Emerson Fisher 480 Installation Instructions

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Page 1

Instruction Manual

D100291X012

480 Series Actuators

Fisherr 480 Series Yokeless Piston Actuators

August 2012

Contents

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

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

Description 1.................................

Specifications 1...............................

Actuator Configurations 4.......................

Installation 5..................................

Principle of Operation 6.........................

Pressure Connections 7.........................

Adjustments 7.................................

Actuator Maintenance 8.........................

Disassembly 8................................

Parts Ordering 12...............................

Parts List 12...................................

Introduction

Figure 1. Fisher 480-15 Piston Actuator

W1867

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for Fisher 480 Series yokeless piston actuators.

Do not install, operate, or maintain 480 Series 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.

Description

480 Series actuators (figure 1) are yokeless piston actuators that are used in either throttling or on-off applications with ball valves, butterfly valves, louvers, dampers, and rheostats. They require pneumatic pressure loading from double-acting positioners (Fisher 3570) or from on-off loading and unloading devices.

Specifications

Table 1 lists specifications for the 480 Series actuator and table 3 lists specifications for the 3570 actuator.

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480 Series Actuators

August 2012

Table 1. Fisher 480 Series Actuator Specifications

Instruction Manual

D100291X012

Available Configurations

See the Actuator Configurations section.

Cylinder Pressure

Maximum Allowable:

(4)

10.3 bar (150 psig) Required to Produce a Given Thrust: Seefigure2 Minimum Recommended: Valves with low torque

Stroking Speeds

See table 2

Operative Ambient Temperature

With Nitrile O-Rings: -46 to 80_C(-50to175_F) With Fluorocarbon O-Rings (Optional):

-18 to 149_C(0to300_F)

requirements -- (2.4 bar [35 psig]); all other valves -(3.4 bar [50 psig])

Actuator Size and Piston Size

See table 2

Maximum Supply Source Consumption

With Positioner and Constant Input Signal: 0.54 normal m

/hr

(1)

(20 scfh

(1)

) of air at 6.9 bar (100 psig)

Without Positioner: Depends on cylinder volume and

Pressure Connections

Standard is 1/4 NPT. For larger sizes, contact your Emerson Process Management sales office.

supply pressure

Construction Materials

Travel Information

Maximum Rated Travels, All 480 Series actuators with Linear Output: See table 2 Travel Stops Available for 480 Series actuators with 105 mm (4.125 inch ) Maximum Rated Travels: See table 2

Actuator:

Part Material

Cylinder and Piston Aluminum

Piston Rod Extension SST, Chrome Plated

Cylinder Seal Bushings Brass

O-Rings Nitrile or Fluorocarbon

Thrust Information

Seefigure2

Torque Output

480, 480-15, and 480-16 (for butterfly valves): Contact your Emerson Process Management sales office

1. Normal m3/hr.- normal cubic meters per hour (0_C and 1.01325 bar, absolute); Scfh - standard cubicfeet per hour (60_Fand14.7psia).

2. These terms are defined in ANSI/ISA StandardS51.1

3. Without snubber. Ifthis actuator has a snubber, the temperature specification is the sa me for the nitrile version.

4. The pressure limits inthis bulletin and any applicablestandard or code limitation for actuator shouldnot be exceeded.

Options

J 376 Series trip valve system to fail actuator J up or J down or J lock in last position J TopWorxt DXP M21GNEB electrical valve stem

position switch

J Micro-Switch limit switches

(2)

(3)

Table 2. Size, Piston, Stroking Speed, and Travel Information

EFFECTIVE

ACTUATOR

SIZE

30 107 16.5 121 4.75 102 4 --- --- 105 4.125 89 3.5

40 60

1. For actuators with positioners at 6.9 bar (100 psig) supply p ressure and all prestrokeconditions satisfied. Strokingspeeds for actuators withoutpositioners or with snubbers will depend on the particular construction involved.

2. See 480 series Actuators Specifications for these travels.

PISTON AREA

Cm2Inch2mm Inch

182

28.25

258

55.5

PISTON

DIAMETER

156 216

6.125

8.5

STROKING

(1)

SPEED

mm/

Inch/s mm Inch mm Inch mm Inch

52332.05

1.30

–16 Versions

206 8.125 105 4.125 89 3.5

SINGLE-FLANGE

All Others Except Fisher 487,

487-1

(2)

TRAVEL STOPS AVAILABLE

FOR ACTUATORS WITH

105 mm (4.125 INCHES)

MAXIMUM RATED TRAVEL

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Table 3. Fisher 3570 Actuator Specifications

480 Series Actuators

August 2012

Available Configurations

3570: Valve positioner with two relays and three pressure gauges for monitoring input signal and output pressures to the top and underside of the actuator piston 3570C: Similar to 3570 except that the positioner is equipped with automotive tire valves instead of pressure gauges. The valves can be used for clip-on test pressures gauges. The relay nozzles on these positioners are locked in place with locknuts to resist unwanted nozzle movement due to vibration

Input Signal

Standard Ranges: 0.2to1.0bar(3to15psig)or0.4 to 2.0 bar (6 to 30 psig) Split Ranges: Typically uses one half of standard range when two control valves are operated by one input signal from a single controller Optional Ranges: As required within the limits of the bellows

Bellows Pressure Rating

Standard Bellows: 3.4 bar (50 psig) Optional Bellows: 6.2 bar (90 psig)

Supply Pressure

Maximum: 10.3 bar (150 psig) Minimum: 2.4 bar (35 psig)

Frequency Response

(1,2)

Seefigure3

Pressure Connections

Vent: 3/8 NPT All Others: 1/4 NPT

Pressure Indications

3570C: Tire valves accept standard pressure gauge chucks 3570: See table below

Type of Indication

Positioner input signal

gauge

Cylinder supply pressure

gauge

Static Air Consumption

Number

Used

0 0to11.0(0to160)

(3)

Standard Gauge Range

bar (psig)

0 to 2.1 (0 to 30) or

0 to 4.1 (0 to 60)

0.56 normal m3/hr (20 scfh) with 6.9 bar (100 psig) supply pressure

Operative Ambient Temperature

With Nitrile O-Rings: -34 to 79_C(-30to175_F) With Fluorocarbon O-Rings (Optional):

(1,2)

(3)

-18 to 149_C(0to300_F)

Output Signal

Type: Pneumatic pressure as required by the actuator Action: Field reversible between direct and reverse (see table 4)

Hysteresis

(1,2)

0.15% of total stroke or instrument pressure span

Resolution

(1,2)

0.2% of instrument pressure span

Repeatability

(1,2)

0.3% of instrument pressure span

1. These terms are definedin ANSI/ISA Standard S51.1

2. For actuator with positioner only. Does not apply toother constructions or actuator-valve combination.

3. Normal m

/hr.- normal cubic meters per hour (0_C and 1.01325 bar,absolute); Scfh - standard cubic feet per hour (60_F and 14.7 psia).

Construction Materials

Actuator:

Part Material

Base, Cover and Beam

Bellows

Bias and Range Spring

Relay Body

Relay Nozzle(s)

Diaphragm

O-Rings

Aluminum, die cast

Brass

Steel, Plated

Zinc, Die Cast

SST Nitrile or Fluorocarbon Nitrile or Fluorocarbon

Options

Fisher SS-52 clip-on chuck (with or without gauge) for 3570C positioners

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480 Series Actuators

August 2012

Figure 2. Supply Pressure and Thrusts

SIZE 30 ACTUATOR

NOTE:

MAY BE INCREASED BY 10% FOR ACTUATORS WITHOUT POSITIONERS. EITHER THIS THRUST, OR THE MAXUMUM ALLOWABLE LOADING FOR THE CONTROL DEVICE IS THE LIMITING FACTOR FORUSABLE ACTUATOR FORCE.

A5961

SIZE 40 ACTUATOR

SIZE 60 ACTUATOR

THRUSTS IN THOUSANDS OF POUNDS (IN THOUSANDS OF NEWTONS) FOR ACTUATORS WITH POSITIONERS

Figure 3. Frequency Response

Instruction Manual

D100291X012

1. SIZE 30– 19mm (0.75 INCH) TRAVEL

2. SIZE 40– 38mm (1.5 INCH) TRAVEL

3. SIZE 60– 38mm (1.5 INCH) TRAVEL

A5962

Actuator Configurations

480: Yokeless piston actuator with positioner.

481: Yokeless piston actuator without positioner. Other actuators may be obtained without positioner by adding -1 to thetypenumber.

The above actuators come with standard mounting flange, 105 mm (4.125 inch) maximum rated travel, and threaded pistonrodconnectionwithsizes30through60formounting on ball valves, louvers, and dampers with brackets.

These actuators may be obtained with the following alternate universal mounting flange constructions:

-15 Added to Type Number: Allows butterfly valve mounting for a standard actuator with 105 mm (4.125 inch) maximum travel and threaded piston rod connection, and comes in sizes 30 through 60.

-16 Added to Type Number: Provides 206 mm (8.125 inch) maximum travelandthreadedpistonrod connection, and comes in sizes 40 through 60.

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480 Series Actuators

August 2012

Table 4. Action Under Normal Operating Conditions

ACTUATOR DESCRIPTION

With Positioner

Without positioner

1. Supply pressure is routed through relays to p iston.

Direct-acting Increasing input signal pressure to bellows

Reverse-acting Decreasing inputsignal pressureto bellows

Down Up

Supply pressure loaded on top of piston,

exhausted from bottom

DESIRED PISTON MOTION

(1)

Decreasing input signal pressure to bellows

(1)

Increasing input signal pressure to bellows

Supply pressure loaded on bottom of piston,

exhausted from top

Installation

WARNING

Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal injury.

Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed where service conditions could exceed the limits given in table 1 or 3 or on the appropriate nameplates. To avoid such injury or damage, provide a relief valve for overpressure protection as required by accepted industry or local, state, and Federal codes and good engineering practices.

Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual.

(1)

Inspect this equipment on arrival to note any damage which may have occurred in transit. If the actuator is attached to a valve body when received, install the valve in the pipeline with flow in the direction of the arrow on the valve body. (Some valve types, notably various butterfly valves, can be installed with flow in either direction and are unmarked as to proper flow direction.)

A three-valve bypass around the main valve is recommended to permit continuous operation during periodic maintenance or inspection of the main valve.

Figure 4. Operation of Actuator with Positioner

FIXED RESTRICTION

RANGE SPRING

BIAS SPRING

BJ8256-A A1286

SUPPLY

RELAY B

INSTRUMENT

SUPPLY

INSTRUMENT PRESSURE SUPPLY PRESSURE TOP CYLINDER PRESSURE BOTTOM CYLINDER PRESSURE NOZZLE PRESSURE

BELLOWS REVERSED POSITION

BEAM

RELAY A

FIXED RESTRICTION

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Instruction Manual

D100291X012

When 480 Series actuators are supplied to operate dampers, louvers, or similar equipment, a suitable mounting plate should be provided, and the piston rod of the actuator connected to the operating arm of the damper, etc., with appropriate linkage.

Figure 5. Cylinder Diameter and Bolt Center Location, All Actuators (refer to table 5)

BH9452-K A1290

Table 5. Cylinder Diameter and Bolt Center Location, All Actuators

ACTUATOR SIZE

30 171 6.75 0 45

40 206 8.12 45 45

60 267 10.50 22.5 45

mm Inch Standard Flange Universal Mounting Flange

C H,DEGREE OF ARC

Figure 6. Operation of Actuator with Snubber

SNUBBER

CHECK VALVES

32A8303-A A1287

POSITIONER OR SWITCH

-ING DEVICE

SUPPLY PRESSURE TOP CYLINDER PRESSURE BOTTOM CYLINDER PRESSURE UPPERSNUBBERPRESSURE LOWER SNUBBER PRESSURE

Principle of Operation

Actuator

These actuators react to a pressure unbalance that is created by loading supply pressure on one side of the piston and unloading the opposite side. Some type of switching device is required to shift the supply pressure from one side of

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the piston to the other. For most actuators in the 480 Series, this device is a 3570 positioner. However, a separate loading device must be provided for actuators without positioners.

For actuators with positioners (figure 4), the pneumatic output signal from a controller or instrument is piped to the positioner bellows. As long as the bellows receives a constant input signal pressure, the beam remains motionless and allows supply pressure to bleed throughbothrelaynozzlessothataconstantpressure is maintained between the nozzle and the fixed orifice. The relays are in equilibrium with their inlet and exhaust valves closed.

Assume that a downward piston motion is required and the bellows receives a corresponding change in input signal pressure. This causes the beam to pivot so that it covers the nozzle on relay A. (Beam movement is accomplished either by increasing the input signal pressure on a direct-acting positioner to expand the bellows, or by decreasing the input signal pressure on a reverse-acting positioner to contract the bellows.)

ThenozzlepressureinrelayAincreasesduetotherestriction created by the beam over the nozzle. Through relay action, the air pressure to the top of the piston is increased. At the same time, relay B reacts to the change in beam position to decrease the pressure to the underside of the piston. Due to the resulting unbalanced forces acting on the piston, it moves down, changing the valve plug position.

Piston movement is fed back to the beam by means of a range spring which is connected to the beam and to the piston rod extension, applying a force to the beam opposite to that caused by the expanding or contracting bellows. This feedback arrangement prevents overcorrection and ensures a definite position of the piston and valve plug for a given instrument signal.

480 Series Actuators

August 2012

If upward piston motion is required, the beam pivots overthenozzleonrelayB.Theresult is relay, piston, and feedback action opposite that for downward piston motion.

Reversal of positioner action is accomplished simply by removing four screws, inverting the bellows, and installing two bellowspostsforsupportitthechangeisfromdirecttoreverse action. Bellows posts are stored in the positioner case and are not used if the change is from reverse to direct.

Actuator with Snubber

As the actuator piston strokes, the snubber piston moves inside an oil-filled cylinder, forcing oil from one side of the piston to the other through two check valves (see figure 6). Theresistancetoflowcreatedby the settings of the check valves and the shock absorbing quality of the oil combine to damp out any tendency of the valve plug to jump. The plug of each check valve is held off its seat by the positioning of the adjusting screws. Thus, with the adjusting screws backed off all the way, maximum damping will be obtained.

Pressure Connections

480

The 3570 positioner, an integral part of 480 actuator units, is factory-assembled to the actuator. Two connections, “Supply” and “Instrument”, remain to be made after valve installation. Both are 1/4 NPT holes in the positioner and are labelled. Minimum supply pressure is 2.4 bar (35 psig), but for optimum performance, supply pressure should be held as near as possible to the 10.3 bar (150 psig) maximum. Supply pressure air or gas should be clean and dry, as well as non-corrosive. Use of a Fisher 252 filter is recommended.

The positioner case should always be vented to prevent pressure buildup. If the valve is installed with the actuator below the pipeline, provide a new vent location in the lowest part of the case by removing the cadmium-plated pipe plug from the case and screwing it into the standard vent location. This also serves as a drain hole to prevent accumulation of condensate.

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480 Series Actuators

August 2012

Instruction Manual

D100291X012

481

The 481 actuator also requires 1/4 NPT external supply pressure piping. The 481 has only a pressure tap cover on top of the cylinder. Supply air pressure must be connected to it, and also to the lower cylinder connection located near the cylinder/cylinder flange joint. An external four-way valve or other switching device must be provided between the main supply pressure line and these two actuator pressure connections.

Adjustments

All three adjustments on the 480 actuator are on the 3570 positioner. For further information on the positioner, such as Adjustments, Maintenance, Reversing, and Relay Operation,refer to the Fisher 3570 instruction manual, D200137X012.

The 481 actuator requires no adjustments.

Actuator Maintenance

WARNING

Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations:

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

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

D Disconnect any operating lines providing air pressure 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

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

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

D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the

pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

It is necessary for efficient and proper operation of the actuator that all parts be free from dirt, abrasives, and foreign material. Upon assembly at the factor, all synthetic rubber O-rings have been coated with water-resistant lithium grease. It is recommended that this lubricant be used on all O-rings, especially those on moving parts or in contact with moving parts, whenever the actuator is dismantled.

Disassembly

Refer to figures 7 and 8.

References to “positioner” can be ignored if a 481 actuator is involved.

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Instruction Manual

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480 Series Actuators

August 2012

1. Bypass the valve body or shut off the pressure in the pipeline.

CAUTION

The adjustable linkage between the actuator and the main valve should not be disconnected when the valve is open with fluid flowing. (Dampers or louvers should be in safe, stable positions prior to disconnection.)

2. Shut off all pressure to the actuator. Remove all tubing lines (cylinder, instrument, and supply) from the actuator.

3. Remove the positioner cover after loosening the four cover screws on the underside of the positioner base.

4. Disengage the range spring by unscrewing the spring retainer from the piston rod extension.

5. Loosen the two cap screws that hold the positioner to the cylinder. When removing the positioner, do not lose the small O-ring that is used in the passage from the positioner to the top of the cylinder.

6. Nextremovetheclevisboltfromtheadjustablelinkage.Removethebottomsnapring(key26)andunscrewthe clevis and the boot locknut from the actuator piston rod.

7. Remove the nuts that hold the cylinder to the mounting flange and lift off the cylinder.

8. Remove the stud bolts (key 123) that hold the cylinder to the cylinder flange. Two slots, 180 degrees apart, are located at the lower edge of the cylinder. Insert a screwdriver in these slots and pry the cylinder loose. The piston and piston rod will come out with the cylinder. the piston can then be removed by pulling it out the open end of the cylinder.

9. Unscrew both seal bushings (keys 7 and 8).

10. Inspect all parts for excessive wear and defects. Replace all worn O-rings. Lubricate as mentioned above.

11. To reassemble, reverse the above procedure.

Note

When reassembling the actuator after the piston rod extension (key 5) has been removed from the piston rod (key 4), clean the threads of the piston rod thoroughly and apply a thread locking adhesive (medium strength) to the threads. Tighten the piston rod extension securely to a torque of 203 NSm (150 lbfSft). This torque is approximately equal to the torque that would be developed by placing a force of 150 pounds on the end of a one-foot wrench, 75 pounds on the end of a two-foot wrench, etc.

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480 Series Actuators

August 2012

Figure 7. Fisher 480 Piston Actuator - Size 30- 60

Instruction Manual

D100291X012

40A9540-A

PARTS NOT SHOWN: 27 AND 112

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Figure 8. Fisher 481 Piston Actuator - Size 30- 60

480 Series Actuators

August 2012

40A9538-A

PARTS NOT SHOWN: 27, 78, 79, AND 112

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480 Series Actuators

August 2012

Instruction Manual

D100291X012

Parts Ordering

When corresponding with your Emerson Process Management sales office about this equipment, refer to the serial number found on the actuator nameplate (key 22). Also, specify the complete 11-character part number from the following Parts List when ordering replacement parts.

WARNING

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management should not, under any circumstances, be used in any Fisher valve, because they may void your warranty, might adversely affect the performance of the valve, and could cause personal injury and property damage.

Parts List

Key Description Part Number

Note

Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office.

Key Description Part Number

1 Cylinder Flange 2Cylinder 3Piston 4PistonRod 5 Piston Rod Extension 7 Upper Seal Bushing 8LowerSealBushing 9* Stem Seal O-ring

Sizes 30, 40, and 60 (2 req'd) 1E73690699

10* Bushing Seal O-ring

Sizes 30, 40, and 60 (2 req'd) 1D34830689

11* Piston Seal O-ring

Size 30 1H86210699 Size 40 1H86220699 Size 60 1H86240699

12* Cylinder Seal O-ring

Size 30 1H86200699 Size 40 1D44480699

Size 60 1H86230699 13 Cylinder Stud 14 CompressionFitting 15 Cylinder Tubing 18 Boot Locknut 22 Nameplate 23 Drive Screw 24* PistonRod Boot

Sizes 30, 40, and 60 1H93790699 25 Top Boot Snap Ring 26 Bottom Boot Snap Ring 27 Travel stop 30 Piston Nut 31 Positioner 45 Spring Retainer Spacer 78* Cover Seal

481 only 1C85380699 79 Cover Screw 160 Pipe Plug

*Recommended spare parts

Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection,use or maintenance of any product. Responsibility for proper selection,use, and maintenance of any product remainssolely with the purchaser andend user.

Fisher and TopWorx are marks owned by one of the companies in the Emerson Process Managementbusiness unit of Emerson Electric Co. EmersonProcess Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are theproperty oftheir respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, whichare availableupon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

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