Emerson Fisher 3025 Installation Instructions

Instruction Manual

D251402X012

3025 Actuator

Fisherr 3025 Sizes P460, P462, P460-200, and P900 Diaphragm Actuator

May 2011

Contents

Introduction 1.................................

Scope of Manual 1.............................

Description 2.................................

Specifications 2...............................

Installation 2...................................

Mounting the Actuator on the Valve 3............

Travel Stop Adjustment 4.......................

Installing the Stem Connector Assembly 5.........

Loading Connection 6..........................

Maintenance 6.................................

Actuator Maintenance 6........................

Size P460 Actuator 7.......................

Size P462 Actuator 9.......................

Size P460-200 Actuator 12..................

Size P900 Actuator 14......................

Side Mounted Handwheel Maintenance 18.........

Parts Ordering 21...............................

Parts List 22...................................

Actuator Assembly 22..........................

Side-Mounted Handwheel 23....................

Figure 1. Fisher 3025 Size P460-200 Actuator

W9088

Introduction

Scope of Manual

This instruction manual includes installation, maintenance, and parts information for Fisher 3025 actuators in sizes P460, P462, P460-200, and P900. Refer to separate manuals for instructions covering the positioner and other accessories used with these actuators.

Do not install, operate, or maintain 3025 actuators without being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson Process Management sales office before proceeding.

www.Fisher.com

3025 Actuator

May 2011

Instruction Manual

D251402X012

Description

The Fisher 3025 size P460, P462, P460-200 and P900 spring-opposed diaphragm actuators position the valve plug in the valve body in response to varying controller or valve positioner pneumatic output signals applied to the actuator diaphragm. They can be specified either direct (air-to-close) or reverse acting (air-to-open). The size P460 offers 65 mm maximum actuator travel. The sizes P462 and P900 provide 120 mm maximum actuator travel. The size P460-200 offers 203 mm maximum actuator travel. The 3025 actuator can be equipped with a side-mounted assembly. It is usually used as an auxiliary manual actuator.

Table 1. Specifications

SPECIFICATION

Nominal Effective Area

Yoke Boss Diameter

Acceptable Valve Stem Connection

Maximum Travel

Maximum Diaphragm Casing Pressure

Temperature Capabilities

Pressure Connections (female)

Approximate Actuator Weights

Approximate Side Handwheel Weights

inch

3-9/16 inch x x x ---

5 inch x x x x

5H inch x x x x

75 mm x x --- --120 mm x x --- x 130 mm --- --- --- x

3/4-16UNF x x x ---

1-14UNS x x x x

1-1/4-12UNF x x x x

M16 x x --- --M20 x x --- x M30 x x --- x mm 65 120 203 120 inch 2-5/8 4-3/4 8 4-3/4

bar 4

Psig 58

_C -30 to 80_C _F -22 to 176_F

1/2 NPT x x x x 3/4 NPT x x --- x

1 NPT --- --- x ---

kg 140 190 250 430

lb 310 420 640 1000

kg 40 40 100 65

lb 90 90 220 140

P460 P462 P460-200 P900

1800 1800 1800 3600

279 279 279 558

ACTUATOR SIZE

Specifications

Refer to table 1 for Specifications of the 3025 actuator. See the actuator nameplate for specific information about your actuator.

Installation

Key number locations are shown in figures 3 through 12, unless otherwise indicated. Figures 3 and 4 show the size P460 actuator, figures 5 and 6 the size P462, figures 7 and 8 the size P460-200 and figures 9, 10, 11 and 12 illustrate the size P900.

Instruction Manual

D251402X012

3025 Actuator

May 2011

If the actuator is equipped with a side-mounted handwheel, also refer to the figures 13, 14, 15 and 16. Figure 13 shows the size P460 and the size P462 side-mounted handwheel, figure 14 the size P460-200 and figure 15 illustrates the size P900.

CAUTION

To avoid parts damage, do not use a normal operating pressure that exceeds the Maximum Diaphragm Casing Pressure of 4 bar or produces a force on the actuator stem greater than the Maximum Allowable Valve Stem Load.

D Valve/Actuator Assembly: If the actuator and valve are shipped together as a control valve assembly, it has been

adjusted at the factory, and may be installed in the pipeline. After installing the valve in the pipeline, refer to the Loading Connection procedures.

D Actuator Mounting: If the actuator is shipped separately or the actuator has been removed from the valve, it is

necessary to mount the actuator on the valve before placing the valve in the pipeline. Refer to the actuator mounting procedures before placing the valve in service.

D Positioner: If a positioner is installed, or is to be installed on the actuator, refer to the positioner instruction manual

for installation. During the adjustment procedures, it will be necessary to provide a temporary loading pressure to the actuator diaphragm.

CAUTION

The 3025 diaphragm actuators are designed to mount on push-down-to close valves. Do not mount these actuators on any other type of valve without first contacting your Emerson Process Management sales office.

Mounting the Actuator on the Valve

CAUTION

If the valve stem is allowed to remain in the up position (towards the actuator) during mounting, it can interfere with the actuator mounting, possibly damage valve stem threads or bend the valve stem. Be sure the valve stem is pushed down (into the valve body), away from the actuator while mounting.

CAUTION

If the actuator is equipped with a side-mounted handwheel, during mounting it can interfere with the valve stem (even if the valve stem is pushed completely down into the valve body), possibly damage valve stem threads or bend the valve stem. Be sure the actuator stem is sufficiently retracted (into the side-mounted handwheel), away from the valve while mounting. If not, the actuator stem can be retracted by turning counterclockwise the handwheel. Be sure the actuator stem does not rotate while turning the handwheel (use the anti-rotator to prevent rotation).

1. Provide a vise or some other method of supporting the valve and the weight of the actuator during assembly. Push the valve stem down away from the actuator while mounting the actuator.

3025 Actuator

May 2011

Instruction Manual

D251402X012

2. Lift or hoist the actuator onto the valve bonnet:

a. For the 3-9/16 yoke boss: Slowly lower the actuator down onto the valve. As the yoke passes over the end of the

valve stem, place the yoke locknut over the valve stem. Once the actuator is in place, screw the yoke locknut onto the valve bonnet and tighten the locknut.

b. For all other yoke bosses: Slowly lower the actuator down onto the valve. Once the actuator is in place, insert the

cap screws and tighten the hex nuts, securing the actuator to the bonnet.

Travel Stop Adjustment

The actuator is normally shipped adjusted at the factory and you may refer directly to the Installing the Stem Connector Assembly procedures.

If the actuator has been disassembled, it is necessary to adjust the travel stop. You may perform the following procedure before connecting the actuator stem to the valve stem.

WARNING

When moving the actuator stem with loading pressure applied, exercise caution to keep hands and tools out of the actuator stem travel path. If the loading pressure is accidentally disconnected, personal injury and property damage is possible if something is caught between the actuator stem and other control valve parts.

Also provide a certified pressure gauge suitable to accurately read the diaphragm pressure from 0 through the upper bench set pressure marked on the nameplate. Apply loading pressure to the diaphragm.

Stroke the actuator a few times to ensure that the pressure gauge is working correctly, and that the actuator is functioning properly. It is important to be sure that the actuator assembly is not binding or producing any loading friction on the actuator stem movement.

Note

For push-down-to-close valves, the valve plug is the limit for downward travel and the actuator up-stop is the limit for upward travel (away from the valve).

1. If not already accomplished, provide a temporary means of applying adjustable loading pressure to the actuator during the travel stop adjustments.

2. Remove the cap (key 43, figures 3 through 6) or loosen the locknut (key 42, figures 7 through 12). Unscrew the travel stop (key 41).

3. Perform one of the following procedures as appropriate:

a. For an air-to-open actuator: apply the upper bench set loading pressure to the diaphragm. Adjust the travel stop

(key 41) so that it touches the actuator stem. Then lock the travel stop by replacing the cap (key 43) or by tightening the locknut (key 42).

b. For an air-to-close actuator: apply the lower bench set loading pressure. The actuator should show movement at

the lower bench set pressure. Adjust the travel stop (key 41) so that it touches the actuator stem. Then lock the travel stop by replacing the cap (key 43) or tightening the locknut (key 42).

4. Stroke the actuator and check that the actuator is capable of the travel shown on the travel indicator scale (key 74). If the travel span is correct, travel stop adjustment is complete. Proceed to the Installing the Stem Connector Assembly subsection.

Instruction Manual

D251402X012

3025 Actuator

May 2011

5. If the travel span is not correct, a wrong or damaged spring has been installed in the actuator. To obtain the correct spring sizing information, refer to Fisher Catalog 14, Actuator Sizing and Sample Calculations to determine the correct spring selection for your application. Or contact your Emerson Process Management sales office for assistance. After replacing the spring, repeat the steps above.

Installing the Stem Connector Assembly

When installing the stem connector assembly, the actuator and valve stem threads should engage the threads of the stem connector by a distance of the diameter of the stem.

1. If necessary, push the valve stem down so that it is touching the seat ring.

2. For an air-to-open actuator only, set the diaphragm loading pressure to approximately 0.5 bar over the upper bench set pressure. The actuator stem should be contacting the upper travel stop.

3. For the size P900 only, screw the actuator and valve stem locknuts away from the connector halves locations.

4. Screw the two stem connectors halves (keys 78 and 79) onto the valve stem and actuator stem. Then place the travel indicator (key 84), the spacer if used (key 86) and the anti-rotator (key 85) on the valve stem connector half.

5. To adjust the travel, perform one of the following procedures as appropriate:

a. If the actuator is equipped with a side-mounted handwheel: turn the handwheel so that the distance between

the anti-rotator and the actuator stem connector half is equal to the valve travel. Be sure the actuator stem does not rotate while turning the handwheel (use the anti-rotator to prevent rotation). Be sure that the actuator and valve stem threads are engaging the threads of the stem connectors by the distance of at least one diameter of the stem.

b. If the actuator is not equipped with a side-mounted handwheel: rotate the connector halves so that the distance

between the anti-rotator and the actuator stem connector half is equal to the valve travel. Be sure that the actuator and valve stem threads are engaging the threads of the stem connectors by the distance of at least one diameter of the stem.

CAUTION

Incomplete engagement of the stem connector onto either the valve stem or actuator stem can result in stripped threads or improper operation. Be sure that the length of the actuator stem or the valve stem in the connector is equal or greater than the diameter of that stem. Damage to threads on either stem or in the stem connector can cause the parts to be replaced prematurely.

6. Perform one of the following procedures as appropriate:

a. For an air-to-open actuator: Slowly decrease the diaphragm pressure and line up the stem connector halves.

b. For an air-to-close actuator: Slowly increase the diaphragm pressure and line up the stem connector halves.

7. Install the cap screws (key 87) with the lock washers if used and tighten them.

8. For sizes P460, P462 and P460-200, install the cap screws (key 80) and the nuts (key 81) and tighten them. For the size P900, screw the valve and actuator stem locknuts against the stem connector halves.

9. Slowly increase and decrease pressure several times, stroking the valve from the lower bench set pressure to the upper pressure.

10. Adjust the travel indicator scale (key 74) to correspond with the travel indicator. Stroke the valve full travel to ensure that the travel matches the valve travel on the travel indicator plate. If travel is not correct repeat the stem connector procedure.

3025 Actuator

May 2011

11. If the actuator is equipped with a side-mounted handwheel, insert the screw (key 139) and the nut (key 140) into the stem connector half (key 78). Then screw the nut against the stem connector half. Adjust the handwheel travel indicator (key 113) to correspond with the screw (key 139) used as neutral position indicator. It may be necessary to take off the protective covers (key 119) by removing the cap screws and washers (keys 120 and 128). Once adjusted, replace the protective covers, washers and tighten the screws.

Instruction Manual

D251402X012

Loading Connection

The loading pressure connections are made at the factory if the valve, actuator, and positioner come as a unit. Keep the length of tubing or piping as short as possible to avoid transmission lag in the control signal. If a volume booster, valve positioner or other accessory is used, be sure that it is properly connected to the actuator. Refer to the positioner instruction manual or other manuals as necessary.

For actuators shipped separately or whenever the actuator pressure connections are installed, use the following steps:

1. Connect the loading pressure piping to the NPT internal connection at the side of the diaphragm casing.

2. Cycle the actuator several times to be sure that the valve stem travel is correct when the correct pressure ranges are applied to the diaphragm.

3. If valve stem travel appears to be incorrect, refer to the travel stop adjustment procedures at the beginning of this section. Do not place the valve in service if it is not reacting correctly to diaphragm loading pressure changes.

Maintenance

Actuator parts are subject to normal wear and must be inspected and replaced when necessary. The frequency of inspection and replacement depends on the severity of service conditions.

WARNING

Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations:

D Do not remove the actuator from the valve while the valve is still pressurized.

D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the

actuator cannot suddenly open or close the valve.

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure

from both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power actuator loading pressure and relieve any actuator spring precompression.

D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

When performing maintenance procedures, isolate the control valve from the process line pressure from both sides of the valve. Use the lock-out procedures to be sure that the above measures stay in effect while you are working on the actuator.

Actuator Maintenance

This procedure describes how the actuator can be completely disassembled and assembled. When inspection or repairs are required, disassemble only those parts necessary to accomplish the job; then, start the assembly at the appropriate step.

Instruction Manual

D251402X012

3025 Actuator

May 2011

Key numbers refer to figures 3 through 12 unless otherwise indicated. Figure 3 and 4 show the size P460, figure 5 and 6 the size P462, figure 7 and 8 the size P460-200 and figures 9 through 12 illustrate the size P900.

It may be necessary to apply a temporary loading pressure to the actuator during the disassembly.

Size P460 Actuator

Size P460 Actuator Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric, and remove the tubing or piping from the diaphragm casing (key 1).

2. If the actuator is equipped with a side-mounted handwheel, refer to the Side-Mounted Handwheel Disassembly procedures in the Side-Mounted Handwheel Maintenance section to separate the actuator and handwheel (steps 2 to 7). Then continue the Size P460 Actuator Disassembly procedure from the step 8.

3. For an air-to-open actuator only: slightly pressurize the actuator diaphragm until movement of the actuator stem is detected and the spring force applied to the stem connector is relieved.

WARNING

To avoid personal injury due to sudden uncontrolled movement of parts, do not loosen yoke locknut or cap screws and do not remove parts of the stem connector when the stem connector has spring force applied to it.

4. Remove the stem connector cap screws (key 87), the anti-rotator (key 85), the spacer if used (key 86) and the travel scale indicator (key 84). Loosen the stem connector halves cap screws and nuts (keys 80 and 81). Remove the stem connector halves.

5. For an air-to-open actuator only: slowly exhaust the diaphragm pressure.

6. To separate the actuator from the valve body, remove the yoke locknut or the bolts and then lift off the actuator.

7. Remove the yoke cap screws (key 77) and then lift the actuator off the yoke.

8. Remove the lifting lug cap screws (key 44), the lifting lug (key 40) and the gasket (key 71). If required remove the cap (key 43) and the travel stop (key 41).

WARNING

To avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator, carefully remove casing cap screws and nuts (keys 45 and 46) (step 9 below) and then relieve the spring compression by unscrewing the nut (key 16) (step 11 below).

9. Remove all the diaphragm casing cap screws and nuts (keys 45 and 46). If required remove the vent (key 49).

10. Remove the set screws (key 57) and if used the travel stop and locknut (keys 65 and 66).

11. Relieve the spring compression by unscrewing slowly the nut (key 16).

12. Remove the washer (key 53), then lift off the diaphragm casing (key 3).

13. Remove the actuator springs (keys 30 and 31).

14. Lift off the stem and diaphragm plate assembly.

15. Unscrew the travel stop (key 54), remove ring (key 17), the wave washers (key 12), the tube (key 51), the diaphragm plate (key 26), the diaphragm (key 47), the O-ring (key 6), the washers if used (key 64) and the travel stop (key 14). Unbend the tab washer (key 13), remove the retaining ring (key 11) and the two nut halves (key 10).

3025 Actuator

May 2011

Instruction Manual

D251402X012

16. From the diaphragm casing (key 1) remove the retaining ring (key 8), the wiper ring and the seal retainer (keys 4 and 5) and the O-ring (key 6).

17. If required remove the casing bushings (keys 7 and 33), the pins (key 28) from the diaphragm casing and diaphragm plate, the hellicoils (key 58), the travel scale, screw and nuts (keys 74, 75 and 76).

Size P460 Actuator Assembly

1. If removed, coat the bushings (keys 7 and 33) with lithium grease (key 201) and slide them into the diaphragm casings.

2. Place the wiper ring (key 4) into the seal retainer (key 5). Apply lithium grease (key 201) to the O-ring (key 6), the wiper ring and seal retainer assembly and install them into the diaphragm casing (key 1). Then place the retaining ring (key 8).

3. If removed, insert the pins (key 28) into the diaphragm casing (key 3) and diaphragm plate (key 26).

4. If removed, insert the hellicoils (key 58) into the nut (key 16).

5. Coat the threads of the stem (key 9) with anti-seize lubricant (key 202).

6. Apply anti-seize lubricant (key 202) to the internal thread of the two nut halves (key 10). Install the nut halves and the retaining ring (key 11). Place the tab washer (key 13) and bend it on the retaining ring. Slide the travel stop (key

14), the washers if used (key 64), the O-ring (key 6), the diaphragm (key 47), the diaphragm plate (key 26), the tube (key 51), the wave washers (key 12) and the ring (key 17).

7. Coat the internal thread of the travel stop (key 54) with anti-seize lubricant (key 202), screw it onto the stem and tighten until the wave washers are completely compressed.

8. Place this stem assembly into the diaphragm casing (key 1). Take care when pushing the actuator stem through the diaphragm casing so that the threads do not damage the bushing, O-ring or wiper ring.

9. Place the actuator springs (keys 30 and 31).

10. Install the diaphragm casing (key 3) so that the vent and air connections are diametrically opposed. Take care when lowering the casing around the stem so that the thread do not damage the bushing. Apply lithium grease (key 201) to the washer (key 53) and place it.

11. Apply anti-seize lubricant (key 202) on the nut internal thread (key 16) and screw it slowly to compress the springs until the two diaphragm casings touch the diaphragm.

Note

When you replace actuator diaphragms in the field, take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage, but not crush the material. Perform the following sequence with a manual torque wrench.

CAUTION

Over-tightening the diaphragm cap screws and nuts (keys 45 and 46) can damage the diaphragm. Do not exceed 16 NSm (12 lbfSft) torque.

Note

Do not use lubricant on these bolts and nuts. Fasteners must be clean and dry.

12. Align the diaphragm casings and diaphragm holes. Be sure the vent and air connections on the diaphragm casings are still diametrically opposed. Install the cap screws and nuts (keys 45 and 46). Tighten the diaphragm cap screws and nuts in the following manner.

Instruction Manual

D251402X012

13. The first four bolts tightened should be diametrically opposed and 90 degrees apart. Tighten these four bolts to 8 NSm (6 lbfSft).

14. Tighten the remaining bolts in a clockwise, crisscross pattern to 8 NSm (6 lbfSft).

15. Repeat this procedure by tightening four bolts, diametrically opposed and 90 degrees apart, to a torque of 16 NSm (12 lbfSft).

16. Tighten the remaining bolts in a clockwise, crisscross pattern to 16 NSm (12 lbfSft).

17. After the last bolt is tightened to 16 NSm (12 lbfSft) all of the bolts should be tightened again to 16 NSm (12 lbfSft) in a circular pattern around the bolt circle.

18. Once completed, no more tightening is recommended.

19. Tighten the set screws (key 57) into the nut (16).

20. If used, place the locknut and travel stop on the stem (keys 65 and 66) and screw the locknut against the travel stop.

21. Place the gasket (71) and the lifting lug cap (40) onto one of the diaphragm casings according to the actuator action (air-to-close: key 1, air-to-open: key 3). Insert the cap screws (key 44) and tighten them.

22. If removed, place the travel stop (key 41) into the lifting lug cap.

23. If the actuator is equipped with a side-mounted handwheel, it is necessary to adjust the actuator travel stop before mounting the actuator onto the side-mounted handwheel. Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section. Then refer to the Side-Mounted Handwheel Assembly procedures in the Side- Mounted Handwheel Maintenance section to complete the actuator assembly (from step

9).

24. Lift the actuator and place it onto the yoke. Insert the cap screws (key 77) and tighten them.

25. If removed, screw the vent (key 49) into the diaphragm casing (key 3).

26. Mount the actuator onto the valve in accordance with the procedures in the Installation section.

3025 Actuator

May 2011

Size P462 Actuator

Size P462 Actuator Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric, and remove the tubing or piping from the diaphragm casing (key 1).

3. For an air-to-open actuator only: slightly pressurize the actuator diaphragm until movement of the actuator stem is detected. The spring force applied to the stem connector is relieved.

WARNING

5. For an air-to-open actuator only: slowly exhaust the diaphragm pressure.

6. To separate the actuator from the valve body, remove the yoke locknut or the bolts and then lift off the actuator.

3025 Actuator

May 2011

Instruction Manual

D251402X012

7. Remove the yoke cap screws (key 77), then lift the actuator off the yoke.

8. Remove the lifting lug cap screws (key 44), the lifting lug (key 40), the gasket (key 71) and the spacer if used (key

67). If required remove the cap (key 43) and the travel stop (key 41).

9. Unscrew the cap screws (key 36) and remove the flange (key 34) and gasket (key 72).

10. Unbend the ring retaining (key 59) and slide towards the casing. Remove the 2 ring halves (key 61) and then the ring retaining.

WARNING

To avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator, relieve the spring compression (step 11 below) and carefully remove casing cap screws and nuts (keys 45 and 46) (step 12 below)

11. Relieve the spring compression by unscrewing alternately and slowly the four cap screws (key 32).

12. Remove all the diaphragm casing cap screws and nuts (keys 45 and 46). If required remove the vent (key 49).

13. Lift off the diaphragm casing (key 3).

14. Remove the spring seat (key 29) and actuator spring (key 30).

15. Lift off the stem and diaphragm plate assembly.

16. Unscrew the set screw (key 57) and remove the travel stop (key 52). Loosen the nut (key 10). Remove the ring retaining (key 11), the wave washers (key 12), the tube (key 51), the diaphragm plate (key 26), the diaphragm (key

47), the O-ring (key 6), the travel stop (key 14), the ring retaining (key 60) and the 2 ring halves.

17. From the diaphragm casing (key 1) remove the retaining ring (key 8), the wiper ring and the seal retainer (keys 4 and 5) and the O-ring (key 6).

18. If required, remove the casing bushings (keys 7 and 33), the pins (key 28) from the diaphragm plate and spring seat, thread the travel stop if used (key 66) out of the stem. If required, remove the travel scale, the screws and nuts (keys 74, 75 and 76).

Size P462 Actuator Assembly

1. If removed, coat the bushings (keys 7 and 33) with lithium grease (key 201) and slide them into the diaphragm casings.

3. If removed, insert the pins (key 28) into the spring seat (key 29) and diaphragm plate (key 26).

4. Coat the threads of the stem (key 9) with anti-seize lubricant (key 202).

5. Place the two ring halves (key 61) and the retaining ring (key 60). Slide the travel stop (key 14), the O-ring (key 6), the diaphragm (key 47), the diaphragm plate (key 26), the tube (key 51), the wave washers (key 12) and the retaining ring (key 11).

6. Coat the internal thread of the 2 nut halves (key 10) with anti-seize lubricant (key 202) and tighten them until the wave washers are completely compressed.

7. Slide the travel stop (key 52) and tighten the set screw (key 57).

9. Place the actuator spring (key 30). Apply anti-seize lubricant (key 202) into the four cap screw beds of the spring seat. Place the spring seat (key 29) so that the cap screw beds will be aligned with the internal threads of the diaphragm casing (key 3).

Instruction Manual

D251402X012

3025 Actuator

May 2011

10. Install the diaphragm casing (key 3) so that the vent and air connection are diametrically opposed. Take care when lowering the casing around the stem so that the threads do not damage the bushing.

Note

CAUTION

Over-tightening the diaphragm cap screws and nuts (keys 45 and 46) can damage the diaphragm. Do not exceed 16 NSm (12 lbfSft) torque.

Note

Do not use lubricant on these bolts and nuts. Fasteners must be clean and dry.

11. Align the diaphragm casings and diaphragm holes. Be sure the vent and air connection on the diaphragm casings are still diametrically opposed. Install the cap screws and nuts (keys 45 and 46). Tighten the diaphragm cap screws and nuts in the following manner.

12. The first four bolts tightened should be diametrically opposed and 90 degrees apart. Tighten these four bolts to 8 NSm (6 lbfSft).

13. Tighten the remaining bolts in a clockwise, crisscross pattern to 8 NSm (6 lbfSft).

14. Repeat this procedure by tightening four bolts, diametrically opposed and 90 degrees apart, to a torque of 16 NSm (12 lbfSft).

15. Tighten the remaining bolts in a clockwise, crisscross pattern to 16 NSm (12 lbfSft).

16. After the last bolt is tightened to 16 NSm (12 lbfSft) all of the bolts should be tightened again to 16 NSm (12 lbfSft) in a circular pattern around the bolt circle.

17. Once completed, no more tightening is recommended.

18. Coat the thread of the four cap screws (key 32) and the internal threads of the diaphragm casing (key 3) with anti-seize lubricant (key 202). Be sure that the cap screw beds into the spring seat are still aligned with the internal threads of the diaphragm casing. Then install and screw alternately and slowly the four cap screws to compress the spring.

19. Place the retaining ring (key 59) onto the stem. Install the ring (key 61) and slide the retaining ring and bend it on the ring.

20. Place the gasket (key 72) and the flange (key 34). Insert the cap screws (key 36) and tighten them.

21. If used, screw travel stop on the stem (keys 66).

22. Place the spacer if used (key 67), the gasket (key 71) and the lifting lug cap (key 40) onto one of the diaphragm casings according to the actuator action (air-to-close: key 1, air-to-open: key 3). Insert the cap screws (key 44) and tighten them.

23. If removed, place the travel stop (key 41) into the lifting lug cap.

24. If the actuator is equipped with a side-mounted handwheel, it is necessary to adjust the actuator travel stop before mounting the actuator onto the side-mounted handwheel. Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section. Then refer to the Side-Mounted Handwheel Assembly

3025 Actuator

May 2011

Instruction Manual

D251402X012

procedures in the Side- Mounted Handwheel Maintenance section to complete the actuator assembly (from step

9).

25. Lift the actuator and place it onto the yoke. Insert the cap screws (key 77) and tighten them.

26. If removed, screw the vent (key 49) into the diaphragm casing (key 3).

27. Mount the actuator onto the valve in accordance with the procedures in the Installation section.

Size P460-200 Actuator

Size P460-200 Actuator Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric, and remove the tubing or piping from the diaphragm casing (key 1).

3. For an air-to-open actuator only: slightly pressurize the actuator diaphragm until movement of the actuator stem is detected. The spring force applied to the stem connector is relieved.

WARNING

To avoid personal injury due to sudden uncontrolled movement of parts, do not loosen yoke locknut or cap screws and do not remove the parts of the stem connector when the stem connector has spring force applied to it.

5. For an air-to-open actuator only: slowly exhaust the diaphragm pressure.

6. To separate the actuator from the valve body, remove the yoke locknut or the bolts and then lift off the actuator.

7. Remove the yoke cap screws (key 77), then lift the actuator off the yoke.

8. Remove the bellows (key 68). Remove the lifting lug cap screws (key 44), the lifting lug (key 40) and the gasket (key

71). If required, loosen the locknut (key 42) and remove the travel stop (key 41).

WARNING

9. Remove all the diaphragm casing cap screws and nuts (keys 45 and 46). If required remove the vent (key 49).

10. Unscrew the locknut (key 62).

11. Relieve the spring compression by unscrewing slowly the nut (key 16).

12. Remove the washer (key 53), then lift off the diaphragm casing (key 3).

13. Remove the actuator springs (keys 30 and 31).

14. Lift off the stem and diaphragm plate assembly.

15. Unscrew the travel stop (key 54), remove the wave washers (key 12), the tube (key 51), the O-ring (key 6), the diaphragm and diaphragm plate assembly (keys 24, 25, 26 and 47). Remove the retaining ring (key 11) and the two nut halves (key 10).

+ 28 hidden pages

Emerson Fisher 3025 Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual