Installation, Operation and Maintenance Manual Table of Contents VA-DC-000-1878 Rev. 0 December 2020 Table of Contents Section 1: Introduction General Service Information ................1 Definitions ....................2 General Safety Information ................2 Bettis Reference Materials ................3 Service Support Items ................... 3 Lubrication and Fluid Requirements ..............
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Table of Contents Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Pneumatic Power Module Installation ............39 Power Swivel Removal ................. 40 Power Swivel Module Installation ..............40 Section 6: Actuator Support Information M18 Hydraulic Override System Fluid Volume ..........42 Module Weights by Item Number and Actuator Housing Size ......
Installation, Operation and Maintenance Manual Section 1: Introduction VA-DC-000-1878 Rev. 0 December 2020 Section 1: Introduction General Service Information 1.1.1 This service procedure is offered as a guide to enable general maintenance to be performed on Bettis™ G01XXX-SR, G2XXX SR, G3XXX SR, G4XXX SR, G5XXX SR, G7XXX SR, G8XXX SR, and G10XXX SR Spring-Return Series Single Pneumatic Power Module Actuators with M18 Hydraulic Override Module.
Section 1: Introduction Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Definitions WARNING If not observed, user incurs a high risk of severe damage to actuator and/or fatal injury to personnel. CAUTION If not observed, user may incur damage to actuator and/or injury to personnel. NOTE: Advisory and information comments provided to assist maintenance personnel to carry out maintenance procedures.
Installation, Operation and Maintenance Manual Section 1: Introduction VA-DC-000-1878 Rev. 0 December 2020 Bettis Reference Materials 1.4.1 Assembly Drawing for G2-SR-M18 through G5-SR-M18 model actuators with one Pneumatic Power Module and one Spring Module with M18 Hydraulic Override Module use part number 121410. 1.4.2 Assembly Drawing for G7-SR-M18 through G10-SR-M18 model actuators with one Pneumatic Power Module and one Spring Module with M18 Hydraulic Override...
Section 1: Introduction Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Lubrication and Fluid Requirements NOTE: Lubricants and Fluids, other than listed in step 1.6.1 and 1.6.2 should not be used without prior written approval of Bettis Product Engineering. 1.6.1 Lubricants: All temperature services (-20 °F to +350 °F) / (-29 °C to 176 °C) use Bettis ESL 5...
Installation, Operation and Maintenance Manual Section 1: Introduction VA-DC-000-1878 Rev. 0 December 2020 Actuator Installation 1.9.1 Since there are many valve and actuator combinations, it is not practical to include detailed instructions for each type. Mountings are designed to be as simple as possible to keep the guess work out of the installation.
Section 1: Introduction Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 1.10.2 Check Connections Pneumatic / hydraulic components connected as per schematic enclosed or in-service manual supplied. Pneumatic supply connected to the identified ports. Electrical connection terminals are secured. Wiring as per enclosed diagram or service manual supplied.
Installation, Operation and Maintenance Manual Section 2: Actuator Disassembly VA-DC-000-1878 Rev. 0 December 2020 Section 2: Actuator Disassembly General Disassembly WARNING Dangerous gas and/or liquids. It is possible, that the actuator may contain a dangerous gas and/or liquid. Ensure that all proper measures have been taken to prevent exposure or release of these types of contaminants before commencing any work.
Section 2: Actuator Disassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Pneumatic Power Module Disassembly NOTE: Review Section 2, steps 2.1.1 through 2.1.5 General Disassembly before proceeding with Pneumatic Power Module Disassembly. Refer to drawings VA121410 or VA121411 for details. WARNING Remove all operating pressure.
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Installation, Operation and Maintenance Manual Section 2: Actuator Disassembly VA-DC-000-1878 Rev. 0 December 2020 CAUTION Do not use pipe wrench to remove tie bars. 2.2.8 TIE BAR REMOVAL: 2.2.8.1 Remove tie bars (3 - 20) as follows: NOTE: G01, G2, G3 and G4 models have flats on outboard end of tie bars (3 - 20) for wrench placement.
Section 2: Actuator Disassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 NOTE: Piston (3 - 30) acts as the retainer for outboard split ring halves (3 - 50). 2.2.10.2 Slide piston (3 - 30) toward the inner end cap (3 - 10) until the outboard split ring halves are exposed enough for removal.
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Installation, Operation and Maintenance Manual Section 2: Actuator Disassembly VA-DC-000-1878 Rev. 0 December 2020 NOTE: For steps 2.3.3 through 2.3.10 refer to assembly drawing sheet 2 Section A-A and Detail “F”. 2.3.3 Before removing position indicator (1 - 220), record or mark its position. Remove position indicator (1 - 220).
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Section 2: Actuator Disassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 NOTE: Groove pins (1 - 130) will remain in housing cover (1 - 20) when housing cover is removed from housing (1 - 10). Groove pins (1 - 130) should not be removed from housing cover (1 - 20) unless they are damaged and require new replacements.
Installation, Operation and Maintenance Manual Section 2: Actuator Disassembly VA-DC-000-1878 Rev. 0 December 2020 2.3.28 Housing (1 - 10) vent check assembly removal as follows: 2.3.28.1 G01, G2 and G3 housing (1 - 10) unscrew and remove one vent check assembly (13) from the front of housing (1 - 10).
Section 2: Actuator Disassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 M18 Pump Disassembly NOTE: Refer to dwg. VA-ED-005-1120 for details. WARNING Disconnect operating pressure. If not already removed, disconnect all operating pressure from actuator power cylinder. 2.6.1 Place the M18 pump control knob (25 - 200) in the auto position.
Installation, Operation and Maintenance Manual Section 2: Actuator Disassembly VA-DC-000-1878 Rev. 0 December 2020 NOTE: The piston, control valve (20 - 10 - 310) is under spring tension and it will eventually pop out, user beware and find means to capture the piston (20 - 10 - 310), spring (20 - 10 - 390), washer bearing (20 - 10 - 380) and thrust bearing (20 - 10 - 370).
Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Section 3: Actuator Reassembly General Reassembly CAUTION Check shelf life of seals. Only new seals, which are still within the seal’s expectant shelf life, should be installed into the actuator being refurbished. 3.1.1 Remove and discard all old seals.
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Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 3.2.1 If guide bar bearings are being replaced install new bearings into guide block (1 - 30). NOTE: The guide bar bearing must be press fit into guide block guide bar bore with the seam located 45 ±5 degrees of the top or bottom centerline as shown in Section A-A.
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Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 3.2.8 Lubricate guide block (1 - 30), two spherical washers (9 - 40) and one extension rod assembly (9 - 50). 3.2.9 Install one spherical washer (9 - 40) into the side of guide block (1 - 30). NOTE: The spherical side of washer (9 - 40) will be facing to the outside of guide block (1 - 30).
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Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 NOTE: The guide block (1 - 30) should be already preassembled with extension rod assembly and associated parts assembled in the guide block. 3.2.16 Install guide block (1 - 30), with yoke/guide block bushings (2 - 30), between arms of yoke (1 - 70).
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Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 3.2.28 Install hex cap screws (1 - 110) with lock washers (1 - 115) through housing cover (1 - 20) and into housing (1 - 10). NOTE: Leave hex cap screws (1 - 110) finger tight - do not tighten.
Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 NOTE: During yoke cover installation be careful not to damage O-ring seal (2 - 70) and rod wiper (2 - 80). 3.2.38 Place lock washers (1 - 170) onto hex cap screws (1 - 160). 3.2.39 Install and tighten hex cap screws (1 - 160) with lock washers through yoke cover (1 - 150) and into housing cover (1 - 20).
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Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 3.3.2 Torque tighten piston rod (3 - 40) to the lubricated torque as listed in Table 3. Table 3. Piston Rod Torque Information Torque (±5%) Torque (±5%) Housing Housing Model...
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Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 3.3.9 Install two split ring halves (3 - 50) into the inner most groove in piston rod (3 - 40) and retain by installing the recessed area of piston (3 - 30) onto the piston rod and over the two split ring halves (3 - 50).
Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 3.3.20 Install tie bar nuts (3 - 90) onto tie bars (3 - 20). Torque tighten tie bar nuts, alternately in 100 lb-ft / Nm increments, until a final lubricated torque, as listed in Table 4, has been achieved.
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Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 CAUTION Install Polypak seal correctly. Install the Polypak seal with energizer ring facing outboard side of inner end cap (3 - 10). 3.4.4 Install piston rod (3 - 40) through inner end cap (3 - 10). NOTE: The piston rod end with retainer grooves to be on the outboard side of inner end cap (3 - 10).
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Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 3.4.10 Install two split ring halves (3-50) into the piston rod, behind the piston and retain with retainer ring (3-60). 3.4.11 Coat two tie bars (3-20) with lubricant and install by carefully pushing tie bars through piston (3-30) and rod T-seal (4-50).
Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly VA-DC-000-1878 Rev. 0 December 2020 3.6.15 Install O-ring seal (8 - 70) into the O-ring groove located on the inner diameter of the hydraulic cylinder assembly flange opening. 3.6.16 Install the outer end cap (7 - 70) assembled piston rod (7 - 20) with piston (7 - 50) onto the open end of the hydraulic cylinder assembly and over the vent tube (7 - 60).
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PED by pressuring both sides of the piston to avoid damage and over torquing of the actuator components. If further future testing in the field is necessary, Emerson should be contacted for guidance. Actuator Reassembly...
Installation, Operation and Maintenance Manual Section 4: Field Conversions VA-DC-000-1878 Rev. 0 December 2020 Section 4: Field Conversions Fail Mode Reversal (CW to CCW, or CCW to CW) 4.1.1 Remove spring module per Section 5.3. 4.1.2 Remove pneumatic power module per Section 5.5. 4.1.3 Reinstall the spring module onto the opposite end of housing (1 - 10) as it was previously located per Section 5.4.
Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Section 5: Module Removal and Installation M18 Override Cylinder Removal 5.1.1 Shut off and exhaust the operating media from both sides of the actuator’s power cylinder.
Installation, Operation and Maintenance Manual Section 5: Module Removal and Installation VA-DC-000-1878 Rev. 0 December 2020 NOTE: To identify hex cap screws (7 - 100) from hex cap screws (7 - 80), hex cap screws (7 - 100) will be located to the left and right of SR cartridge top dead center and will then be counted as every other hex cap screw.
Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 5.2.6 Using pipe dope on threads reinstall all piping between hydraulic override cylinder assembly and the M18 pump. 5.2.7 Fluid filling instructions for M18 and M18-S Hydraulic Override Sytems: 5.2.7.1 To fluid fill M18 Manual Hydraulic Override System refer to instructions part number VA-DC-000-1879.
Installation, Operation and Maintenance Manual Section 5: Module Removal and Installation VA-DC-000-1878 Rev. 0 December 2020 5.3.7 The spring cartridge "pre-load" must be removed before spring cartridge assembly (5 - 10) is removed from housing (1 - 10). Refer to steps 5.3.4 through 5.3.6 for spring cartridge "pre-load"...
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Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Spring Module Installation CAUTION Use heavy duty support equipment. Due to the weight and size of spring module, heavy duty support equipment will be required when installing spring cartridge module to the actuator housing.
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Installation, Operation and Maintenance Manual Section 5: Module Removal and Installation VA-DC-000-1878 Rev. 0 December 2020 5.4.5.2 After confirming initial thread engagement, rotate tension rod into extension rod assembly (9 - 50) per the following Table: WARNING Rotate tension rod properly. After initial thread engagement the tension rod must be rotated clockwise the minimum number of turns listed in Table 8.
Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 5.4.12 G7 through G10 M18 Override Cylinder installation. 5.4.12.1 Insert M18 Hydraulic Override Cylinder assembly into spring cartridge outer end. 5.4.12.2 Install lock washers (7 - 80) on to eight hex cap screws (7 - 100). 5.4.12.3 Install eight hex cap screws (7 - 100) with lock washers (7 - 90) through end cap (7 - 70) and into outer end of spring cartridge (5 - 10).
Installation, Operation and Maintenance Manual Section 5: Module Removal and Installation VA-DC-000-1878 Rev. 0 December 2020 NOTE: When removing power module from housing (1 - 10) be careful not to lose O-ring seal (4 - 90). 5.5.4 Remove power module from actuator housing (1-10). Pneumatic Power Module Installation NOTE: Reinstall the power module onto the opposite side of housing (1 - 10) as it was...
Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Power Swivel Removal 5.7.1 Push the guide block to the side of housing (1 - 10) that will expose the extension rod assembly (1 - 50). NOTE: The guide block can be moved by inserting a long nonmetallic rod through the hole where the blind end cap was removed and pushing on the guide block.
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Installation, Operation and Maintenance Manual Section 5: Module Removal and Installation VA-DC-000-1878 Rev. 0 December 2020 5.8.2 Lubricate two spherical washers (1 - 40), and one extension rod assembly (1 - 50). 5.8.3 Install one spherical washer (1 - 40) into the side of guide block (1 - 30). NOTE: The spherical side of washer (1 - 40) will be facing to the outside of guide block (1 - 30).
Installation, Operation and Maintenance Manual Section 6: Actuator Support Information VA-DC-000-1878 Rev. 0 December 2020 6.10 G10 Tool Style and Wrench Size Table 20. G10 Tool Style and Wrench Size Location or Recommended Item No. Wrench Size Item Qty. Description Tool Style 1 - 110 3/4”...
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Section 6: Actuator Support Information Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Location or Recommended Item No. Wrench Size Item Qty. Description Tool Style 30-100 7/32” Socket Cap Screws Allen 30-110 3/8” Socket Cap Screws Allen 11/16”/5/8”” Male Elbow Open End or Adjustable 11/16”/5/8””...
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the service engineer to perform troubleshooting. This Table is designed to cover as wide a range of Emerson Bettis actuators as possible. Reference to equipment not supplied should be ignored.
Section 7: Troubleshooting Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 Operational Test 7.2.1 Full Stroke Test The “Full Stroke Test” (“On-line”) must be performed to satisfy the PFD (average probability of failure on demand) value. The full stroke test frequencies will be defined by the final installer to achieve the defined SIL level.
If a conflict arises between this procedure and the customer's procedures, the differences should be resolved in writing between an authorized customer’s representative and an authorized Emerson / Bettis representative. CAUTION Isolate and power off actuator. Make sure actuator is isolated before removing from valve.
List of Tables Installation, Operation and Maintenance Manual December 2020 VA-DC-000-1878 Rev. 0 List of Tables Table 1 G-Series Models .................... 3 Table 2 Housing Cover Screw Quantity and Torque ..........20 Table 3 Piston Rod Torque Information ..............22 Table 4 Tie Bar Nuts ....................
Installation, Operation and Maintenance Manual Appendix VA-DC-000-1878 Rev. 0 December 2020 Appendix A: List of Drawings Part No. 121410, G1/2/3/4/5-SRX-H Pneumatic Assembly Drawing, Sheet 1 of 2 Figure A-1 Appendix...
Installation, Operation and Maintenance Manual Appendix VA-DC-000-1878 Rev. 0 December 2020 A.11 Part No. VA-ED-005-1120, M18 Assembly Drawing, Sheet 7 of 7 Figure A-11 Appendix...
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Tianjin 301700 Holland Fasor 6 P. R. China Székesfehérvár 8000 The Emerson logo is a trademark and service mark of Emerson Electric Co. T +86 22 8212 3300 Hungary Bettis is a mark of one of the Emerson family of companies.