Emerson Process Management 3024C User Manual

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Instruction Manual

Form 5760 March 2007

Type 3024C Diaphragm Actuator

Contents

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

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

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

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

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

Mounting the Actuator on the Valve 5. . . . . . . . .

Actuator Maintenance 7. . . . . . . . . . . . . . . . . . . . . .

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

Assembly 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Actuator Action 11. . . . . . . . . . . . .

Side-Mounted Handwheel 11. . . . . . . . . . . . . . . .

Adjustable Travel Stops 12. . . . . . . . . . . . . . . . . .

Parts Ordering 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3024C Actuator

Introduction

Scope of Manual

This instruction manual provides information on installation, adjustment, maintenance, and parts ordering for the Type 3024C actuator (figure 1) for sizes 30 to 45 and 30E to 45E.

Note

This manual assumes throughout that the valve construction is “push-down-to-close.”

Do not install, operate, or maintain a Type 3024C actuator without first D being fully trained and qualified in valve, actuator, and accessory installation, operation and maintenance, and D carefully reading and understanding the contents of this manual. If you have any questions about these instructions contact your Emerson Process Managementt sales office before proceeding.

W8488

Figure 1. Type 3024C Actuator with Sliding-Stem Valve

Note

Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.

Description

The Type 3024C direct acting (extends stem/air-to-close) actuator (figure 8) and the reverse acting (retracts stem/air-to-open) actuator (figure 9) are spring-opposed pneumatic diaphragm actuators that provide automatic throttling or on-off operation of sliding-stem control valves.

The actuator will position the valve plug in response to varying pneumatic loading pressure on the actuator diaphragm. Figure 2 shows the operation of

www.Fisher.com

D103048X012

3024C Actuator

ifi

Maximum Operating Pressure

Maxi

Val

Maximum Approximate

Instruction Manual

Form 5760

March 2007

1Q57489

AIRĆTOĆCLOSE (ATC)

AIRĆTOĆOPEN (ATO)

1Q574760

Figure 3. Type 3024C Actuator Nameplate

Figure 2. Schematic of Type 3024C

The 3024C can be equipped with a side mounted an ATC (air-to-close) actuator and an ATO (air-to-open) actuator.

handwheel if required (figure 10). An adjustable up

travel stop can also be fitted (figures 11 and 12).

The Type 3024C ATC (air-to-close) actuator springs are located under the diaphragm plate and they fully retract the actuator stem for fail action upon loss of diaphragm casing pressure. The Type 3024C ATO (air-to-open) actuator springs are located on top of the diaphragm plate and they fully extend the actuator stem upon loss of diaphragm casing pressure. The actuator is mounted on the valve by means of a cast yoke.

Table 1. Specifications

pec

cation

Nominal Effective Area See tables 2 and 3.

Maximum Operating Pressure

to Diaphragm

mum Trave

Yoke Boss Diameter

ve Stem Connector Threa

emperature Range

Pressure Connections Inch 1/4 – 18 NPT

Maximum Approximate

Weight (without handwheel)

Maximum Approximate

Weight (with handwheel)

Bar 6 psig 87 mm 16 - - - 16 - - - 32 - - - 32 - - Inch - - - 0.75 - - - 0.75 - - - 2 - - - 2 Inch

(mm)

mm M12 x 1.75 - - - M12 x 1.75 - - - M16 x 2 - - - M16 x 2 - - Inch - - - 3/8-24 - - - 3/8-24 - - - 1/2-20 - - - 1/2-20

_C _F

kg 9.5 9.5 18.0 18.0 19.5 21.5 33.5 35.5

lb 20.9 20.9 39.7 39.7 43.0 47.4 73.9 78.3

kg 16.5 16.5 25.0 25.0 26.5 28.5 40.5 42.5

lb 36.4 36.4 55.1 55.1 58.4 62.8 89.3 93.7

30 30E 34 34E 40 40E 45 45E

2-1/8

(54 mm)

2-1/8

(54 mm)

Nitrile diaphragm and steel studs and nuts: –40 to +82

Nitrile diaphragm and steel studs and nuts: –40 to +180

Specifications

Refer to table 1 for Specifications of the Type 3024C actuator. See the actuator nameplate (figure 3) for specific information about your actuator.

Actuator Size

2-1/8

(54 mm)

2-1/8

(54 mm)

2-13/16

(71 mm)

2-13/16

(71 mm)

2-13/16

(71 mm)

2-13/16 (71mm)

Instruction Manual

Quantity

217/3

218/5

217/3

30E

218/5

0.75

219/3

212/5

219/3

34E

212/5

0.75

212/3

213/6

212/3

213/6

1.125

213/4

40E

214/5

1.5

213/4

214/5

221/8

221/12

221/8

221/12

1.125

221/8

45E

221/12

1.5

221/8

221/12

Form 5760 March 2007

Table 2. Additional Specifications (Action Air-to-Close)

Size

30E

34E

40E

45E

Note 1: Effective diaphragm area at 0% valve travel from seat. Note 2: Based upon 6 bar operating pressure to the diaphragm and valve travel at 0% from seat. This does not consider limitation to the valve such as stem buckling load. Consult your Emerson Process Management sales office for details.

Spring Set/

Quantity

217/3 218/5 218/7

219/3 212/5 212/7

212/3 213/6 214/7

213/4 214/5 214/7

221/8 221/12 223/12

Travel Spring Range

mm Inch Bar Psig cm

0.3 - 1.1 4 - 16 160 24.8 7840 1760

16 -

- 0.75

16 -

- 0.75

32 -

- 1.125

- 1.5

- 2

32 -

- 1.125

- 1.5

- 2

1.3 - 2.0 19 - 29 160 24.8 6400 1440

1.8 - 2.9 26 - 42 160 24.8 4960 1120

0.3 - 1.3 4 - 19 160 24.8 7520 1690

1.3 - 2.2 19 - 32 160 24.8 6080 1360

1.8 - 3.0 26 - 44 160 24.8 4800 1070

0.3 - 1.1 4 - 16 400 62.0 19,600 4400

0.9 - 1.7 13 - 25 400 62.0 17,200 3840

1.3 - 2.3 19 - 33 400 62.0 14,800 3350

0.3 - 1.3 4 - 19 400 62.0 18,800 4220

0.9 - 1.8 13 - 26 400 62.0 16,800 3780

1.3 - 2.5 19 - 36 400 62.0 14,000 3160

0.4 - 1.3 6 - 19 390 60.5 18,300 4110

0.8 - 1.8 12 - 26 390 60.5 16,400 3690

1.2 - 2.4 17 - 35 390 60.5 14,000 3150

0.4 - 1.2 6 - 17 390 60.5 18,700 4230

0.8 - 1.7 12 - 25 390 60.5 16,800 3750

1.2 - 2.3 17 - 33 390 60.5 14,400 3270

0.3 - 1.0 4 - 15 380 58.9 19,000 4240

0.6 - 1.5 9 - 22 380 58.9 17,100 3830

0.9 - 2.1 13 - 30 380 58.9 14,800 3360

0.2 - 1.2 3 - 17 370 57.4 17,800 4220

0.5 - 1.7 7 - 25 370 57.4 15,900 3560

0.7 - 2.4 10 - 35 370 57.4 13,300 2980

0.8 - 1.6 12 - 23 790 122 34,800 7810

1.2 - 2.5 17 - 36 790 122 27,600 6220

1.5 - 3.1 22 - 45 790 122 22,900 5120

0.8 - 1.6 12 - 23 790 122 34,800 7810

1.2 - 2.3 17 - 33 790 122 29,200 6590

1.5 - 3.0 22 - 44 790 122 23,700 5250

0.5 - 1.4 7 - 20 780 121 35,900 8110

0.8 - 2.2 12 - 32 780 121 29,600 6650

1.0 - 2.7 15 - 39 780 121 25,700 5810

0.5 - 1.7 7 - 25 770 11 9 33,100 7380

0.7 - 2.5 10 - 36 770 11 9 26,900 6070

0.9 - 3.1 12 - 45 770 11 9 22,300 5000

Effective Diaphragm Area

(Note 1)

3024C Actuator

Maximum Output Thrust

(Maximum Actuator Stem

Inches

Force) (Note 2)

N Lb

Instruction Manual

Quantity

217/3

218/5

217/3

30E

218/5

0.75

219/3

212/5

219/3

34E

212/5

0.75

212/3

213/6

212/3

213/6

1.125

213/4

40E

214/5

1.5

213/4

214/5

221/8

221/12

221/8

221/12

1.125

221/8

45E

221/12

1.5

221/8

221/12

Form 5760

3024C Actuator

Table 3. Additional Specifications (Action Air-to-Open)

Size

30E

34E

40E

45E

Note 1: Effective diaphragm area at 0% valve travel from seat. Note 2: Based on zero operating pressure to the diaphragm and valve travel at 0% from valve seat. This does not consider limitations such as stem buckling load. Consult your Emerson Process Management sales office for details.

Spring Set/

Quantity

217/3

218/5

218/7

217/3

218/5

218/7

219/3

212/5

212/7

219/3

212/5

212/7

212/3

213/6

214/7

212/3

213/6

214/7

213/4

214/5

214/7

213/4

214/5

214/7

221/8 221/12 223/12

Travel Spring Range

mm Inch Bar Psig cm

0.5 - 1.3 7 - 19 170 26.4 780 170

- 0.75

16 -

- 0.75

32 -

- 1.125

- 2

32 -

- 1.125

- 1.5

- 2

1.4 - 2.2 20 - 32 170 26.4 2360 530

2.0 - 3.1 29 - 45 170 26.4 3360 760

0.3 - 1.3 4 - 19 175 27.1 550 120

1.2 - 2.2 17 - 32 175 27.1 2180 490

1.8 - 3.1 26 - 45 175 27.1 3110 700

0.6 - 1.4 9 - 20 410 63.6 2450 550

1.1 - 1.9 16 - 28 410 63.6 4610 1040

1.6 - 2.7 23 - 39 410 63.6 6560 1480

0.4 - 1.4 6 - 20 420 65.1 1880 420

1.0 - 1.9 15 - 28 420 65.1 4120 930

1.4 - 2.7 20 - 39 420 65.1 5870 1320

0.4 - 1.3 6 - 19 450 69.8 1880 420

0.8 - 1.8 12 - 26 450 69.8 3640 820

1.2 - 2.4 17 - 35 450 69.8 5530 1240

0.5 - 1.3 7 - 19 440 68.2 2200 500

0.9 - 1.8 13 - 26 440 68.2 3970 890

1.3 - 2.4 19 - 35 440 68.2 5920 1330

0.4 - 1.1 6 - 16 410 63.6 1560 350

0.7 - 1.6 10 - 23 410 63.6 3010 680

1.0 - 2.3 15 - 33 410 63.6 4270 960

0.2 - 1.2 3 - 17 440 68.2 1060 240

0.5 - 1.8 7 - 26 440 68.2 2390 540

0.8 - 2.5 12 - 36 440 68.2 3400 760

0.8 - 1.7 12 - 25 940 146 7790 1750

1.2 - 2.5 17 - 36 940 146 11,700 2630

1.6 - 3.2 23 - 46 940 146 14,700 3300

0.9 - 1.7 13 - 25 910 141 8350 1880

1.4 - 2.5 20 - 36 910 141 12,500 2810

1.7 - 3.2 25 - 46 910 141 15,700 3530

0.7 - 1.6 10 - 23 870 135 6150 1380

1.1 - 2.4 16 - 35 870 135 9230 2080

1.3 - 3.1 19 - 45 870 135 11,500 2590

0.5 - 1.7 7 - 25 940 146 4740 1070

0.8 - 2.6 12 - 38 940 146 7110 1600

0.9 - 3.2 13 - 46 940 146 8800 1980

Effective Diaphragm Area

(Note 1)

Inches

Maximum Output Thrust

(Maximum Actuator Stem

March 2007

Force) (Note 2)

N Lb

Instruction Manual

SIZE

Form 5760 March 2007

3024C Actuator

Table 4. Handwheel Specifications

ACTU-

ATO R

SIZE

30 and

30E

34, 34E,

40, and

40E

45 and

45E

1. Tangential handwheel force required to produce the handwheel output force shown.

2. Brass operating nut and stainless steel screw.

HAND-

WHEEL

DIAMETER

mm In. mm In. N lb N lb

200 7.87 0.24 6.1 179 40 5000 1125

250 9.84 0.21 5.4 286 64 10,000 2250

250 9.84 0.21 5.5 400 90 14,000 3150

TURNS PER

mm/INCH

TRAVEL

RIM

FORCE

(1,2)

Installation

WARNING

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

Personal injury or equipment damage caused by sudden release of pressure may result if the actuator assembly is installed where service conditions could exceed the limits given in tables 1, 2, and 3 or the appropriate nameplates. To avoid such injury or damage, provide a relief valve for overpressure protection as required by accepted industry and governmental codes and good engineering practices.

To avoid parts damage, do not use a normal operating pressure that exceeds the Maximum Diaphragm Casing Pressure (see table 1) or produces a force on the actuator stem greater than the Maximum Allowable Output Thrust (see table 2 or 3) or Maximum Allowable Valve Stem Load.

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

HAND-

WHEEL

OUTPUT

FORCE

When ordered, the valve configuration and construction materials were selected to meet particular pressure, temperature, pressure drop, and controlled fluid conditions.

Responsibility for the safety of process media and the compatibility of valve materials with the process media rests solely with the purchaser and end user. Since some valve body/trim materials combinations are limited in their pressure drop and temperature ranges, do not apply any other conditions to the valve without first contacting your Emerson Process Management sales office.

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

A Type 3024C diaphragm actuator is normally shipped mounted on a valve. Refer to the appropriate valve instruction manual when installing the valve in the pipeline. If the actuator is shipped separately or if it is necessary to mount the actuator on the valve, perform the Actuator Mounting procedure given below. For information on mounting the positioner refer to the appropriate positioner instruction manual.

CAUTION

The Type 3024C actuators are designed to mount on push-downto-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

The following procedure describes how to mount a Type 3024C actuator on a push-down-to-close valve so that the actuator stem and valve stem thread engagement allows full travel and proper shut-off. Refer to table 4 and figures 6 and 7 for actuator

3024C Actuator

W8484-1

Instruction Manual

Form 5760

March 2007

between the actuator stem and other parts of the valve assembly.

Perform one of the following procedures as appropriate:

For a Type 3024C Air-To-Close Actuator with a Push-Down-to-Close Valve:

a. Carefully place the actuator on the valve so that the yoke boss fits over the valve bonnet.

b. Screw the yoke lock nut onto the bonnet and tighten.

c. Lift the valve plug off the seat by the correct valve travel for the valve. This is stated on the nameplate or in table 1.

d. Place the stem connector half (key 50) approximately halfway between the actuator and valve stems but observing the F dimension in table 5 so that any positioner lever (if fitted) is horizontal at mid-travel. Be sure that the actuator and valve stem threads are engaging the threads of the stem connector by at least the distance of one diameter of the stem.

Figure 4. Actuator Mounting Components for Assembly

with a Valve

dimensions. Key numbers referenced in the following steps are shown in figures 8 and 9.

1. Provide a temporary method of applying diaphragm air loading pressure to the diaphragm to move the actuator stem during adjustments.

2. Provide a vice or some other method of supporting the valve and the weight of the actuator during assembly.

3. Push the valve stem down until the valve plug is fully closed.

4. Screw the two stem locknuts (key 52) to the lower end of the valve stem thread.

WARNING

When moving the actuator stem with diaphragm loading pressure use caution to keep hands and tools out of the actuator stem travel path. Personal injury and/or property damage is possible if something is caught

CAUTION

Be sure that the length of the actuator stem and the valve stem in the connector (key 50) is equal to or greater than the diameter of that stem. Incomplete engagement of either the valve or actuator stem in the stem connector can result in stripped threads or improper operation.

In the following procedure do not rotate the valve plug while it is seated. This may damage the seating surface and cause excessive leakage. While making adjustments, use tools carefully to avoid damaging the valve stem. A damaged stem could cut the packing and allow leakage through the packing box.

e. Install the other half of the stem connector and insert the socket screws and nuts and tighten them.

f. Screw the two stem locknuts (key 52) up the valve stem to the stem connector and tighten. Do not over tighten.

Instruction Manual

Form 5760 March 2007

3024C Actuator

g. Slowly decrease and then increase the diaphragm pressure several times stroking the valve from the lower end to the upper end of the spring range.

h. Apply air pressure to the diaphragm until the valve is in the closed position. Loosen the screws of the travel scale (key 26) and align it with the indicator on the stem connector.

i. Stroke the valve full travel to ensure that the travel matches the valve travel on the travel indicator plate.

j. If the valve travel is not correct, repeat the stem connector procedure. Remove the air pressure from the diaphragm, remove the stem connector and repeat steps c to i.

For a Type 3024C Air-to-Open Actuator with a Push-Down-to-Close Valve:

a. Apply approximately 0.5 bar pressure above the upper setting of the spring pressure range to the bottom of the diaphragm. This positions the actuator stem (key 8) at the highest point. The spring range is stated on the nameplate or in table 3.

b. Carefully place the actuator on the valve so that the yoke boss fits over the valve bonnet.

c. Screw the yoke lock nut onto the bonnet and tighten.

h. Slowly decrease and then increase the diaphragm pressure several times stroking the valve from the lower end to the upper end of the spring range.

i. Remove all air pressure from the diaphragm so that the valve is in its closed position. Loosen the screws of the travel scale (key 26) and align it with the indicator on the stem connector.

j. Stroke the valve full travel to ensure that the valve travel matches the valve travel on the travel indicator plate.

k. If the valve travel is not correct repeat the stem connector procedure. Apply approximately

0.5 bar pressure above the upper setting of the spring range to the bottom of the diaphragm, remove the stem connector and then repeat steps d to j.

Note

When disassembling the stem connector on Air-to-Open constructions it is essential to apply enough air pressure to the underside of the diaphragm to lift the valve plug off its seat. This will ensure that all residual spring compression in the actuator is supported while the stem connector is removed.

d. Lift the valve plug off the seat by the correct travel for the valve. The travel is stated on the nameplate or in table 1.

e. Place the stem connector half (key 50) approximately halfway between the actuator and valve stems but observing the F dimension in table 5 so that any positioner lever (if fitted) is horizontal at mid-travel. Be sure that the actuator and valve stem threads are engaging the threads of the stem connector by at least the distance of one diameter of the stem.

f. Install the other half of the stem connector and insert the socket screws and nuts and tighten them.

g. Screw the two stem locknuts (key 52) up the valve stem to the stem connector and tighten. Do not over tighten.

Actuator Maintenance

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

This section 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 to assemble at the appropriate step.

Key numbers refer to figures 8 and 9.

3024C Actuator

Instruction Manual

Form 5760

March 2007

WARNING

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

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, 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.

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, or when loosening the packing box pipe plug.

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

Disassembly

1. For complete disassembly, the positioner and all accessories (if attached) must be removed from the actuator. Follow appropriate removal procedures in the instruction manuals supplied with the positioner and accessories.

2. Bypass the control valve. For a top-loaded Type 3024C Air-to-Close actuator reduce the diaphragm

air pressure to zero and remove the piping or tubing from the connection in the upper diaphragm casing (key 16). For a bottom loaded Type 3024C Air-to-Open apply air pressure to the diaphragm to open the valve.

Note

3. Undo the stem connector by first slackening the valve stem locknuts and then removing the socket bolts.

4. Undo the yoke locknut on the valve bonnet and carefully lift the actuator off the valve. As you undo the yoke locknut, ensure that the actuator is properly supported. If the actuator is a bottom loaded Air-to-Open type, reduce the diaphragm pressure to zero and remove the piping or tubing from the connection in the lower diaphragm casing (key 1).

5. Slightly loosen all diaphragm casing cap screws (key 19 and 21). Remove the plastic hose (key 22). Unscrew the short and long diaphragm casing cap screws and nuts (keys 19, 20 and 21) alternately, until only the long casing cap screws (key 21) remain engaged. Then allow the remaining spring compression to be slowly released by alternately unscrewing the long casing cap screws.

6. When removing the diaphragm and actuator springs perform one of the following procedures as appropriate:

For a Type 3024C Air-to-Open Actuator (figure 9)

a. Lift off the upper diaphragm casing (key 16), the casing spacer (key 29) and seal ring (key 30) if fitted (see figure 13), and remove the springs (Key 15).

b. Using a strap wrench or soft-jawed vice, hold the actuator stem (key 8) and remove the travel stop nut (key14).

c. Remove the diaphragm plate (key 13), diaphragm (key 11), O-Ring (key 12), pressure plate (key10) and the split ring halves (key 9).

Instruction Manual

Form 5760 March 2007

3024C Actuator

For a Type 3024C Air-to-Close Actuator (figure 8)

a. Lift off the upper diaphragm casing (key 16) and casing spacer (key 29) and seal ring (key 30) if fitted (see figure 14).

b. Using a strap wrench or soft-jawed vice, hold the actuator stem (key 8) and remove the travel stop nut (key14).

c. Remove the pressure plate (key 10), O-ring (key 12), diaphragm (key 11), diaphragm plate (key 13) and the split ring halves (key 9).

7. Carefully slide the actuator stem (key 8) out of the bottom of the lower diaphragm casing (key 1) and set it on a protective surface to prevent damage to the O-ring sealing surface.

8. Remove the bellows (key 31), if used.

9. Unscrew the cheese head screws (key 7), then remove the bushing (key 6).

10. With the actuator disassembled, inspect all parts for excessive wear and replace as necessary.

Assembly

This procedure assumes that the actuator is completely disassembled. If it is not, start the instructions at the appropriate step.

1. Before starting assembly, apply lithium grease (key 200) to the O-ring in the bushing (key 6 and key 12). Install the new bushing (key 6) and assemble with the cheese head screws (key 7) onto the lower diaphragm casing (key 1). Use a torque of

0.4 NSm (3 lbfSin).

2. Assemble the ring halves (key 9), pressure plate (key 10), O-ring (key 12), diaphragm (key 11) and diaphragm plate (key 13) on to the actuator stem as shown in figure 9 for Air-to-Open or figure 8 for Air-to-Close.

3. Apply thread locking adhesive (high strength) (key 201) to the thread on the upper end of the actuator stem, fit the travel stop nut (key 14) but do not tighten. Then perform one of the following procedures as appropriate.

For a Type 3024C Air-to-Open Actuator (figure 9)

a. Carefully slide the actuator stem (key 8) (with the assembled parts) down through the bushing (key 6).

3024C Actuator

Instruction Manual

Form 5760

March 2007

SIZE 30 AND 30E

3 SPRINGS

SIZE 34, 34E, 40, AND 40E

3 SPRINGS

SIZE 40 AND 40E

6 SPRINGS

SIZE 30 AND 30E

5 SPRINGS

SPRING

SIZE 40E

4 SPRINGS

SIZE 34, 34E, 40, AND 40E

7 SPRINGS

SIZE 30 AND 30E

7 SPRINGS

SPRING LOCATOR

SIZE 34, 34E, AND 40E

5 SPRINGS

SIZE 45 AND 45E

8 SPRINGS

2Q57503

Figure 5. Type 3024C Spring Arrangements

b. Position the actuator springs (key 15) symmetrically on the diaphragm plate (key 13) as shown in figure 5.

c. Install the upper diaphragm casing (key 16) so that the springs fit correctly over the seat bosses

SPRING

SPRING LOCATOR

SIZE 45 AND 45E

12 SPRINGS

SPRING

SPRING LOCATOR

of the spring locator (key 17). Rotate the upper diaphragm casing along with the diaphragm/diaphragm plate assembly so that the air connection in the upper diaphragm casing is located directly above the air connection in the lower diaphragm casing. Then rotate the

Instruction Manual

Form 5760 March 2007

3024C Actuator

diaphragm without moving either the upper diaphragm casing or the diaphragm plate so that the diaphragm holes line up with those in the casings.

d. Lift off the upper diaphragm casing and remove the springs. Tighten the travel stop nut (key 14 as follows: Sizes 30, 30E, 34, and 34E, tighten to 36 NSm (27 lbfSft); Sizes 40, 40E, 45, and 45E, tighten to 87 NSm 64 lbfSft).

e. Replace the spring as previously.

f. For actuator sizes 40E and 45E with 1.5 and 2 inch travels, a casing spacer is fitted between the upper and lower diaphragm casings. Place the casing spacer (key 29) on the diaphragm and then the gasket (key 30) as shown in figure 13.

For a Type 3024C Air-to-Close Actuator (figure 8)

a. Position the actuator springs symmetrically on the spring locator (key 17) as shown in figure 5.

b. For actuator sizes 40E and 45E with 1.5 and 2 inch travels, a casing spacer (key 29) is fitted between the upper and lower diaphragm casings. Place the gasket (key 30) on the lower casing and then the casing spacer (key 29) as shown in figure 14.

CAUTION

Over tightening the diaphragm cap screws and nuts can damage the diaphragm. Do not exceed the torque of 13 NSm (10 lbfSft) for sizes 30, 30E, 34 and 34E and 17 NSm ( 12 lbfSft) for sizes 40, 40E, 45, and 45E.

Note

Be sure to use the long cap screws (key 21) first, installing them on opposite sides of the diaphragm casing. Tighten them evenly, using a criss-cross pattern to ensure a proper seal.

5. Mount the actuator on the valve in accordance with the Installation Procedures.

Changing the Actuator Action

The actuator can be changed from a Type 3024C Air-to-Open to a 3024C Air-to-Close action or vice versa. Remove the pressure plate, diaphragm, O-ring, diaphragm plate, travel stop nut, springs, spring locator, self tapping screws and vent assembly (keys 10, 11, 12, 13, 14, 15, 17, 18 and 23) and reinstall them for the appropriate action. Follow the instructions in the section on Assembly on page 8.

c. Carefully slide the actuator stem with the assembled parts down through the bushing and position it so that the springs fit correctly over the seat bosses on the upper side of the diaphragm plate (key 13). Rotate the diaphragm (key 11) without moving the diaphragm plate (key 13) so that the diaphragm holes line with the lower diaphragm casing holes.

d. Tighten the travel stop nut (key 14) as follows: Sizes 30, 30E, 34 and 34E tighten to 36 NSm (27 lbfSft); Sizes 40, 40E, 45 and 45E tighten to 87 NSm (64 lbfSft).

4. Install the upper diaphragm casing (key 16) so that the air connection is located directly above the air connection in the lower diaphragm casing (key 1). Using the long cap screws (key 21) and hex nuts (key 20) first, and then the shorter cap-screws (key 19) and hex nuts (key 20), bolt the two diaphragm casings together. Fit the safety plastic hose (key 22) over the exposed thread of the long cap-screws (key 21).

Side-Mounted Handwheel

A side-mounted handwheel assembly (figure 10) is usually used as a manual operator. When mounted on an Air-to-Close Type 3024C actuator, turning the handwheel clockwise always closes the valve. When mounted on an Air-to Open actuator, turning the handwheel clockwise always opens the valve. A lever (key 101, figure 10) on the handwheel assembly opens or closes the valve by moving the valve stem.

Instructions are given below for complete disassembly and assembly. Perform the disassembly only as far as is necessary to accomplish the required maintenance; then begin the assembly at the appropriate step.

Refer to figure 10 for key numbers.

Disassembly

1. If desired, the handwheel assembly can be removed from the actuator yoke. To do this, remove

3024C Actuator

Instruction Manual

Form 5760

March 2007

the eight hex cap screws (key 113) that hold the assembly to the yoke.

2. Loosen the lock (key 115) that secures the drive screw assembly (key 103).

3. Remove the retaining ring (key 110) and screw out the drive screw assembly (key 103).

4. Remove the retaining ring (key 108) and drive out the pivot pin (key 104).

5. Remove the bushings (key 107) from the body (key 100).

6. There is a cap screw (key 111), hex nut (key 112) and spacer (key 105) that hold the two levers (key

101) together. Remove the cap-screw and hex nut and the two levers can be separated in order to remove the operating nut (key 102).

Assembly

1. Assemble the operator nut (key 102), the two levers (key 101) and the spacer (key 105) using the cap-screw (key 111) and hex nut (key 112).

2. Install the bushings (key 107) in the body (key 100).

3. Attach the levers (key 101) to the body (key 100) using the pivot pin (key 104) and the retaining ring (key 108).

4. Apply lithium grease (key 200) to the drive screw assembly (key 103) and screw it on to the operating nut (key 102).

5. Install the retaining ring (key 110) to secure the collar to the body (key 100).

6. If the handwheel assembly was removed from the actuator yoke, position the assembly within the yoke so that the eight mounting holes on the assembly align with those on the yoke and fit the cap-screws (key 113) tightening to 28 NSm (20 lbfSft). Should difficulty be experienced fitting the levers (key 101) over (for ATC) or under (for ATO) the actuator/valve stem connector, then partially stroke the actuator/valve by applying air pressure to the actuator diaphragm.

Adjustable Travel Stops

The adjustable up travel stop (figures 11 and 12) limits the actuator stroke in the upward direction (limits retraction of the actuator stem).

avoid injury when positioning components.

For Sizes 30, 30E, 34, 34E, 40, and 40E

1. Relieve the air pressure on the diaphragm. Loosen the hex nut (key 25) and turn the adjuster (key 24) clockwise into the diaphragm case to move the actuator stem downward or counter-clockwise to allow the actuator stem to move upward. Since the valve has push-down-to-close action, full opening can be restricted. Check the actuator travel and then tighten the hex nut (key 25).

CAUTION

The travel stop hex nut (key 25) has an elastic stop on its underside to provide an air seal around the travel stop thread. It is therefore important, before slackening this nut, to release any air pressure on the diaphragm.

For Sizes 45 and 45E

The adjustable up travel stop for the sizes 45 and 45E is shown in figure 12. For sizes 45 and 45E, the adjustable up travel stop cannot be used with a side mounted handwheel.

1. Remove the screws (key 41) and nuts (key 42) which hold the protective covers (key 40) to the actuator yoke and remove the covers.

2. Loosen the machined cheese head screw (key 37) and turn the adjustment nut (key 38) clockwise into the bushing (key 36) to increase travel or counter-clockwise to shorten the actuator travel.

3. Check the actuator travel and then tighten the machined cheese head screw (key 37).

WARNING

When performing the following adjustment procedures, take care to

4. Assemble the protective cover plates (key 40) to the actuator yoke with the screws (key 41) and nuts (key 42) taking care to ensure that there is no gap between the cover plate and the diaphragm casing.

Instruction Manual

Actuator

Valve

Yoke Boss

Form 5760 March 2007

3024C Actuator

AR (ACTUATOR

REMOVAL)

1Q57491

Figure 6. Actuator Dimensions

Actuator Dimensions

Refer to figures 6 and 7 and table 5 for dimensions.

Table 5. Dimensions

Actuator Valve Yoke Boss,

Size

30 16 mm 2-1/8 (54 mm) 215 370 140 105 205 280 185 80 34 16 mm 2-1/8 (54 mm) 315 400 140 105 250 280 185 80 40 32 mm 2-13/16 (71 mm) 315 420 170 133 250 280 210 100 45 32 mm 2-13/16 (71 mm) 420 450 170 133 250 280 210 100

30E 0.75 2-1/8 8.5 14.6 5.6 4.7 8.1 11.0 7.3 3.1 34E 0.75 2-1/8 12.4 15.8 5.6 4.7 9.8 11.0 7.3 3.1 40E 1.125 2-13/16 12.4 17.9 8.1 6.6 9.8 11.0 9.6 5.5 40E 1.5 2-13/16 12.4 18.9 8.3 6.6 40E 2 2-13/16 12.4 18.9 8.5 6.2 45E 1.125 2-13/16 16.5 19.3 8.1 6.6 9.8 11.0 9.6 5.5 45E 1.5 2-13/16 16.5 20.1 8.3 6.6 45E 2 2-13/16 16.5 20.1 8.5 6.2

1. This is the distance between the base of the yoke to the centre of the stem connector at the fully-up postion. This ensures the positioner feedback arm, if fitted, is horizontal at mid-travel.

Travel

Inches

C E F

Inches

(1)

AR Js Hs M (ATO) M (ATC)

Millimeters

- - - - - - - - - - - -

3024C Actuator

Instruction Manual

Form 5760

March 2007

1Q57490

REVERSEĆACTING DIRECTĆACTING

Figure 7. Actuator Dimensions with Handwheel

Parts Ordering

Each actuator has a serial number stamped on the nameplate (figure 2 and key 34 on figures 8 and 9). Refer to the serial number when ordering replacement parts or when corresponding with your Emerson Process Management sales office for technical assistance. Also specify the complete 7 or 11 character part number from the following parts list when ordering replacement parts.

WARNING

Use only genuine Fisherr replacement parts. Components that are not supplied by Emerson Process

Management should not, under any circumstances, be used in any Fisher valve, because they will void your warranty, might adversely affect the performance of the valve, and could give rise to personal injury and property damage.

Note

Instruction Manual

Form 5760 March 2007

3024C Actuator

3Q57478

Figure 8. Direct-Acting Actuator (Air-to-Close)

3024C Actuator

Instruction Manual

Form 5760

March 2007

3Q57479

Figure 9. Reverse-Acting Actuator (Air-to-Open)

Instruction Manual

Form 5760 March 2007

3024C Actuator

Parts List

Note

For part numbers not shown, contact your Emerson Process Management sales office.

Actuator

Key Description

1 Lower Diaphragm Casing, steel 3* O-Ring (2 required)

Sizes 30 & 30E 0409073

Sizes 34, 34E, 40, 40E, 45 & 45E 0411736 4 Cap-Screw, hex head (2 required) 5 Yoke, steel 6* Bushing Assembly

Sizes 30, 30E, 34, 34E, 40 and 40E 0409065

Sizes 45 and 45E 0411159 7 Machined Screw, pan head (6 required) 8 Actuator Stem 9 Split Ring, half (2 required) 10 Pressure Plate 11* Diaphragm

Sizes 30 and 30E 0410705

Sizes 34, 34E, 40 and 40E 0410357

Sizes 45 and 45E 0411868 12* O-Ring

Sizes 30, 30E, 34, 34E, 40 and 40E 0409073

Sizes 45 & 45E 0411736 13 Diaphragm Plate 14 Nut, Hex

Springs (see tables 2 and 3 for quantity, 15

set number & colour) 16 Upper Diaphragm Casing, Steel 17 Spring Locator 18 Drive Screw (2 required) 19 Hex Head Cap Screw

Sizes 30, 30E (7 required)

Sizes 34, 34E, 40, and 40E (12

required)

Size 45, 45E (17 required) 20 Hex Nut

Size 30, 30E (10 required)

Size 34, 34E, 40, and 40E (15 required)

Size 45, 45E (20 required) 21 Hex Head Cap Screw (3 required) 22 Plastic Hose (3 required) 23 Vent 26 Travel Indicator Scale 27 Twin-Speed Nut 28 Self-Tapping Screw (2 required) 29 Casing Spacer (Size 40E and 45E only) 30 Seal Ring (Size 40E and 45E only)

Part

Number

30* Gasket

Size 40E 0598313

Size 45E 0607304 31* Bellows 32 Plain Washer

Size 30, 30E (10 required)

Size 34, 34E, 40, and 40E (15 required)

Size 45, 45E (20 required) 33 Warning Label 34 Nameplate 35 Drive Screw (2 required) 50 Stem Connector Assembly 52 Hex Jam Nut (2 required) 200 Lithium Grease

Thread Locking Adhesive (High 201

Strength)

Side Mounted Handwheel

Key Description

100 Body 101 Lever (2 required) 102 Operating Nut 103 Drive Screw Assembly 104 Pivot Pin 105 Spacer 106 Shim Ring 107 Bushing (2 required) 108 Retaining Ring (2 required) 109 Thrust Washer 110 Retaining Ring 111 Cap-Screw, hex head 112 Nut, hex

Cap-Screw, hex head (8 113

required) 115 Lock 117 Nut, hex 200 Lithium Grease

Adjustable Up Travel Stop

Key Description

Sizes 30, 30E, 34, 34E, 40 and 40E

16 Upper Diaphragm Casing 24 Cap-Screw, hex head 25 Hex Nut

Sizes 45 and 45E

16 Upper Diaphragm Casing 36 Adjustment Nut 37 Machined Screw, cheese head 38 Bushing 40 Protective Cover (2 required) 41 Hex Cap Screw (2 required) 42 Hex Nut (2 required)

Part

Number

Part

Number

*Recommended spare parts

3024C Actuator

Instruction Manual

Form 5760

March 2007

1Q57480

Figure 10. Side-Mounted Handwheel for Type 3024C Actuators

3Q57478

Figure 11. Adjustable Up Travel Stop for Sizes 30 to 40E

Instruction Manual

Form 5760 March 2007

3024C Actuator

3Q57478

Figure 12. Adjustable Up Travel Stop for Sizes 45 to 45E

Figure 13. Casing Spacer Detail for ATO

Figure 14. Casing Spacer Detail for ATC

3024C Actuator

Instruction Manual

Form 5760

March 2007

Fisher is a mark owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their 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 are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user.

Emerson Process Management

Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461

www.Fisher.com

Emerson Process Management 3024C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual