Emerson Fisher 480 Installation Instructions
Contents
1. normal cubic meters per hour 0 C and 1 01325 bar absolute Scfh standard cubic feet per hour 60 F and 14 7 psia 480 Series Actuators Instruction Manual August 2012 D100291X012 Figure 2 Supply Pressure and Thrusts SIZE 30 ACTUATOR SIZE 40 ACTUATOR SIZE 60 ACTUATOR 10 4 8 6 H 6 9 1 1111 11111111111111111111 3 4 RENE HHHH BEER eee 11111211 11117121111111 Lr 1 7 2 4 8 12 24 26 28 30 8 9 26 7 44 5 62 3 80 9779 1157 133 5 REQUIRED SUPPLY PRESSURE BAR REQUIRED SUPPLY PRESSURE PSIG THRUSTS IN THOUSANDS OF POUNDS IN THOUSANDS OF NEWTONS NOTE FOR ACTUATORS WITH POSITIONERS 1 MAY BE INCREASED BY 10 FOR ACTUATORS WITHOUT POSITIONERS EITHER THIS THRUST OR THE MAXUMUM ALLOWABLE LOADING FOR THE CONTROL 5961 DEVICE IS THE LIMITING FACTOR FOR USABLE ACTUATOR FORCE 3 Frequency 1 SIZE 30 19mm 0 75 INCH TRAVEL 2 SIZE 40 38mm 1 5 INCH TRAVEL 3 SIZE 60 38mm 1 5 INCH TRAVEL PHASE LAG DEGREES NORMALIZED GAIN 5962 FREQUENCY HERTZ 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 the type number The above actuators come with standard mounting flange 105 mm 4 125 inch maxim2. Operative Ambient Temperature With Nitrile O Rings 46 to 80 C 50 to 175 F With Fluorocarbon O Rings Optional G 18 to 149 C 0 to 300 F Actuator Size and Piston Size See table 2 Pressure Connections Standard is 1 4 NPT For larger sizes contact your Emerson Process Management sales office Construction Materials Actuator Part Material Cylinder and Piston Aluminum Piston Rod Extension SST Chrome Plated Cylinder Seal Bushings Brass O Rings Nitrile or Fluorocarbon Options 376 Series trip valve system to fail actuator B up or down or lock in last position TopWorx M21GNEB electrical valve stem position switch Bi Micro Switch limit switches 1 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 2 These terms are defined in ANSI ISA Standard S51 1 3 Without snubber If this actuator has a snubber the temperature specification is the same for the nitrile version 4 The pressure limits in this bulletin and any applicable standard or code limitation for actuator should not be exceeded Table 2 Size Piston Stroking Speed and Travel Information SINGLE FLANGE TRAVEL STOPS AVAILABLE EFFECTIVE PISTON STROKING FOR ACTUATORS WITH ACTUATOR PISTON AREA DIAMETER SPEED 16 Versions Others RA Fisher 487 105 mm 4 125 INCHES SIZE 487 102 MAXIMUM RATED TRAVEL 182 28 25 6
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4. can be ignored if a 481 actuator is involved Instruction Manual 480 Series Actuators D100291X012 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 Shut off all pressure to the actuator Remove all tubing lines cylinder instrument and supply from the actuator Remove the positioner cover after loosening the four cover screws on the underside of the positioner base Disengage the range spring by unscrewing the spring retainer from the piston rod extension BR UJ N 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 Next remove the clevis bolt from the adjustable linkage Remove the bottom snap ring key 26 and unscrew the 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 o
5. input signal pressure the beam remains motionless and allows supply pressure to bleed through both relay nozzles so that a constant pressure 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 The nozzle pressure in relay A increases due to the restriction 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 If
6. upward piston motion is required the beam pivots over the nozzle on relay B The result 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 bellows posts for support it the change is from direct to reverse 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 The resistance to flow created by 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 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 S
7. 0 258 55 5 EILEEN NE MN EN 6 125 2 05 SEIS es oe 1 For actuators with positioners at 6 9 bar 2 psig supply pressure and all prestroke conditions satisfied Stroking speeds for actuators without positioners or with snubbers will depend on the particular construction involved 2 See 480 series Actuators Specifications for these travels Instruction Manual D100291X012 Table 3 Fisher 3570 Actuator Specifications 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 2 to 1 0 bar 3 to 15 psig or 0 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 Output Signal Type Pneumatic pressure as required b
8. Instruction Manual 480 Series Actuators D100291X012 August 2012 Fisher 480 Series Yokeless Piston Actuators Contents Figure 1 Fisher 480 15 Piston Actuator PERO GUGHION ous gases oan ed OR ub awed once 1 Scope of 1 eee 1 see ve ES b YR 1 Actuator Configurations 4 instalation ee ce 5 Principle of Operation 6 Pressure Connections ie eoe ees 7 AGIUSEITIBINDS nto 7 Actuator Maintenance 9 DISASSEMIDIV det Soup Lies 9 Parts OPdetificg ice mb eke eons 12 12 Introduction 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 us
9. T SHOWN 27 78 79 AND 112 480 Series Actuators August 2012 Parts Ordering Instruction Manual D100291X012 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 A 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 Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Key Description Cylinder Flange Cylinder Piston Piston Rod Piston Rod Extension Upper Seal Bushing Lower Seal Bushing Stem Seal O ring Sizes 30 40 and 60 2 req d 10 Bushing Seal O ring Sizes 30 40 and 60 2 req d 11 Piston Seal O ring Size 30 Size 40 Size 60 Part Number 1E73690699 1D34830689 1H86210699 1H86220699 1H86240699 Key 12 13 14 15 18 23 24 25 26 30 31 45 78 79 160 Description Cylinder Seal O ring Size 30 Size 40 Size 60 Cylinder Stud Compression Fitting Cylinder Tubing Boot Lockn
10. ed 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 EMERSON www Fisher com Process Management 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 See figure 2 Minimum Recommended Valves with low torque requirements 2 4 bar 35 psig all other valves 3 4 bar 50 psig Maximum Supply Source Consumption With and Constant Input Signal 0 54 normal m3 hr 20 scfh 1 of air at 6 9 bar 100 psig Without Positioner Depends on cylinder volume and supply pressure 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 Thrust Information See figure 2 Torque Output 480 480 15 and 480 16 for butterfly valves Contact your Emerson Process Management sales office Stroking Speeds See table 2
11. id 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 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 RELAY B INSTRUMENT mee nn cto c a SUPPLY BEAM RELAY A FIXED RESTRICTION s ee eet ee INSTRUMENT PRESSURE SUPPLY PRESSURE TOP CYLINDER PRESSURE BOTTOM CYLINDER PRESSURE BJ8256 A EZ NOZZLE PRESSURE 1286 480 Series Actuators Instruction Manual D100291X012 August 2012 When 480 Serie
12. ile the valve is still pressurized e Always wear protective gloves clothing and eyewear when performing any maintenance operations to avoid personal injury 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 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 Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment 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 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
13. s 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 Um H DEGREE OF ARC mm m StmdadHange Universal Mounting Flange m s CE 777 Figure 6 Operation of Actuator with Snubber 5 POSITIONER ORSWITCH IN SUPPLY PRESSURE TOP CYLINDER PRESSURE BOTTOM CYLINDER PRESSURE UPPER SNUBBER PRESSURE LOWER SNUBBER PRESSURE 32A8303 A A1287 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 Instruction Manual 480 Series Actuators D100291X012 August 2012 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
14. um rated travel and threaded piston rod connection with sizes 30 through 60 for mounting 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 travel and threaded piston rod connection and comes in sizes 40 through 60 Instruction Manual 480 Series Actuators D100291X012 August 2012 Table 4 Action Under Normal Operating Conditions DESIRED PISTON MOTION Direct acting Increasing input signal pressure to bellows Decreasing input signal pressure to bellows With Positioner Decreasing input signal pressure to bellows Increasing input signal pressure to bellows Supply pressure loaded on top of piston Supply pressure loaded on bottom of piston 1 Supply pressure is routed through relays to piston Installation A 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 avo
15. upply 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 480 Series Actuators Instruction Manual August 2012 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 A WARNING Avoid personal injury from sudden release of process pressure Before performing any maintenance operations e Do not remove the actuator from the valve wh
16. ut Nameplate Drive Screw Piston Rod Boot Sizes 30 40 and 60 Top Boot Snap Ring Bottom Boot Snap Ring Travel stop Piston Nut Positioner Spring Retainer Spacer Cover Seal 481 only Cover Screw Pipe Plug Recommended spare parts Part Number 1 86200699 1D44480699 1H86230699 1H93790699 1C85380699 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 remains solely with the purchaser and end user Fisher and TopWorx are marks owned by one of the companies in the Emerson Process Management business unit 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 All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA
17. ut 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 Nem 150 Ibfeft 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 480 Series Actuators Instruction Manual August 2012 Figure 7 Fisher 480 Piston Actuator Size 30 60 efi D100291X012 M M M n M M y a D TE i EIS Se 5 Ol P m M 1 fe h 22 a ca NEN I A e Oe m wy NO VA PARTS NOT SHOWN 27 AND 112 Instruction Manual 480 Series Actuators D100291X012 August 2012 Figure 8 Fisher 481 Piston Actuator Size 30 60 A Zo AVAVAVAVAVEY E A PARTS NO
18. y 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 2 0 2 of instrument pressure span Repeatability 2 0 3 of instrument pressure span 1 These terms are defined in ANSI ISA Standard 51 1 480 Series Actuators August 2012 Frequency Response 2 See figure 3 Pressure Connections Vent 3 8 NPT All Others 1 4 NPT Pressure Indications 3570 Tire valves accept standard pressure gauge chucks 3570 See table below Standard Gauge Range bar psig 0 to 2 1 0to 30 or Type of Indication Positioner input signal gauge 0 to 4 1 0 to 60 Cylinder supply pressure 0 to 11 0 0 to 160 gauge Static Air Consumption 0 56 normal m hr 20 scfh with 6 9 bar 100 psig supply pressure Operative Ambient Temperature 2 With Nitrile O Rings 34 to 79 C 30 to 17558 With Fluorocarbon O Rings 1 9 18 to 149 C 0 to 300 F Construction Materials Actuator Part Material Base Cover and Beam Aluminum die cast Bellows Brass Bias and Range Spring Steel Plated Relay Body Zinc Die Cast Relay Nozzle s SST Diaphragm Nitrile or Fluorocarbon O Rings Nitrile or Fluorocarbon Options Fisher 55 52 clip on chuck with or without gauge for 3570C positioners 2 For actuator with positioner only Does not apply to other constructions or actuator valve combination 3 Normal
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