Bettis Canada Ltd.
4112 91A Street
Edmonton, Alberta, Canada T6E 5V2
Tel: (403) 450-3600
Fax: (403) 450-1400
SERVICE MANUAL No. I-0006
ROTARY GAS / HYDRAULIC OPERATOR
CUSTOMER:
P.O.#:
W.O.#:
TAG:
DATE:
APPLIES TO OPERATOR MODEL:
I-0006--.WPD/1
REV9: APR-29-98
SECTION I GAS / HYDRAULIC ROTARY VALVE OPERATOR
DESCRIPTION DWG.NO PAGE
I SAFETY WARNINGS ..................................................... 4
DECAL, GAS / HYDRAULIC OPERATING PROCEDURES ........................ 5
II OPERATING INSTRUCTIONS .............................................. 6
MOUNTING INSTRUCTION DRAWING ........................ I-0097 ......... 7
III INSTALLATION .......................................................... 8
LUBRICATOR STEM EXTENSION (PLUG VALVES) .............. C-0180 ........ 9
IV INSTALL CONNECTIONS.................................................. 11
V PRESTART-UP CHECKS .................................................. 11
VI START-UP CHECKS ...................................................... 12
VII SCHEDULED MAINTENANCE AND TESTING .................................. 14
VIII LIMIT SWITCH INSTRUCTIONS ............................................. 15
IX END OF STROKE VALVE INSTRUCTIONS .................................... 16
LIMIT SWITCH AND END OF STROKE VALVE LAYOUT .......... I-0046 ......... 17
X OPERATOR MAINTENANCE ............................................... 18
XI OPERATOR DISASSEMBLY ................................................ 19
XII OPERATOR ASSEMBLY .................................................. 20
OPERATOR CUTAWAY ................................................... 22
XIII FLUID MAINTENANCE GUIDE .............................................. 23
XIV HYDRAULIC FLUID SPECIFICATIONS ....................................... 23
GAS / HYDRAULIC TANK FILLING............................ I-0006-13 ...... 24
XV OPERATOR SPECIFICATIONS ............................................. 25
XVI OPERATOR REPAIR KITS ................................................. 27
XVII TROUBLE SHOOTING .................................................... 28
XVIII GENERAL SERVICE NOTES ............................................... 29
GAS / HYDRAULIC OPERATOR BASIC SCHEMATIC ............. C-0201-03 ..... 31
BASIC MANIFOLD ASSEMBLY DRAWING ..................... A-0197 ........ 32
A324-M RELAY DRAWING .................................. C-0032 ........ 33
A324-DM RELAY DRAWING ................................. C-0034-00 ..... 34
WBMC SELECTOR DRAWING............................... APB0648 ...... 35
SPEED (FLOW) CONTROL VALVES ......................................... 36
HV HANDPUMP DRAWING ................................. A-0181 ........ 37
GFMA-48 FILTER DRAWING ................................ A-0182 ........ 38
(i-0006--.wpd) 2
. . . continued
SECTION I GAS / HYDRAULIC ROTARY VALVE OPERATOR
DESCRIPTION DWG.NO PAGE
MECO REGULATOR...................................................... 39
END OF STROKE VALVE ASSEMBLY ......................... C-0082 ........ 42
SWITCHPAK INSTALLATION AND ADJUSTMENT DRAWING ...... IB0048-08 ..... 43
SV-06 HANDPUMP SAFETY VALVE DRAWING ................. APB0815 ...... 44
FIELD SERVICE REQUEST FORM ........................... I-0100 ......... 45
XIX MAINTENANCE LOG ..................................................... 47
XX NOTES. . . . ............................................................. 48
SECTION II WORK ORDER SPECIFIC CONTROLS AND COMPONENTS
(49...)
SECTION III SCHEMATICS, WIRING DIAGRAMS, DIMENSIONAL DRAWINGS
(50...)
(i-0006--.wpd) 3
I SAFETY WARNINGS
1. OPERATING INSTRUCTIONS (Page 6)
This equipment exhausts gas as part of its operating cycle. Wear hand, ear, and eye
protection, and keep sparking devices and open flames away.
2. INSTALLATION (Page 8)
For final assembly over stem to valve lifting eyes are to be used in combination, with a 3 leg
sling with one shortening hook, to lift the operator only.
3. INSTALLATION (Page 8)
Excess operator travel can cause damage to end of stroke (trigger) valve if over-travel
occurs and the trigger interferes with the component. The operators mechanical end-stops
are preset at the factory for 90b travel.
4. START-UP CHECKS (Page 12)
If unit has a fail or ESD (Emergency Shut Down) position, the failsafe or ESD controls may
have to be temporarily disabled, bypassed or overridden by AUTO / MANUAL selector to
prevent inadvertent valve operation.
5. MAINTENANCE AND OPERATIONAL TESTING (Page 14)
DE-PRESSURIZE operator before attempting to service power gas filter, check tank fluid
level or check manual operation of handpump.
6. END OF STROKE VALVE INSTRUCTIONS (Page 16)
Changing operator travel can cause damage to end of stroke (trigger) valve if over travel
occurs and trigger strikes component.
7. OPERATOR MAINTENANCE (Page 18)
Gas / Hydraulic tanks should be drained and flushed if fluid is contaminated with scale, rust,
particulates, water, foam, or etc. Flush only with hydraulic fluid. Refill with filtered fluid.
Please refer to the applicable section for details and further information.
(i-0006--.wpd) 4
II OPERATING INSTRUCTIONS
Refer to specific schematic drawing and list of components at the end of this document and
"Operating Procedure" diagram which is located inside the control package cover on the unit,
also reproduced on pages 5 through 9.
NOTE: Operating procedures for equipment with automatic switching capability vary with
particular applications. Refer to Owner's Procedures
remote switching devices.
NOTE: The four valves needed for local manual operation are located on a manifold plate
inside the control package compartment. The handpump is located below the control
package compartment.
CAUTION: This equipment exhausts gas as part of its operating cycle. Wear hand, ear
and eye protection, and keep sparking devices and open flames away.
for operators with automatic or
A. WITH POWER GAS
or auxiliary nitrogen bottle present, appropriate supply shutoff valves
open, and both handles of lower hydraulic handpump switching valves in vertical position
against stops:
1. To close the line valve, press and hold handle on upper left gas switching relay.
Release after line valve is closed.
2. To open the line valve, press and hold handle on upper right gas switching relay.
Release after line valve is open.
B. WITHOUT POWER GAS
, and supply shutoff valve closed:
1. To close the line valve, rotate the handle on lower left hydraulic switching valve
clockwise against stop. Operate handpump to close valve. Return valve handle to
vertical position against stop when line valve is closed.
2. To open line valve, rotate the handle on lower right hydraulic switching valve counter
clockwise against stop. Operate handpump to open line valve. Return valve handle to
vertical position against stop when line valve is open.
Placing hydraulic switching valve in mid position at the completion of handpump operation will
allow the handpump plunger to be returned to retracted position. Do so, and then return
hydraulic switching valve handle to vertical position.
C. TO DISARM OPERATOR
, shut off supply valve and press handle on either upper gas
switching relay halfway to vent power gas:
NOTE: Read this document through to understand the general arrangement and functioning,
and be able to proceed safely and efficiently. Have the necessary tools and
equipment at hand.
(i-0006--.wpd) 6
III INSTALLATION
NOTE: Mounting hardware is usually in a separate box on shipping pallet / crate or inside
panel cover of unit. Gas / Hydraulic tanks must
of valve and valve stem orientation. Lifting eyes are to be used in combination, with
a 3 leg sling with one shortening hook, to lift the operator only.
A. FIELD MOUNTING
1. If valve is installed in line, fully open or closed position can be determined only with
reference to valve stem key and run of valve, or valve stops. Refer also to valve
manufacturer's instructions. But in general:
a) The operator internal stops, not the line valve's, must govern travel.
b) Valve manufacturer and buried extension manufacturer must provide a precise
mechanical stem stop or indicator marks calibrated before valve installation. For
example, ±1b valve closure position translates to only ±0.035" [0.89 mm] at periphery
of 4" [100 mm] diameter stem.
c) For block and bleed type ball valves only, if the indicator marks are lost or covered,
the closed and / or open position may be found by trial and error body blowdowns.
This is a task for a millwright and a valve technician, and requires special equipment.
Different types of valves have other ways for checking these positions, so check with
valve manufacturer's instructions, if at all possible.
remain generally vertical, regardless
d) For most valves, if the valve stop is wrong or the indicator marks are lost or
obscured, the closed position may be assumed 90b ±1b, from full open.
e) For central stem lubrication valve refer to drawing C-0180 on page 9.
2. Place operator and valve in the same position (both open or both closed). Damage to
valve and / or operator can be caused if operator tries to open or close a valve against
valve internal stops. Operator position can be controlled and confirmed safely by
operation with handpump.
3. Check mounting surfaces, valve stem, operator bore and orientation for any dimensional
discrepancy, dirt, rust, etc.
4. If access to yoke cover is obstructed by limit switch or other accessories, it is
recommended that the stem key be set in place at this point (before actuator is installed
on the valve stem). If so, double check item 1 above, be sure that tapped hole in key is
to top of valve stem, and ignore item 7 below.
5. Set operator in position on the valve. Keep hooks and chains clear of tubing and
accessories.
6. Install mounting bolts to fasten operator to valve. Align operator to valve while bolts are
slightly loose, then tighten mounting bolts evenly and thoroughly to industry standard for
the grade and size of bolt.
7. If necessary, temporarily remove yoke cover and install key with tapped hole for eyebolt
to top of valve stem.
(i-0006--.wpd) 8
FIELD MOUNTING continued. . .
8. If necessary, adjust operator end stops for line valve fully open and fully closed
positions. (Stops are factory adjusted for approximately 90b rotation.) Refer to Operator
Cutaway drawing on page 22.
a) Rotate operator against its stop to be adjusted.
b) Remove stop cover. It should be tight and may require torque wrench; call for
assistance or proper tools rather than improvise.
c) Adjust end-stop into or away from operator as required. To adjust the end-stop into
the operator, first use the handpump to position the operator. (Estimate based on
thread pitch if adjustment is away.)
d) Rotate operator against stop if adjustment (c) was away.
e) Install and tighten stop cover against o-ring.
Notice the end stop adjustment table below. The stop cover must be tightened firmly to seal
against full rated pressure.
NOTE: Excess operator travel adjustment can cause damage to end of stroke (trigger)
valve if over-travel occurs and trigger interferes with the component. Refer to
limit switch layout on page 17.
END STOP MOVEMENT VS. DEGREES ROTATION
Series 7 Series 6 Series 5 Series 3 Series 2
End Stop
.125 .125 .125 .125 .091
Movement per turn
(inches)
Stem / Shaft
1.02 1.30 1.43 2.05 1.65
Rotation per turn
(degrees)
End Stop Location cylinder cylinder cylinder cylinder drive
case
Cover or Jam Nut
360 130 90 45 40
Torque (ft-lb)
9. Replace yoke cover and gasket, proceed to "Install Connections" and "Prestart-up
Checks".
(i-0006--.wpd) 10
IV INSTALL CONNECTIONS
1. Supply gas take-off should be from top or side of header. Supply gas connection is as per
schematic drawing. User should provide a shutoff valve on supply, and size lines to ensure
draw down when operating valve does not interfere with pressure sensing devices, that is,
use proper size of tubing for flow and pressure purposes.
2. In the case of a volume tank (power gas storage bottle) with inlet check, user should
confirm that the tank is rated and / or protected against any possible supply overpressure or
thermal expansion overpressure.
3. Electrical connection(s), to junction box if any, are as per wiring diagram and electrical
drawings.
4. Conduit connection to limit or pressure switch, if field installed, are to comply with all local
regulations (seal within 18 inches for explosion proof).
V PRESTART-UP CHECKS
A. CHECK OPERATOR
1. Unit has been mounted on valve properly. Gear flange mounting bolts, stem key,
setscrew(s) installed and secured.
2. No tubing damaged or accessories dislodged during shipping or installation.
3. Indicated position confirms valve position.
4. All switching valves in normal operating position as per DIAGRAM / INSTRUCTIONS.
5. If removed, yoke cover bolts, limit switch / end of stroke mounting bolts have been
replaced and secured.
6. Limit switch / end of stroke valve trigger(s), if removed for valve installation, have been
replaced and are properly set. Refer to "Instructions to Set Limit Switches..." on page 15
for applicable instructions.
7. Switchpak shaft centerline aligned with yoke cover / operator stem centerline. Refer to
drawing IB0048-08 on page 43.
8. In case of valve stem lubricator, two piece yoke cover setscrews are secured and stem
section is centered in yoke cover. There is a gap between top of stem and switchpak
adapter. Refer to drawing C-0180 on page 9.
(i-0006--.wpd) 11
PRESTART-UP CHECKS continued. . .
B. CHECK CONNECTIONS
1. Pneumatic / hydraulic components connected as per schematic enclosed or in service
manual supplied.
2. Power gas / signal gas connected to identified ports.
3. Electrical connections in junction box terminals are secure.
4. Wiring as per enclosed diagram or service manual supplied.
5. SWITCHPAK . . . remove cover . . .
a) ensure wiring will not become tangled or hooked by nylon trigger screws during
rotation.
b) nylon trigger screws are in correct location between switch stacks, if ALLEN
adjusting screws are accessible when valve / operator is in either open or closed
position.
NOTE: 'ZSO_' actuated at fully open position.
'ZSC_' actuated at fully closed position.
LOWEST 'ZS__' IN STACK IS ZSOA; the one next to operator.
VI START-UP CHECKS
NOTE: If unit has a fail or ESD (Emergency Shut Down) position, the failsafe or ESD controls
may have to be temporarily disabled, bypassed or overridden by
AUTO / MANUAL selector to avoid inadvertent valve operation.
To check operation in AUTO or MANUAL mode, temporarily disconnect the ESD control
component (pilot, solenoid, switching relay) signal line, and plug or cap it so it does not bleed
the system during check out procedures.
1. If possible, manually operate unit to full open and close positions by a handpump on unit, or
low pressure (100 psi) power gas applied to supply port. When each position has been
reached, CHECK:
a) Operator stop settings. If adjustment is required refer to installation on page 8.
b) Fluid levels in tanks. Refer to tank filling drawing I-0006-13 on page 24 and the decal on
the manifold plate for correct level for each position.
c) Limit switch / end of stroke actuated at or before respective correct position.
2. Power gas supply. CONFIRM power gas supply PRESSURE.
a) Gas / Hydraulic rotary or linear maximum operating pressure as per tank and operator
Name Plates, minimum as specified by user's Engineer.
(i-0006--.wpd) 12
START-UP CHECKS continued . . .
3. Leak test by applying power gas supply and at end of stroke manually maintain power gas
on system for TWO MINUTES. CHECK:
a) for leaks at supply points / fittings in supply line.
b) for hydraulic / air leaks at fittings while operator is operating.
4. To check manual and automatic operation:
a) if unit has auto / manual selector place selector in "MANUAL" position
b) open power gas supply valve or apply power gas to unit
c) Manually operate upper relays as per instructions to stroke unit to "open" and / or "close"
position. Check for leaks at connections and exhaust gas / blowby after stroke is
completed. There will be exhaust during travel of the operator.
d) Put selector in "AUTO" position.
e) Simulate automatic operation by energizing or de-energizing solenoid(s), and / or
switching relays.
f) Check for leaks / blowby at exhaust port of components during operation, limit switch
actuation and end of stroke venting.
g) Put operator in normal operating position for ESD / Fail operation check out which
follows below.
5. SHUT OFF POWER GAS SUPPLY, DISARM OPERATOR AS PER INSTRUCTIONS.
a) Replace any tubing that was removed, or disconnect any that bypassed ESD
COMPONENT for above test.
b) Remove electrical jumper(s) installed to simulate "AUTO" operation unless required to
operate ESD device.
6. EMERGENCY SHUTDOWN / FAIL POSITION OPERATION CHECK OUT
a) Ensure operator is in normal operating position.
b) Apply / remove the required ESD signal to operate the unit.
c) Apply power gas supply to the unit, it should operate to ESD / Fail position.
NOTE: If unit has power gas storage bottle on it, you may want to install a gauge in high
pressure (inlet) gauge port of regulator and check the consumption and number of
strokes available.
7. RESTORE ALL TUBING AND WIRING AS PER FACTORY SHIPPED OR NORMAL
OPERATING CONDITIONS.
(i-0006--.wpd) 13
VII SCHEDULED MAINTENANCE AND OPERATIONAL TESTING
A program of scheduled maintenance and operational testing of the operator by a trained
technician is recommended.
NOTE: DE-PRESSURIZE operator before attempting to service power gas filter, check tank
fluid level or check manual operation of handpump.
The following test and maintenance procedure should be performed AT LEAST ONCE PER
YEAR.
1. Drain accumulated moisture and contaminants from gas filter. Refer to "General Service
Notes" on page 29.
2. If step (1) indicates heavy accumulations, drain contaminants from GAS / HYDRAULIC
TANK(S) and check tank levels. Refer to "General Service Notes" on page 29.
NOTE: Consider replacing filter element(s) as it may be clogged with contaminants.
3. If line valve position must not be changed, remove valve stem key if necessary to
disconnect operator from valve before proceeding or proceed to verify system for given line
valve position; only to do opposite side at later date.
NOTE: With gate valve operator, decoupling is not recommended, also shut speed
controls off if provided, to prevent line valve movement.
4. Refer to "Operating Instructions" on page 6 to ensure that proper method of operation is
followed.
5. Check manual operation with handpump (if applicable).
a) There should be noticeable suction on the suction stroke, decreasing as the pump
cylinder fills, indicating suction lines are open and full of fluid.
b) Handle effort on the pressure stroke will depend on line pressure and line valve position.
c) Pressure stroke should be smooth and feel solid, not spongy, indicating pressure lines
are open and full of fluid.
d) At the end of operator stroke (line valve open or closed) the handle should stop solid on
the pressure stroke, indicating no bypass flow in operator or hydraulic components.
e) Test by applying 150 lb force for two minutes to the pump handle provided with the unit.
6. Check manual operation with power gas (if applicable).
a) Depress appropriate relay handle. There should be a momentary flow of gas from
exhaust port in intermediate position.
NOTE: Some effort (up to 50 lbs) should be required to fully depress handle,
indicating adequate supply pressure.
b) The operator should stroke smoothly, indicating Gas / Hydraulic tank levels are okay and
operator mechanicals are okay.
(i-0006--.wpd) 14
SCHEDULED MAINTENANCE AND OPERATIONAL TESTING continued . . .
c) Fluid returning to the opposite tank during stroking will cause a continuous slight exhaust
gas flow from exhaust port, but which stops when the operator reaches end of stroke.
This indicates proper relay function and no bypass flow in operator or Gas / Hydraulic
components.
d) There should be no leaks of gas or hydraulic fluid.
e) Upon releasing relay handle, there should be a momentary rush of gas from exhaust
port as the pressurized Gas / Hydraulic tank is vented.
7. Operating with power gas, check remote / automatic operation (if applicable).
NOTE: Ensure that adequate pressure and flow of gas, and correct hydraulic fluid levels
are present.
a) Shutoff valve should be open.
b) There should be no gas leaks.
c) Hydraulic speed control valves should be partially open..
d) With appropriate meter or gauge, check for correct signal condition.
e) Simulate remote or automatic switching.
f) During stroking of the operator, there should be no signal gas leakage indicating that the
signal section of the switching relay is okay.
g) Test the handpump safety feature. With the handpump handle in place and the
handpump in manual mode, while standing well clear
, apply power gas manually in the
same direction (open / close) as handpump selected and observe for any handpump
handle movement.
VIII INSTRUCTIONS TO SET LIMIT SWITCH
NOTE: Operator stops must be set for valve travel before attempting adjustments.
Determine operator / valve position (ie. open / closed, fail position) before making
adjustments.
Refer to drawing IB0048-08 on page 43. SW Switchpaks are supplied with up to 8 microswitches. For example, the SW14XX has four micro-switches and the SW28XX has eight
micro-switches.
A. INSTALLATION
1. Remove cover (3).
2. Attach housing (1) to stationary bracket with cam shaft and rotary stem (adapter)
engaged.
3. Before tightening mounting screws check that the Switchpak cam shaft is concentric to
(i-0006--.wpd) 15
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