

above the air connection interface.

— Move the pistons of the actuator outwards by applying pressure to the

A-port.

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-4 DSA Limit Stop Screw Setting

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

Appendix

April 2019

Installation, Operation and Maintenance Manual

DOC.IOM.BQ.E Rev. 3

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

3. Turn in both the adjustment screws (41) as dened in step 2. Both the adjustment screws should be turned in with the same length or number of revolutions.

CAUTION: DO NOT SET SCREWS UN-EQUAL

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

4. Test cycle the actuator to check if the correct rotation angle is set. If required, repeat steps 1 to 3 to adjust the rotation angle to the required angle.

Table C-2 Actuator angle rotation per full revolution of Full Stroke adjustment screw

Actuator

size

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

Appendix

World Area Conﬁ guration Centers (WACC) offer sales support, service, inventory and commissioning to our global customers. Choose the WACC or sales ofﬁ ce nearest you:

NORTH & SOUTH AMERICA

19200 Northwest Freeway Houston TX 77065 USA T +1 281 477 4100

Av. Hollingsworth 325 Iporanga Sorocaba SP 18087-105 Brazil

MIDDLE EAST & AFRICA

P. O. Box 17033 Jebel Ali Free Zone Dubai T +971 4 811 8100

P. O. Box 10305 Jubail 31961 Saudi Arabia T +966 3 340 8650

T +55 15 3413 8888

24 Angus Crescent

ASIA PACIFIC

Longmeadow Business Estate East

P.O. Box 6908 Greenstone No. 9 Gul Road #01-02 Singapore 629361 T +65 6777 8211

No. 1 Lai Yuan Road

1616 Modderfontein Extension 5

South Africa

T +27 11 451 3700

EUROPE

Wuqing Development Area Tianjin 301700 P. R. China T +86 22 8212 3300

Holland Fasor 6

Székesfehérvár 8000

Hungary

T +36 22 53 09 50

Strada Biffi 165

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 info.actuationtechnologies@emerson.com

www.emerson.com/bettis

The Emerson logo is a trademark and service mark of Emerson Electric Co.

is a mark of one of the Emerson family of companies.

Bettis 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.

Bettis Installation, Operation and Maintenance Q-Series - Release 2 - 2019 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Installation, Operation and Maintenance Reference Documents

Before You Start

1.2 Warehouse Storage

1.3 On-Site Storage

2.1 Identification

Introduction

2.2 Intended Use

2.3 Specifications

4.1 Before You Start

4.2 Actuator Rotation Direction

4.2.1 Valve Rotation

Installation

4.2.2 Position After Failure

4.3 Principles of Operation

4.3.1 Pneumatic Operation of the Base Actuator

4.3.2 Ingress Protection (IP) Rating

4.3.3 Control Module Operation

4.3.4 Double-Acting Operation with Fail-In-Last Position Function

4.3.5 Spring-Return Actuators

4.3.6 Position Feedback

4.4 Actuator Assembly Codes

4.5 Actuator to Valve Installation

4.6 Mounting of Control Modules or Generic Control and Feedback Accessories

4.7 Recommended Tubing Sizes

Mechanical Stroke Adjustment

5.1 Travel Stop Adjustment

5.1.1 Double-Acting Actuators

5.1.2 Spring-Return Actuators

5.1.3 Angular Displacement

6.1 Normal Maintenance

Maintenance

6.2 Inspection and Repair

6.2.1 Service Kits

6.2.2 Spring-Return Actuator

7.1 Before You Start

Decommission (Out of Service)

7.2 Removing the Actuator from the Valve

Disassembly

8.1 Removing End Caps (Size 40 to 600)

8.2 Removing End Caps (Size 950 to 1600)

8.3 Removing Spring Cartridges or Springs

8.4 Removing of Limit Stop Screws

8.5 Removing Pistons

8.6 Removing Pinion

8.7 Cleaning the Components

Reassembly

9.1 Grease Instructions

9.2 Reassembly of the Pinion

9.3 Reassembly of the Pistons

9.4 Reassembly and Settings of the Limit Stops

9.5 Reassembly of the End Caps

9.5.1 Double-Acting Actuators

9.5.2 Spring-Return Actuators (Size 40 to 600)

9.5.3 Spring-Return Actuators (Size 950 to 1600)

9.6 Basic Function and Air Leak Test

10.1 Mechanical Problems

Troubleshooting

10.2 Pneumatic Problems

10.3 Electrical Problems

11.1 Actuator Size Q40 to Q600

11.2 Actuator Size Q950 to Q1600

Appendix A: Spring Load Removal

A.1 Spring Load Relief

Appendix B: Tool & Torque Table

Appendix C: Full Stroke Adjustment Option

C.1 Full Stroke Adjustment Option

C.2.1 Procedure

C.3 Full Stroke Adjustment Setting

C.3.1 Factory Setting Procedure