Bettis XTE3000
Electric Actuator
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
June 2022
Revision Details
June 2022
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Revision Detail
Rev. Date Description Prepared Checked Approved
2 June 2022 Document update
1 October 2019 Migration to new template
Revision Details
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Table of Contents
Section 1: General Safety Instructions
1.1 Range of Applications ................................................................................... 1
1.2 Safety Instructions for Installation in Hazardous Areas...........................................2
1.2.1 Marking .............................................................................................. 3
1.3 Applicable Standards and Regulations ........................................................... 3
1.4 Terms and Conditions ................................................................................... 4
Section 2: Storage and Pre-Installation
2.1 Tests to be Carried Out When the Actuator is Received ................................. 5
2.2 Storage Procedure ........................................................................................ 5
2.2.1 General .............................................................................................. 5
2.2.2 Short-term Storage (One Year or Fewer) ............................................. 6
2.2.3 Long-term Storage (More Than One Year) .......................................... 6
2.3 Checks to be Performed Before Installation ................................................... 8
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June 2022
Section 3: Installation
3.1 Working Condition ........................................................................................ 9
3.1.1 Heater Options ................................................................................... 9
3.2 Coupling Block: Disassembly from the Actuator .......................................... 11
3.2.1 Type “A” Coupling Block ................................................................... 11
3.2.2 Types “B1” and “B2” Coupling Blocks ............................................... 13
3.2.3 Types “B3” and “B4” Coupling Blocks ............................................... 14
3.2.4 Attaching the Coupling Block to the Gear Reduction Unit ................. 15
3.3 Manual Operation ....................................................................................... 16
3.4 Mounting the Actuator onto the Valve ........................................................ 18
3.4.1 Coupling Type “A” ............................................................................ 18
3.4.2 Coupling Types “B1”, “B2”, ”B3” and “B4” ........................................ 18
3.4.3 Actuator Mounting ........................................................................... 19
3.5 Electrical Connections ................................................................................. 20
3.5.1 Plant Requirements .......................................................................... 20
3.6 Removing the Terminal Board Enclosure...................................................... 20
3.7 Removing the Terminal Board Enclosure...................................................... 21
3.8 Terminal Board ............................................................................................ 22
3.9 Instructions For Explosion proof Enclosures ................................................. 24
3.10 Installation in Environments with Explosive Dusts ........................................25
Section 4: Lubrication
4.1 Lubrication Inspection................................................................................. 26
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June 2022
Section 5: Operating the XTE3000
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
5.1 Operation By Handwheel ............................................................................ 28
5.1.1 Operation By Handwheel in Absence of a Power Supply
and With the Lithium Battery ........................................................... 28
5.2 Electrical Operation ....................................................................................29
5.3 Local Control ............................................................................................... 29
5.4 Local Indication ........................................................................................... 30
5.5 Locking the 3-Position Selector ................................................................... 32
5.6 Remote Control ...........................................................................................32
5.6.1 Remote Commands.......................................................................... 32
5.6.2 Output Contacts .............................................................................. 34
5.6.3 ESD Operation .................................................................................. 34
5.6.4 Interlock Inputs ................................................................................ 35
5.7 Operating the XTE3000 for the First Time ................................................... 36
5.8 Optional Modules ........................................................................................ 36
5.8.1 Fieldbus Interface for Remote Control via FIELDBUS .......................... 36
5.8.2 Ain/Aout Card .................................................................................. 37
5.9 Base Card of the XTE3000 ........................................................................... 39
5.10 Absolute Encoder of the XTE3000 ............................................................... 41
Section 6: Local Controls
6.1 Description of the Local Operator Interface ................................................. 42
6.2 Conguration Options ................................................................................ 46
6.3 Entering the View Mode .............................................................................. 48
6.4 Entering the Set-Up Mode ........................................................................... 49
6.5 Exit from View and Set-Up Mode ................................................................. 49
Section 7: Set-Up Menu
Set-Up Menu ......................................................................................................... 51
Section 8: View Menu
View Menu ............................................................................................................ 53
Section 9: Set-Up Routines
9.1 Actuator Set-Up .......................................................................................... 55
9.1.1 Set Stroke Limits ...............................................................................55
9.1.2 Torque Set-up ................................................................................... 57
9.1.3 ESD (Emergency Shut Down) Control ............................................... 57
9.1.4 Remote Controls .............................................................................. 58
9.1.5 Local Controls................................................................................... 59
9.1.6 Output Relays ................................................................................... 60
9.1.7 Positioner ......................................................................................... 62
9.1.8 Fail-Safe ............................................................................................ 64
9.1.9 OUT 4 - 20 mA .................................................................................. 66
9.1.10 Interlock ........................................................................................... 67
9.1.11 2-Speed Timer ..................................................................................67
9.1.12 BUS (or FDI Control) ......................................................................... 68
9.1.13 Miscellaneous ................................................................................... 69
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9.2 Valve Data ................................................................................................... 72
9.2.1 Sample Conguration Procedure ...................................................... 72
9.3 Maintenance ............................................................................................... 72
9.3.1 Set Password .................................................................................... 73
9.3.2 Clear Alarm Log ................................................................................ 73
9.3.3 Set Torque Reference ........................................................................73
9.3.4 Set Curve Reference ......................................................................... 74
9.3.5 Clear Recent Data Log .......................................................................74
9.3.6 Conguration (Backup/Restore) ....................................................... 75
9.3.7 Set PST Reference ............................................................................. 76
9.3.8 PST Command.................................................................................. 76
9.3.9 Set Maintenance Date ......................................................................77
9.3.10 Set Data Logger ................................................................................ 78
9.4 Example of Set-Up Routine .......................................................................... 79
9.4.1 Torque Set-Up .................................................................................. 79
Section 10: View Routines
10.1 Actuator Set-Up .......................................................................................... 80
10.2 Nameplate .................................................................................................. 81
10.3 Valve Data ................................................................................................... 82
10.4 Maintenance ............................................................................................... 82
10.4.1 Alarm Log .........................................................................................82
10.4.2 Torque Prole ................................................................................... 83
10.4.3 Torque Curve .................................................................................... 84
10.4.4 Operation Log .................................................................................. 85
10.4.5 Maintenance Date ............................................................................ 88
10.4.6 Data Logger ...................................................................................... 88
10.5 Example of View Routine ............................................................................. 91
10.5.1 View Torque Set-up .......................................................................... 91
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June 2022
Section 11: Maintenance
11.1 Standard Maintenance ................................................................................ 92
11.2 Special Maintenance ................................................................................... 93
11.3 Lithium Battery Change .............................................................................. 94
Section 12: Troubleshooting
12.1 The Electronics Do Not Switch ON When Powered ...................................... 98
12.2 DC Output Voltage Not Available at the Terminals ........................................99
12.3 The Actuator Does Not Work from Remote Controls ....................................... 99
12.4 The Motor is Very Hot and Does Not Start ................................................. 100
12.5 The Motor Runs but the Actuator Does Not Move the Valve ......................100
12.6 The Manual Override Cannot Be Engaged ..................................................101
12.7 The Valve Does Not Seat Correctly ............................................................ 101
12.8 Valve Operation Requires Excessive Torque ............................................... 102
12.9 The Actuator Does Not Stop in the Fully Open or Fully Closed Position.......103
12.10 The Numeric Position Display Indicates “---” .............................................. 103
12.11 Diagnostic Messages ................................................................................. 103
Section 13: Parts List and Drawings
Parts List and Drawings ....................................................................................... 109
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Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Appendix A: XTE3000/XTE3000AD
A.1 Safety Instructions .................................................................................... 119
A.1.1 General .......................................................................................... 119
A.2 Instructions for Proper Installation ............................................................ 119
A.2.1 Marking .......................................................................................... 120
A.3 Applicable General Standards and Regulations .......................................... 121
A.4 Terms and Conditions ............................................................................... 121
A.5 Manufacturer’s Liability ............................................................................. 121
A.6 Storage and Pre-Installation ...................................................................... 122
A.6.1 Storage Procedure ..........................................................................122
A.6.2 Checks to be Performed Before Installation .................................... 122
A.7 Installation ................................................................................................ 122
A.7.1 Working Condition ......................................................................... 122
A.7.2 Identication of Entries ...................................................................123
A.7.3 Electrical Connections .................................................................... 124
A.7.4 Cable Connection ........................................................................... 124
A.7.5 Installation in Environments with Explosive Dusts ........................... 125
A.8 Maintenance ............................................................................................. 125
A.8.1 Periodic Inspection ......................................................................... 126
A.8.2 Disassembly and Reassembly..........................................................126
A.8.3 Repairs ........................................................................................... 127
Appendix B: XTE3000/XTE3000AD/XTE3000LP
B.1 Safety Instructions .................................................................................... 128
B.1.1 General .......................................................................................... 128
B.1.2 Identication of Main Parts ............................................................. 129
B.2 Instructions for Proper Installation ............................................................ 130
B.2.1 Marking .......................................................................................... 130
B.3 Applicable General Standards and Regulations .......................................... 131
B.4 Terms and Conditions ...............................................................................132
B.5 Manufacturer’s Liability ............................................................................. 132
B.6 Storage and Pre-Installation ...................................................................... 132
B.6.1 Storage Procedure ..........................................................................132
B.6.2 Checks to be Performed Before Installation .................................... 133
B.7 Installation ................................................................................................ 133
B.7.1 Working Condition ......................................................................... 133
B.7.2 Identication of Entries ................................................................... 134
B.7.3 Electrical Connections .................................................................... 136
B.7.4 Cable Connection ........................................................................... 137
B.7.5 Installation in Environments with Explosive Dusts ........................... 138
B.8 Maintenance ............................................................................................. 138
B.8.1 Periodic Inspection ......................................................................... 138
B.8.2 Disassembly and Reassembly..........................................................138
B.8.3 Repairs ........................................................................................... 139
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Appendix C: XTE3000/XTE3000AD
C.1 Safety Instructions .................................................................................... 140
C.1.1 General .......................................................................................... 140
C.2 Instructions for Proper Installation ............................................................ 140
C.2.1 Marking .......................................................................................... 141
C.3 Applicable General Standards and Regulations .......................................... 142
C.4 Terms and Conditions ............................................................................... 142
C.5 Manufacturer’s Liability ............................................................................. 142
C.6 Storage and Pre-Installation ...................................................................... 143
C.6.1 Storage Procedure .......................................................................... 143
C.6.2 Checks to be Performed Before Installation .................................... 143
C.7 Installation ................................................................................................ 143
C.7.1 Working Condition ......................................................................... 143
C.7.2 Identication of Entries ...................................................................144
C.7.3 Electrical Connections .................................................................... 145
C.7.4 Cable Connection ...........................................................................145
C.7.5 Installation in Environments with Explosive Dusts ........................... 146
C.8 Maintenance ............................................................................................. 146
C.8.1 Periodic Inspection ......................................................................... 146
C.8.2 Disassembly and Reassembly..........................................................147
C.8.3 Repairs ........................................................................................... 147
Table of Contents
June 2022
Appendix D: XTE3000
D.1 Safety Instructions .................................................................................... 148
D.1.1 General .......................................................................................... 148
D.1.2 Identication of Main Parts ............................................................. 149
D.2 Instructions for Proper Installation ............................................................ 150
D.2.1 Marking .......................................................................................... 150
D.3 Applicable Directives, General Standards, and Norms ............................... 151
D.4 Terms and Conditions ............................................................................... 152
D.5 Manufacturer’s Liability ............................................................................. 152
D.6 Storage and Pre-Installation ...................................................................... 152
D.6.1 Storage Procedure .......................................................................... 152
D.6.2 Checks to be Performed Before Installation .................................... 153
D.7 Installation ................................................................................................ 153
D.7.1 Working Condition ......................................................................... 153
D.7.2 Identication of Entries ................................................................... 153
D.7.3 Electrical Connections .................................................................... 155
D.7.4 Cable Connection ........................................................................... 156
D.7.5 Installation in Environments with Explosive Dusts ........................... 157
D.8 Maintenance ............................................................................................. 157
D.8.1 Periodic Inspection ......................................................................... 157
D.8.2 Disassembly and Reassembly.......................................................... 158
D.8.3 Repairs ........................................................................................... 159
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Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Appendix E: XTE3000
E.1 Safety Instructions .................................................................................... 160
E.1.1 General .......................................................................................... 160
E.1.2 Identication of Main Parts ............................................................. 161
E.2 Instructions for Proper Installation ............................................................ 162
E.2.1 Marking .......................................................................................... 162
E.3 Applicable General Standards and Regulations .......................................... 163
E.4 Terms and Conditions ............................................................................... 164
E.5 Manufacturer’s Liability ............................................................................. 164
E.6 Storage and Pre-Installation ...................................................................... 164
E.6.1 Storage Procedure .......................................................................... 164
E.6.2 Checks To be Performed Before Installation .................................... 165
E.7 Installation ................................................................................................ 165
E.7.1 Working Condition ......................................................................... 165
E.7.2 Identication of Entries ................................................................... 166
E.7.3 Electrical Connections .................................................................... 168
E.7.4 Cable Connection ........................................................................... 168
E.7.5 Installation in Environments with Explosive Dusts ........................... 169
E.8 Maintenance ............................................................................................. 169
E.8.1 Periodic Inspection ......................................................................... 169
E.8.2 Disassembly and Reassembly.......................................................... 170
E.8.3 Repairs ........................................................................................... 171
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Installation, Operation and Maintenance Manual
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Section 1: General Safety Instructions
Section 1: General Safety Instructions
1.1 Range of Applications
The Bettis XTE3000 and the XTE3000v2 electric actuator covered in this manual are
designed for the operation of any type of industrial valve used in heavy industrial, chemical,
and petrochemical facilities. Emerson will not be liable for potential damage resulting from
use in anything other than these designated applications. Such risk lies entirely with the
user. Where not explicitly highlighted with the generic indication XTE3000, it is intended
to refer to both XTE3000 and XTE3000v2 versions.
WARNING
!
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
June 2022
WARNING
!
The warning symbol labelled on the actuator means that it is mandatory to read the
manual before installing, operating and servicing the equipment.
Bettis electric actuators are designed in accordance with the applicable international rules
and specications; nonetheless, the following regulations must be observed in any case:
• The general installation and safety regulations
• The plant specic regulations and requirements
• The proper use of personal protective devices (glasses, clothing, gloves)
• The proper use of tools, lifting and transport equipment
General Safety Instructions
1
Section 1: General Safety Instructions
June 2022
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
1.2
Safety Instructions for Installation in
Hazardous Areas
WARNING
!
When installing in a hazardous area as dened by the applicable rules, verify that the
actuator nameplate conforms to site safety requirements.
WARNING
!
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
The XTE3000 is designed according to IEC/EN 60079-0, IEC/EN 60079-1, and
IEC/EN 50079-31 standards. Different types of protection are available, depending
on the marking printed on the actuator label:
• Ex d IIB Txx, Ex d IIC Txx with “Explosion proof” terminal board enclosure, or
• Ex d e IIB Txx, Ex d e IIB+H2 Txx, Ex d e IIC Txx with “Increased safety”
terminal board enclosure
These are suitable for use in hazardous areas classied as at risk of explosion caused by the
presence of gas and dust.
The XTE3000 has IP66/68 degree of protection according to EN 60529.
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General Safety Instructions
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
1.2.1 Marking
Table 1.
IECEx INE XX.ZZZZ IECEx reference certicate (CoC)
XX ATEX ZZZZ ATEX reference certicate
0080 Notied body for ATEX quality assurance (INERIS)
II Group II (surface industries)
2 Category 2 apparatus
G Explosive atmospheres caused by gas, mists, or vapors
D Explosive atmospheres caused by gas and dusts
P66/68 Degree of protection
FM18US0279X FM reference certicate for USA
FM18CA0134X FM-c reference certicate for Canada
Table 2.
Hazardous Zones Zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors 0 1G
Gas, mists, or vapors 1 2G or 1G
Gas, mists, or vapors 2 3G or 2G or 1G
Dust 20 1D
Dust 21 2D or 1D
Dust 22 3D or 2D or 1D
Section 1: General Safety Instructions
June 2022
Table 3. Equipment Protection Level (EPL) EN 60079-14
Explosive atmosphere Zone EPL
Gas, mists, or vapors 0 1G
Gas, mists, or vapors 1 2G or 1G
Gas, mists, or vapors 2 3G or 2G or 1G
Dust 20 1D
Dust 21 2D or 1D
Dust 22 3D or 2D or 1D
1.3 Applicable Standards and Regulations
Table 4.
EN ISO
12100Safety of machinery - General principle for design - Risk assessment and risk reduction
EN 60204-1 Safety of machinery - Electrical equipment of industrial machines
2006/42/EC Machinery directive
2014/35/EU Low voltage directive
2014/30/EU EMC directive
2014/34/EU ATEX directive
2014/53/EU RED directive
FM (for USA) FM3600, FM3810, ANSI/ISA 60079-0, ANSI/ISA 60079-1, ANSI/NEMA 250
FM-C
(for Canada)
CAN/CSA C22.2 No. 60079-0, CAN/CSA C22.2 No. 60079-1, CAN/CSA 61010-1,
CSA-C22.2 No. 94
General Safety Instructions
3
Section 1: General Safety Instructions
June 2022
Low Voltage Requisition in accordance with IEC-61010-1
All MAINS circuits are to be considered in overvoltage CATEGORY II.
Applications at altitudes below 2,000 meters must comply with:
• All circuits connected to the actuator relays contacts (OUTPUT SIGNALS) must
refer to the same power supply system (both SELV or NON-SELV).
• All remote commands (INPUT SIGNALS) must refer to the same power
supply system.
Applications in altitude between 2,000 and 4,000 meters must have INPUT and OUTPUT
SIGNALS referred to the same power supply system (both SELV or NON-SELV).
Figure 1
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Internal gears
Handwheel
Terminal box
Electric motor
1.4 Terms and Conditions
Absolute Encoder
Engagement lever
Local interface
Emerson guarantees every product to be free from defects and to conform to industry
standards. The warranty period is one year from the date of installation by the rst user,
or eighteen months from the date of shipment to the rst user, whichever occurs rst.
No warranty is given for products or components manufactured by third-party companies,
or for goods which have been subject to misuse, improper installation, corrosion, or which
have been modied or repaired by unauthorized personnel. Repair work due to improper
use will be charged at standard rates.
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General Safety Instructions
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Section 2: Storage and Pre-Installation
Section 2: Storage and Pre-Installation
2.1 Tests to be Carried Out When the Actuator
is Received
If the actuator is received already mounted on the valve, all the below operations should
have already been performed during valve/actuator assembly.
• Check that the display is active.
• Turn the handwheel until the valve is in a completely open position.
• Check that the display reads 100%, which indicates that the valve is completely open.
• Rotate the handwheel clockwise and bring the valve to a completely closed position.
• Check that the display reads 0%, which indicates that the valve is completely
closed. If the test result is satisfactory, the actuator has already been adjusted
and one can proceed with the electrical connection. If the actuator is delivered
separately from the valve or the above procedure shows that the position is
incorrect, all operations described in this manual must be carried out.
• Check that no damage has occurred during transport. Pay particular attention
to the push-buttons, the display area glass, and the selector.
• Check the information on the nameplate. In particular, check the serial number
and performance data (nominal torque, operation speed, protection class, motor
supply voltage, etc.) and verify that this data matches the data on the display
(see Section 10, View Routines).
Make sure all accessories have been received with the shipment as described in the
delivery documentation.
June 2022
2.2 Storage Procedure
NOTICE
Not following the procedures according to this document will invalidate the product warranty.
2.2.1 General
The actuator leaves the factory in perfect condition, guaranteed by an individual test
certicate. In order to maintain these characteristics until the actuator is installed
on-site, proper procedures must be followed for preservation during the storage period.
XTE3000 actuators are weather proof to IP66/68; this condition can only be maintained if
the unit is correctly installed on-site and if the actuator was correctly stored. The standard
plastic plugs used to close the cable entries are not weather proof; their only function is to
prevent the entry of foreign objects during transport.
Storage and Pre-Installation
5
Section 2: Storage and Pre-Installation
June 2022
Installation, Operation and Maintenance Manual
2.2.2 Short-term Storage (One Year or Fewer)
2.2.2.1 Indoor Storage
Make sure that the actuator is kept in a dry place, laid on a wooden pallet, and protected
from dust.
2.2.2.2 Outdoor Storage
• Make sure that the actuator is protected from the elements (e.g. protected from
rain by covering with a canvas tarp).
• Place the actuator on a wooden pallet or some other raised platform, such that it is
not in direct contact with the ground.
• If the actuator is supplied with standard plastic plugs, remove them from the
conduit entries and replace them with weather proof plugs.
2.2.3 Long-term Storage (More Than One Year)
MAN-02-04-97-0713-EN Rev. 2
2.2.3.1 Indoor Storage
In addition to the instructions in Section 2.2.2.1:
• If the actuator is supplied with standard plastic plugs, replace them with
weather proof plugs.
• If the actuator is provided with a lithium battery, remove it and store it in a clean
and dry location (see Section 11.3, Lithium Battery Change).
2.2.3.2 Outdoor Storage
In addition to the instructions in Section 2.2.2.2:
• Check the general condition of the actuator, paying particular attention to the
terminal board and local display glass.
• If the actuator is provided with a lithium battery, remove it and store it in a clean
and dry location (see Section 11.3, Lithium Battery Change).
Figure 2
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Storage and Pre-Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Figure 3
Figure 4
Section 2: Storage and Pre-Installation
June 2022
Figure 5
Storage and Pre-Installation
7
Section 2: Storage and Pre-Installation
June 2022
Figure 6
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MAN-02-04-97-0713-EN Rev. 2
2.3 Checks to be Performed Before Installation
• Make sure that the valve to be motorized is appropriate for coupling
to the actuator.
• The electrical supply cables must be suitable for the power rating
(refer to the test certicate that comes with the actuator).
• Gather the right tools for assembly and for setting the actuator controls.
If the actuator has been stored for a long period of time prior to its installation, make sure to:
• Check the condition of the O-ring seals.
• Check the installation of the plugs or conduit glands on the conduit entries.
• Check if the enclosure covers or the actuator body are cracked or broken.
• Check the oil level in the actuator and top up if necessary.
• Put the batteries back into place (see Section 11.3, Lithium Battery Change).
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Storage and Pre-Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Section 3: Installation
3.1 Working Condition
Standard actuators are suitable for the following environment temperatures:
-20 °C +85 °C (-4 °F to +185 °F)
Special versions are available for extreme environment temperatures:
-40 °C +85 °C (-40 °F to +185 °F)
-55 °C +65 °C (-67 °F to +149 °F)
Altitude up to 4,000 meters max.
NOTICE
The above conditions apply only to Ex d or Ex de versions. For other applications, refer to
the applicable addendum.
Section 3: Installation
June 2022
3.1.1 Heater Options
Actuators are suitable for ambient temperature range as per Product Data Sheet.
Heater options are available for specic application.
Table 5.
Model Ambient Temperature Range Control type
Heater
Typ e
1 PTC - A 24 V DC max 15 W Optional N/A
2 PTC -B 110-240 1 ph max 15 W Optional N/A
3 PTC - C* 24 V DC max 65 W N/A Mandatory
4 PTC - D* 110-240 1 ph max 45 W N/A Mandator y
(*) Default in case of Extreme Low Temperature Range.
NOTICE
PTC (C) Actuator Power Supply ON ( Start up or after Power shortage)
In the event of an ambient temperature below -40 °C (°F), the Actuator Main Power supply
must be kept ON or preceded by a preheating time. Actuator Main Power supply can be
switch ON after a warming up period. The minimum heating time must not be less than
60 minutes in case of ambient temperatures down to -60 °C.
Heater Power
Supply
Heater
Power
Low Temperature
up to -40 °C (-40 °F)
Extreme Low
Temperature
-41 °C (-41.8 °F) to
-60 °C (-76 °F)
Power ON and OFF
managed by thermostat
assembled on the kit;
Power ON: < 0 °C;
Power OFF: > 10 °C
Heater Externally
powered
✓
✓
✓
✓
Installation
9
Section 3: Installation
June 2022
NOTICE
Installation in an environment where the ambient temperature range falls outside
the rated temperature will invalidate the warranty. Refer to the nameplate to verify the
rated ambient temperature.
Figure 7
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MAN-02-04-97-0713-EN Rev. 2
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Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Section 3: Installation
June 2022
3.2 Coupling Block: Disassembly from the Actuator
The bushing is delivered already assembled to the drive sleeve, even when it is
unmachined. In order to perform the necessary machining, remove the bushing from its
housing. Remove the xing screws from the coupling block. View the actuator from the
coupling side, with the block separated from the gearbox. Do not misplace the seal ring
between the coupling block and the gear reduction unit.
3.2.1 Type “A” Coupling Block
3.2.1.1 Preparing the Bushing
Using a spanner wrench, unscrew the lower ring nut.
Figure 8
Installation
11
Section 3: Installation
June 2022
Extract the stem nut from the block housing.
Figure 9
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
The internal thrust bearing will remain at the bottom of the block housing.
Figure 10
NOTICE
Before remounting the stem nut, make sure that coupling tolerances to the valve stem are
correct.
stem of the motorized valve by screwing the nut entirely along the valve stem without
excessive friction.
The threaded stem nut must be checked either with a thread gauge or with the
12
The bore can now be machined in the stem nut to suit coupling requirements. The same
procedure is also used if maintenance is required.
Installation
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MAN-02-04-97-0713-EN Rev. 2
3.2.1.2 Reassembling the Internal Parts
It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal lings or foreign bodies remain; spread a lm of
grease on all parts (for grease type, see Section 4, Lubrication).
Proceed with the assembly of the internal parts by following the disassembly procedure
in reverse; tighten the lower ring nut with thread sealant LOCTITE 270 or equivalent,
and ensure that the stem nut still rotates freely. Attach the unit to the gear reducer as
described further on.
3.2.2 Types “B1” and “B2” Coupling Blocks
3.2.2.1 Preparing the Bushing
Using a spanner wrench, unscrew the lower ring nut.
Figure 11
Section 3: Installation
June 2022
Installation
13
Section 3: Installation
June 2022
Extract the bushing from the block housing.
Figure 12
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
The internal thrust washer will remain at the bottom of the block housing.
The bore can now be machined in the bushing to suit coupling requirements.
The same procedure is also used if maintenance becomes necessary.
3.2.2.2 Reassembling the Internal Parts
It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal lings or foreign bodies remain; spread a lm of
grease on all parts (for grease type, see Section 4, Lubrication). Proceed with assembly
of the internal parts by following the disassembly procedure in reverse order; tighten the
lower ring nut with thread sealant LOCTITE 270 or equivalent, and ensure that the bushing
still rotates freely. Attach the unit to the gear reducer as described further on.
3.2.3 Types “B3” and “B4” Coupling Blocks
3.2.3.1 Preparing the Bushing
Remove the mounting bolts of the coupling ange.
Figure 13
14
Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Figure 14
Extract the bushing and machine it according to the mating needs.
Figure 15
Section 3: Installation
June 2022
3.2.3.2 Reassembling the Internal Parts
It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal lings or foreign bodies remain; spread a lm of
grease on all parts (for grease type see Section 4, Lubrication).
Proceed with the assembly of the internal parts by following the disassembly procedure in
reverse order. Attach the unit to the gear reducer as described further on.
3.2.4 Attaching the Coupling Block to the Gear Reduction Unit
Check the integrity of the O-ring seal and place it in its slot on the coupling block.
Ensure that the lugs of the drive sleeve t in the correct slots on the bushing.
Attach the screws previously removed.
Installation
15
Section 3: Installation
June 2022
3.3 Manual Operation
To engage manual operation, depress (by 20° - 30°) the lever in the direction shown in
Figure 18 and then let the lever automatically return to its rest position. If no engagement
is obtained, slowly rotate the handwheel and repeat the operation.
Rotate the handwheel to achieve the desired operation (normally clockwise rotation
closes the valve).
A label is located on the handwheel with an arrow showing the closing direction
(clockwise by default). If the closing direction is counterclockwise, the label must be
removed and remounted upside-down.
! WARNING
Do not manually operate the actuator with devices other than the handwheel and the
declutch lever. Using cheater bars, wheel wrenches, pipe wrenches, or other such devices
on the actuator handwheel or declutch lever may cause serious personal injury and/or
damage to the actuator or valve.
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Figure 16
Engagement lever locked in motor operation position: manual operation cannot be
engaged, thus preventing unwarranted local operation.
Figure 17
16
Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Engagement lever locked in handwheel operation position: operation with the electric
motor is mechanically disengaged.
TO CLOSE
Figure 18
Section 3: Installation
June 2022
Figure 19
Figure 20
Installation
YES NO
17
Section 3: Installation
June 2022
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
! WARNING
Never lift the valve/actuator assembly without securing slings to both the valve and
the actuator. Never use the handwheel to lift the actuator.
Table 6.
Model Max. weight, kg (lb)
010 32 (70.6)
020 38 (83.8)
030 46 (101.4)
040 56 (123.5)
050 73 (160.9)
3.4 Mounting the Actuator onto the Valve
Lubricate the valve stem.
Thoroughly clean the coupling surfaces of the valve and actuator anges, and degrease
them carefully since torque is transmitted by friction.
Lift the actuator with slings suitable for its weight.
The actuator will operate properly in any position. When mounted upside-down, a 5 mm
diameter hole should be drilled in the end of the stem cover to avoid build-up of service
uid or rainwater.
3.4.1 Coupling Type “A”
Place the actuator vertically on the stem, screw the threaded bushing of the coupling block
on the valve stem, and then rotate (normally counterclockwise) until the coupling block
and ange surfaces of the valve are securely in contact.
For safety purposes, rotate the handwheel in the opening direction for about two turns in
order to lift the valve gate from its seat to avoid imparting (during bolt xing) excessive
axial thrust on the internal parts of the valve and the actuator.
Depending on the conditions of assembly, it could be easier to separate the thrust block
from the actuator and mount it onto the valve yoke.
3.4.2 Coupling Types “B1”, “B2”, ”B3” and “B4”
Check the dimensions of the valve mounting details, and pay particular attention to the
protrusions of the valve stem in order to avoid any axial thrust on the internal parts of the
actuator or the valve when the screws are tightened.
18
Manually engage the actuator using the handwheel and place the actuator vertically on
the valve stem. Perform the coupling operations (with the aid of manual operation if
necessary); make sure no mating parts are forced.
Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
3.4.3 Actuator Mounting
NOTICE
If the actuator is supplied without stud bolts and nuts, these must be provided by the
customer and conform to the material requirements in Table 7.
CAUTION
!
Failure to use proper torque values can result in damage to the actuator and/or valve.
Figure 21
Section 3: Installation
June 2022
Table 7.
Model Tightening Torque, Nm (lb.ft) Material
010 40 (29.5)
020 150 (110.6)
030 150 (110.6)
040 300 (221.3)
050 150 (110.6)
Studs/Bolts: ISO Class 8.8 or
ASTM A 320 Grade L7 or L7M
Nuts: ISO Class 8.8 or ASTM A 194
Grade 4
Installation
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Installation, Operation and Maintenance Manual
3.5 Electrical Connections
Before powering the actuator check that the supply voltage details on the nameplate
are correct for the receiving plant. Access to terminals for electrical connections and
commissioning is via the terminal cover, since all settings are non-intrusive. The removal of
any other covers without Emerson approval will invalidate the warranty; Emerson will not
accept responsibility for any damage or deterioration that may be caused.
NOTICE
All accessories (including cable glands) must comply with approved specications for the
site requirements and be certied according to the standard directive.
3.5.1 Plant Requirements
Protection devices (overcurrent breakers, magneto-thermal switches, or fuses) should be
provided at the plant by the administrating customer to protect the mains line in case of
motor overcurrent or loss of insulation between phases and earth.
MAN-02-04-97-0713-EN Rev. 2
For the proper sizing of protection devices, refers to certicate attached to the actuator
(Is current).
Protection devices must be easily reached and identiable by the operator.
3.6 Removing the Terminal Board Enclosure
Using an 8 mm Allen key, loosen the four screws and remove the cover.
! WARNING
Be careful to not damage the joint surfaces of the terminal cover or seal during removal.
CAUTION
!
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
NOTICE
If the screws of the cover must be replaced, a SS AISI 316 must be used with minimum yield
strength of 450 N/mm2 (65,266 psi).
20
CAUTION
!
Failure to use proper torque values can result in damage to the actuator and/or valve.
Installation
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
Figure 22
Section 3: Installation
3.7 Removing the Terminal Board Enclosure
The sealing of cables and conduit entries should be carried out in accordance with the
relevant national standards or the regulatory authorities that certied the actuators. This is
especially true for units that are certied for use in hazardous areas, where the method of
sealing must be to an approved standard and cable glands, reducers, plugs, and adapters
must be approved and separately certied.
June 2022
Standard cable entries (housing)
1" NPT, Qty 2
1-1/2" NPT, Qty 1
Optional: 3/4" NPT, up to Qty 2
On request, certied conduit entry adapters may be added
(Metric, Pg, Rc, ASA, etc.)
Remove the conduit entry plugs.
NOTICE
All accessories (including cable glands) must comply with approved specications for the
site requirements and be certied according to the standard directive.
To guarantee a weather proof and explosion proof t, screw the cable glands tightly
(at least 5 turns) and coat them with a thread sealant. The use of a thread sealant is
necessary in explosion proof and weather proof applications.
Installation
21
Section 3: Installation
June 2022
Figure 23
If some parts of the cable glands have been removed while working on the conduit entries,
put them back into place immediately to avoid misplacing the dismantled parts.
Unused entries:
Installation, Operation and Maintenance Manual
MAN-02-04-97-0713-EN Rev. 2
• For explosion proof construction: unused entries must be plugged with metal
explosion proof plugs and coated with a thread sealant.
• For weather proof construction: replace the plastic standard protection plugs
(supplied with the actuator) with metal plugs.
3.8 Terminal Board
! WARNING
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
! WARNING
The actuator is non-intrusive. The control compartment is sealed in dry and clean conditions
and contains no site-serviceable components. Do not open the control compartment unless
absolutely necessary. Unauthorized access will invalidate the warranty.
NOTICE
Be careful to not damage the joint surfaces of the terminal cover or seal during removal.
22
NOTICE
When removing the cover assembly or terminal block cover on existing installations, follow
all safety and applicable site-specic rules.
Installation
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