Emerson Fisher 3025 Installation Instructions
Contents
1. 3025 Actuator Instruction Manual May 2011 0251402 012 16 From the diaphragm casing key 1 remove the retaining ring key 8 the wiper ring and the seal retainer keys 4 and 5 and the O ring key 6 17 If required remove the casing bushings keys 7 and 33 the pins key 28 from the diaphragm casing and diaphragm plate the hellicoils key 58 the travel scale screw and nuts keys 74 75 and 76 Size P460 Actuator Assembly 1 If removed coat the bushings keys 7 and 33 with lithium grease key 201 and slide them into the diaphragm Casings 2 Place the wiper ring key 4 into the seal retainer key 5 Apply lithium grease key 201 to the O ring key 6 the wiper ring and seal retainer assembly and install them into the diaphragm casing key 1 Then place the retaining ring key 8 If removed insert the pins key 28 into the diaphragm casing key 3 and diaphragm plate key 26 If removed insert the hellicoils key 58 into the nut key 16 Coat the threads of the stem key 9 with anti seize lubricant key 202 ou W Apply anti seize lubricant key 202 to the internal thread of the two nut halves key 10 Install the nut halves and the retaining ring key 11 Place the tab washer key 13 and bend it on the retaining ring Slide the travel stop key 14 the washers if used key 64 the O ring key 6 the diaphragm key 47 the diaphragm plate key 26 the tube key 51 the wave washers key 12. C 1 l mmm mmm mmm mmm Ft E ee S P m 2011 Se Se FY ee 7 E A A E E dr E me ee A M B RH 8 818 RR C APPLY LUBRICANT 33 Instruction Manual 3025 Actuator May 2011 D251402X012 toe 2 S D YHOOHQOQOEHHOOOOSVOE S Figure 12 Fisher 3025 Size P900 Air to Close Actuator long stroke high bench set AV 534 5 EE 4 a Zen cx 2411 5 iin D Ki CH cC Cl JEN EORR e 0 S C APPLY LUBRICANT 34 Instruction Manual 3025 Actuator D251402X012 May 2011 Figure 13 Fisher 3025 Size P460 and P462 Side Mounted Handwheel 1 a m g pos 207201 e _ ie 201 ian qu o 796 C APPLY LUBRICANT 35 Instruction Manual 3025 Actuator May 2011 D251402X012 Figure 14 Fisher 3025 Size P900 Sid
3. 12 ARE r7 l SH i d i NW o Ba ee UNS EL _ __ __ 11 Lie 7 CHA Lu YA mi Lat a Wa NN a LI 18 Wee Le 5 E LT be D TII P ri n a a Pa a d a P a a A SS ai 5 1 D D 4 3686 9989 90000 olio J 29 C APPLY LUBRICANT Instruction Manual 3025 Actuator May 2011 D251402X012 8 899909999oogoG RIR 9 y HE pres ae a ah ala al ca it al al a ait i 5 A s 5 7 ER LP mE SEP TIT T UA Kee Ge d eee wi X UR b SE HC fex E HH Parra a d pr A un aar an n FP PU a n zs 96060GoG0 96 AOG 2 8 8 2 5 Figure 8 Fisher 3025 Size P460 200 Air to Close Actuator C APPLY LUBRICANT 30 Instruction Manual D251402X012 Figure 9 Fisher 3025 Size P900 Air to Open Actuator PJ CH e S 000
4. the pins key 28 from the diaphragm plate and spring seat If required remove the travel scale the screws and nuts keys 74 75 and 76 Size P900 Actuator Assembly 1 If removed coat the bushing keys 7 and 33 with lithium grease key 201 and slide them into the diaphragm Casings 3025 Actuator Instruction Manual May 2011 0251402 012 2 Place the wiper rings key 4 into the seal retainers key 5 Apply lithium grease key 201 to the O rings key 6 the wiper ring and seal retainer assemblies and install them into the diaphragm casings key 1 Then insert the cap screws key 21 and tighten them 3 If removed insert the pins key 28 into the spring seat key 29 and diaphragm plate key 26 4 Assemble the two travel stop parts keys 14 and 15 install the lock washers key 18 and the cap screws key 18 and tighten them 5 Place the diaphragm key 47 on the diaphragm plate key 26 Install the ring key 24 and the cap screws key 25 and tighten them Note The size P900 is a double stacked diaphragm casings actuator First assemble the stack made of a short and along diaphragm casing keys 1 and 3 Then mount the stack composed of two short diaphragm casings keys 1 and 2 6 Coat the threads of the stem key 9 with anti seize lubricant key 202 7 Apply anti seize lubricant key 202 to the internal thread of the two nut halves key 10 Install the nut halves and the retaining ring key 11 Slide the
5. Maximum Travel 087 Temperature Capabilities 22 to 176 F Pressure Connections female 3 4 NPT NEN Approximate Actuator Weights a Approximate Side Handwheel Weights Specifications Refer to table 1 for Specifications of the 3025 actuator See the actuator nameplate for specific information about your actuator Installation Key number locations are shown in figures 3 through 12 unless otherwise indicated Figures 3 and 4 show the size P460 actuator figures 5 and 6 the size P462 figures 7 and 8 the size P460 200 and figures 9 10 11 and 12 illustrate the size P900 Instruction Manual 3025 Actuator D251402X012 May 2011 If the actuator is equipped with a side mounted handwheel also refer to the figures 13 14 15 and 16 Figure 13 shows the size P460 and the size P462 side mounted handwheel figure 14 the size P460 200 and figure 15 illustrates the size P900 CAUTION To avoid parts damage do not use a normal operating pressure that exceeds the Maximum Diaphragm Casing Pressure of 4 bar or produces a force on the actuator stem greater than the Maximum Allowable Valve Stem Load Valve Actuator Assembly If the actuator and valve are shipped together as a control valve assembly it has been adjusted at the factory and may be installed in the pipeline After installing the valve in the pipeline refer to the Loading Connection procedures Actuator Mounting If the actuator
6. 103 with lithium grease key 201 and slide it into the housing key 102 3 Coat the bushing key 103 the bearing key 104 and the gear ring key 105 with lithium grease key 201 Place the gear housing key 102 onto the yoke install the bearing key 104 and the gear ring key 105 4 Coat the thread of the shafts keys 110 and 111 and the internal threads of the shaft connector key 109 with anti seize lubricant key 202 Insert the lower threaded shaft key 110 into the shaft connector key 109 by engaging three or four threads 5 For the size P460 200 if the upper threaded shaft key 111 was separated from the bridge key 112 screw the shaft into the bridge Align the holes and insert the pin key 127 6 Apply lithium grease key 201 to the inside of the gear ring key 105 Place the shaft assembly keys 109 and 110 into the gear ring and align the grooves Apply lithium grease key 201 to the key key 106 and insert it Place the washer key 107 insert the screws key 108 and tighten them 7 Coat the handwheel assembly cog key 114 and the gear ring cog key 105 with anti seize lubricant key 202 Place the handwheel assembly Insert the cap screws keys 115 and 126 and adjust the gap between the gear cogs by screwing or unscrewing the cap screws Then tighten the cap screws key 115 8 Place the bridge key 112 and the upper shaft key 111 Insert the upper shaft into the shaft connector key 109 by
7. Screw 130 Hex Socket Cap Screw 109 Shaft Connector 131 HexNut 110 Threaded Shaft 132 HexNut 111 Threaded Shaft 133 Bellows 112 Bridge Size P460 200 0264571 113 Travel Indicator 134 Ring 114 Driving Shaft Assembly 135 Bellows 114 1 Driving Shaft Housing Size P460 200 0142948 114 2 Bushing 136 JamHexNut 114 3 Bearing 137 Hex Head Screw 114 4 Driving Shaft 138 Bellows Holder 114 5 Handwheel Rotation Indicator 139 Slotted Headless Screw 114 6 Clamp 140 Hex Nut 114 7 Anti Rotator 201 Lithium Grease 114 8 Spacer 202 Anti Seize Lubricant Keys 30 and 31 Size P460 Actuator Spring TRAVEL DIAPHRAGM PRESSURE RANGE 02 09 04 08 om2 107 13 20 02 10 04 08 0 4 0 9 30 1340387 1269356 1285548 1280023 1285548 1285548 23 3025 Actuator Instruction Manual May 2011 0251402 012 Key 30 Size P462 Actuator Spring wea o 16 Key 30 Size P460 200 Actuator Spring TRAVEL DIAPHRAGM PRESSURE RANGE 127 5 0 6 1 2 0 8 1 9 1 5 2 8 152 6 0 6 1 3 0 8 2 1 1 5 3 0 165 6 1 2 0 6 1 4 0 8 2 2 1 5 3 1 178 7 0 6 1 5 0 8 2 3 1 5 3 3 203 8 0 6 1 6 0 8 2 5 1 5 3 5 Key 30 Spring 0265144 0265144 0413917 Keys 30 and 31 Size P900 Actuator Spring TRAVEL DIAPHRAGM PRESSURE RANGE 1 1 1 6 Key 30 Spring 1261029 1280732 1280821 1230328 Key 31 Spring 1261037 1280759 1280848 1230344 24 2011 3025 Actuator Figure 3 Fisher 3025 Size P460 Air to Open Actuator Instruc
8. Tighten these four bolts to 8 Nem 6 Ibfeft 14 Tighten the remaining bolts in a clockwise crisscross pattern to 8 Nem 6 Ibfeft 15 Repeatthis procedure by tightening four bolts diametrically opposed and 90 degrees apart to a torque of 16 Nem 12 Ibfeft 16 Tighten the remaining bolts in a clockwise crisscross pattern to 16 Nem 12 Ibfeft 17 After the last bolt is tightened to 16 Nem 12 Ibfeft all of the bolts should be tightened again to 16 Nem 12 Ibfeft in a circular pattern around the bolt circle 18 Once completed no more tightening is recommended 19 Screw the locknut key 62 against the nut key 16 20 Place the bellows key 68 and 69 21 Place the gasket key 71 and the lifting lug cap key 40 onto one of the diaphragm casings according to the actuator action air to close key 1 air to open key 3 Coat the cap screws key 44 with lithium grease and tighten them 22 If removed place the travel stop and the locknut keys 41 and 42 into the lifting lug cap 23 If the actuator is equipped with a side mounted handwheel it is necessary to adjust the actuator travel stop before mounting the actuator onto the side mounted handwheel Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section Then refer to the Side Mounted Handwheel Assembly procedures in the Side Mounted Handwheel Maintenance section to complete the actuator assembly from step 9 24 Lift the ac
9. is accidentally disconnected personal injury and property damage is possible if something is caught between the actuator stem and other control valve parts Also provide a certified pressure gauge suitable to accurately read the diaphragm pressure from 0 through the upper bench set pressure marked on the nameplate Apply loading pressure to the diaphragm Stroke the actuator a few times to ensure that the pressure gauge is working correctly and that the actuator is functioning properly It is important to be sure that the actuator assembly is not binding or producing any loading friction on the actuator stem movement Note For push down to close valves the valve plug is the limit for downward travel and the actuator up stop is the limit for upward travel away from the valve 1 If not already accomplished provide a temporary means of applying adjustable loading pressure to the actuator during the travel stop adjustments 2 Remove the cap key 43 figures 3 through 6 or loosen the locknut key 42 figures 7 through 12 Unscrew the travel stop key 41 3 Perform one of the following procedures as appropriate a Foran air to open actuator apply the upper bench set loading pressure to the diaphragm Adjust the travel stop key 41 so that it touches the actuator stem Then lock the travel stop by replacing the cap key 43 or by tightening the locknut key 42 b Foran air to close actuator apply the lower bench set loading pres
10. nuts keys 45 and 46 If required remove the vent key 49 13 Lift off the diaphragm casing key 3 14 Remove the spring seat key 29 and actuator spring key 30 15 Lift off the stem and diaphragm plate assembly 16 Unscrew the set screw key 57 and remove the travel stop key 52 Loosen the nut key 10 Remove the ring retaining key 11 the wave washers key 12 the tube key 51 the diaphragm plate key 26 the diaphragm key 47 the O ring key 6 the travel stop key 14 the ring retaining key 60 and the 2 ring halves 17 From the diaphragm casing key 1 remove the retaining ring key 8 the wiper ring and the seal retainer keys 4 and 5 and the O ring key 6 18 If required remove the casing bushings keys 7 and 33 the pins key 28 from the diaphragm plate and spring seat thread the travel stop if used key 66 out of the stem If required remove the travel scale the screws and nuts keys 74 75 and 76 Size P462 Actuator Assembly 1 If removed coat the bushings keys 7 and 33 with lithium grease key 201 and slide them into the diaphragm Casings 2 Place the wiper ring key 4 into the seal retainer key 5 Apply lithium grease key 201 to the O ring key 6 the wiper ring and seal retainer assembly and install them into the diaphragm casing key 1 Then place the retaining ring key 8 3 If removed insert the pins key 28 into the spring seat key 29 and diaphragm plate key 26 4 Coa
11. ring key 6 18 If required remove the casing bushings keys 7 and 33 and the pins key 28 from the diaphragm plate and casing If required remove the travel scale screw and nuts keys 74 75 and 76 Size P460 200 Actuator Assembly 1 If removed coat the bushings keys 7 and 33 with lithium grease key 201 and slide them into the diaphragm casings 2 Place the wiper ring key 4 into the seal retainer key 5 Apply lithium grease key 201 to the O ring key 6 the wiper ring and seal retainer assembly and install them into the diaphragm casing key 1 Then insert the cap screws key 70 and tighten them 3 If removed insert the pins key 28 into the diaphragm casing key 3 and diaphragm plate key 26 4 Place the diaphragm key 47 on the diaphragm plate key 26 Install the ring key 24 and the cap screws key 25 and tighten them 5 Coatthe threads of the stem key 9 with anti seize lubricant key 202 6 Apply anti seize lubricant key 202 to the internal thread of the two nut halves key 10 Install the nut halves and the retaining ring key 11 Slide the diaphragm and diaphragm plate assembly keys 24 25 26 and 47 the O ring key 6 the tube key 51 the wave washers key 12 7 Coatthe internal thread of the travel stop key 54 with anti seize lubricant key 202 screw it onto the stem and tighten until the wave washers are completely compressed 8 Place this stem assembly into the diaphragm cas
12. the diaphragm casings are still diametrically opposed Install the cap screws and nuts keys 45 and 46 Tighten the diaphragm cap screws and nuts in the following manner Instruction Manual 3025 Actuator D251402X012 May 2011 13 The first four bolts tightened should be diametrically opposed and 90 degrees apart Tighten these four bolts to 8 Nem 6 Ibfeft 14 Tighten the remaining bolts in a clockwise crisscross pattern to 8 Nem 6 Ibfeft 15 Repeatthis procedure by tightening four bolts diametrically opposed and 90 degrees apart to a torque of 16 Nem 12 Ibfeft 16 Tighten the remaining bolts in a clockwise crisscross pattern to 16 Nem 12 Ibfeft 17 After the last bolt is tightened to 16 Nem 12 Ibfeft all of the bolts should be tightened again to 16 Nem 12 Ibfeft in a circular pattern around the bolt circle 18 Once completed no more tightening is recommended 19 Tighten the set screws key 57 into the nut 16 20 If used place the locknut and travel stop on the stem keys 65 and 66 and screw the locknut against the travel stop 21 Place the gasket 71 and the lifting lug cap 40 onto one of the diaphragm casings according to the actuator action air to close key 1 air to open key 3 Insert the cap screws key 44 and tighten them 22 If removed place the travel stop key 41 into the lifting lug cap 23 If the actuator is equipped with a side mounted handwheel it is necessary to adjust the actua
13. turning counter clockwise the handwheel Engage three or four threads as done previously for the lower shaft Note The actuator is normally shipped adjusted at the factory and you may refer directly to the following steps If the actuator has been disassembled it is necessary to adjust the travel stop You may perform the Travel Stop Adjustment in accordance with the procedures in the Installation section 9 Lift the actuator and place it onto the handwheel Insert the cap screws key 77 and tighten them WARNING When moving the actuator stem with loading pressure applied exercise caution to keep hands tools out of the actuator stem travel path If the loading pressure is accidentally disconnected personal injury and property damage is possible if something is caught between the actuator stem and other control valve parts 10 For an air to open actuator only set the diaphragm loading pressure to approximately 0 5 bar over the upper bench set pressure The actuator should be contacting the upper travel stop 20 Instruction Manual 3025 Actuator D251402X012 May 2011 11 For sizes P900 and P460 200 only screw the actuator stem locknut away from the from the connector half location 12 Screw the stem connector half key 124 onto the actuator stem 13 Perform one of the following procedures as appropriate a Foran air to open actuator position the bridge key 112 at the lower location and wedge it by inserting the sto
14. 0000000090000000009000900 OOG ICH C APPLY LUBRICANT mJ e e e G 42 40 64 489 IN HANS iS H201 mmm 7 2008 81 E E 10H 202 Zl 98 18 23 ge i we 10 4201 2 49 m 10 202 Die D 44201 05 52 73 3025 Actuator 2011 31 3025 Actuator Instruction Manual May 2011 D251402X012 Figure 10 Fisher 3025 Size P900 Air to Close Actuator E e N 5 OO 399969699 6 G 969 9 6 9 96 0 9 Q Q 5 1117 hJ N gt ret eet lt lt eS N e 5 N N a 3 a 22 Ld um 1 2 rn We G 22 72 ee 3212 N CH N N N N eo N e di Zu 553 a 1221 BEE aim L LKE 960696099099 OAO 6 6 9 C APPLY LUBRICANT 32 3025 Actuator Instruction Manual D251402X012 May 2011 Figure 11 Fisher 3025 Size P900 Air to Open Actuator long stroke high bench set 8 99999000 0990090999 e E ei d Bi ria
15. 2 and the ring key 17 7 Coatthe internal thread of the travel stop key 54 with anti seize lubricant key 202 screw it onto the stem and tighten until the wave washers are completely compressed 8 Place this stem assembly into the diaphragm casing key 1 Take care when pushing the actuator stem through the diaphragm casing so that the threads do not damage the bushing O ring or wiper ring 9 Place the actuator springs keys 30 and 31 10 Install the diaphragm casing key 3 so that the vent and air connections are diametrically opposed Take care when lowering the casing around the stem so that the thread do not damage the bushing Apply lithium grease key 201 to the washer key 53 and place it 11 Apply anti seize lubricant key 202 on the nut internal thread key 16 and screw it slowly to compress the springs until the two diaphragm casings touch the diaphragm Note When you replace actuator diaphragms in the field take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage but not crush the material Perform the following sequence with a manual torque wrench CAUTION Over tightening the diaphragm cap screws and nuts keys 45 and 46 can damage the diaphragm Do not exceed 16 Nem 12 Ibf ft torque Note Do not use lubricant on these bolts and nuts Fasteners must be clean and dry 12 Align the diaphragm casings and diaphragm holes Be sure the vent and air connections on
16. 3 Remove the driving shaft assembly keys 114 116 117 and 118 by loosening the cap screws that hold it in place keys 115 and 126 3025 Actuator Instruction Manual May 2011 0251402 012 14 If required the driving shaft assembly can be broken down by removing the nut key 118 the washer key 117 the rotation indicator key 114 5 the handwheel key 116 and then the driving shaft key 114 4 and the bearing key 114 3 If required remove the cap screws and nuts keys 114 9 and 114 10 of the anti rotator clamped on the driving shaft housing key 114 1 the anti rotator key 114 7 the spacer 114 8 and the two clamps key 114 6 15 Remove the screws key 108 the washer key 107 the key key 106 the gear ring key 105 and the bearing key 104 If required remove the bushing key 103 from the gear housing key 102 Side Mounted Handwheel Assembly 1 If the driving shaft assembly was separated coat the bushings key 114 2 the bearing key 114 3 and the shaft key 114 4 with lithium grease key 201 Place the bearing and then insert the shaft into the housing key 114 1 Place the handwheel key 116 the rotation indicator key 114 5 the washer key 117 and then insert and tighten the nut key 118 Place the two clamps key 114 6 the spacer and the anti rotator at the opposite keys 114 7 and 114 8 insert the cap screws and nuts key 114 9 and 114 10 and tighten them 2 If removed coat the bushing key
17. 739 Size P460 200 0413860 Size P900 1221728 Diaphragm Size P900 1221701 Elbow Vent Spring Lock Washer Tube Travel Stop Washer Travel Stop Washer Plain Washer Hex Socket Set Screw Hellicoil Retaining Ring Size P462 1269828 Size P900 1261088 Retaining Ring Ring 2 parts Jam Hex Nut Washer Jam Hex Nut Travel Stop Spacer Bellows Size P460 200 0264571 Ring Hex Head Cap Screw Gasket Size P460 and P462 Size P460 200 Size P900 Gasket Size P462 Size P900 Yoke Travel Indicator Scale Pan Head Screw Speed Nut Hex Head Cap Screw 1607596 1630342 1632205 1630369 1632191 Nut Half Stem Connector Bolt Half Stem Connector Hex Socket Cap Screw Hex Nut Jam Hex Nut Jam Hex Nut Travel Indicator Anti Rotator Spacer Hex Socket Cap Screw Spring Lock Washer Nameplate Drive Screw Recommended spare parts Instruction Manual 3025 Actuator D251402X012 May 2011 Key Description Part Number Key Description Part Number 114 9 Hex Head Cap Screw 114 10 Hex Nut 115 Hex Head Cap Screw 116 Handwheel 117 Plain Washer 201 Lithium Grease 202 Anti Seize Lubricant e 118 Hex Nut Side Mounted Handwheel 119 Protective Cover 120 Hex Head Screw figures 13 through 16 522 101 Yoke 122 Hex Head Cap Screw 102 Gear Housing 124 Stem Connector 103 Bushing 125 Hex Socket Cap Screw 104 Bearing 126 Hex Head Cap Screw 105 GearRing 127 Pin 106 Key 128 Plain Washer 107 Washer 129 HexNut 108 Countersunk Head
18. Figure 13 shows the sizes P460 and P462 Handwheel figure 14 the size P900 figure 15 the size P460 200 and figure 16 illustrates the driving shaft assembly It may be necessary to apply a temporary loading pressure to the actuator during the assembly Side Mounted Handwheel Disassembly 1 Bypass the control valve Reduce the actuator loading pressure to atmospheric and remove the tubing or piping from the diaphragm casing 2 Foran air to open actuator only Turn counterclockwise until movement of the handwheel stem is detected The spring force applied to the stem connector is relieved WARNING To avoid personal injury due to sudden uncontrolled movement of parts do not loosen yoke screws and do not remove the parts of the stem connector when the stem connector has spring force applied to it Instruction Manual 3025 Actuator D251402X012 May 2011 Figure 2 Side Mounted Handwheel 3 Remove the stem connector cap screws key 87 the anti rotator key 78 the spacer if used key 86 and the travel scale indicator key 85 For the sizes P460 P462 and P460 200 loosen stem connector halves cap screws and nuts keys 80 and 81 and unscrew the connector halves For the size P900 unscrew the stem connector locknuts keys 82 and 83 and then the connector halves 4 To separate the actuator from the valve body remove the yoke locknut or the bolts and then lift off the actuator 5 For the sizes P460 P462 and P900 remove t
19. Instruction Manual 3025 Actuator D251402X012 May 2011 Fisher 3025 Sizes P460 P462 P460 200 and P900 Diaphragm Actuator Contents Figure 1 Fisher 3025 Size P460 200 Actuator 1 Scope of Manual EE 1 2 Specifications 2 2 Mounting the Actuator onthe Valve 3 Travel Stop Adjustment 4 Installing the Stem Connector Assembly 5 Loading Connection 6 Maintenance 6 Actuator Maintenance 6 Size P460 Actuator 7 Size P462 Actuator g Size P460 200 Actuator 12 Size P900 Actuator 14 Side Mounted Handwheel Maintenance 18 Parte 956 EE 2 Parts LISE EE 22 Actuator Assembly 22 Side Mounted 23 Introduction Scope of Manual This instruction manual includes installation maintenance and parts information for Fisher 3025 actuators in sizes P460 P462 P460 200 and P900 Refer to separate manuals for instructions covering the positioner and other accessories used with these actuators Do not install operate or maintain 3025 actuators without being fully trained and qualified in valve ac
20. N E ER 71 CO guum 22 LL mA KA E E E 1222 2 2 S ill Eu E HH lt TTT a zi 200 22 25 48000606 27 ugs 22 222 2 22 22 Instruction Manual D251402X012 Figure 5 Fisher 3025 Size P462 Air to Open Actuator C APPLY LUBRICANT Instruction Manual 3025 Actuator May 2011 D251402X012 Figure 6 Fisher 3025 Size P462 Air to Close Actuator Leg Lg HS 78 MH ee eee GENE ee i SE ae i We SNR Ls SH eg TE oa Z EH Cip AO L Y m EN NON 1 yy al 110277 a 8 nix EC Voy a vm A e em pu 2 924009 T up C APPLY LUBRICANT 28 3025 Actuator Instruction Manual D251402X012 May 2011 Figure 7 Fisher 3025 Size P460 200 Air to Open Actuator 9909 900808 000 9 9 0 7
21. all and screw alternately and slowly the three cap screws to compress the springs 21 Place the retaining ring key 59 onto the stem Install the ring key 61 and slide the retaining ring and bend it on the ring 22 Place the gasket key 72 and the flange key 34 Insert the cap screws key 34 and tighten them 23 Place the diaphragm casing key 2 so that the vent connection is diametrically opposed to the air connection of the diaphragm casing key 1 next to Install the lock washers key 23 and the cap screws key 22 and tighten them 24 Apply anti seize lubricant key 202 to the internal thread of the two nut halves key 10 Install the nut halves and the retaining ring key 11 Slide the lock washer key 50 the diaphragm plate key 27 the diaphragm key 48 the O ring key 20 the washer key 55 the retaining ring key 11 25 Coatthe internal thread of the two nut halves key 10 with anti seize lubricant key 202 and tighten them until the lock washer is completely compressed 26 Place the diaphragm casing key 1 so that the vent and air connection are diametrically opposed Take care when sliding the diaphragm casing around the stem so that the threads do not damage the bushing O ring or wiper ring Note When you replace actuator diaphragms in the field take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage but not crush the material Perform the following sequen
22. 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 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 Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore 4 4 RW www Fshercom EMERSON Fisher Controls International LLC 2004 201 1 All Rights Reserved
23. bellows keys 134 135 and 133 19 Install the travel indicator key 113 by tightening the cap screw or nuts 20 Lift the actuator and handwheel assembly and place it onto the yoke For the sizes P460 P462 and P900 insert the cap screws key 122 For the size P460 200 insert the cap screws and nuts keys 122 and 132 Then tighten them 21 Mount the actuator and handwheel assembly in accordance with the procedures in the Installation section Parts Ordering Each actuator has a serial number stamped on the nameplate Always mention this number when corresponding with your Emerson Process Management sales office regarding technical information or replacement parts Also reference the complete part number of each part needed as part as found in the following Parts List 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 Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user 21 3025 Actuator 2011 Parts List Note Part numbers are show
24. cator It may be necessary to take off the protective covers key 119 by removing the cap screws and washers keys 120 and 128 Once adjusted replace the protective covers washers and tighten the screws Loading Connection The loading pressure connections are made at the factory if the valve actuator and positioner come as a unit Keep the length of tubing or piping as short as possible to avoid transmission lag in the control signal If a volume booster valve positioner or other accessory is used be sure that it is properly connected to the actuator Refer to the positioner instruction manual or other manuals as necessary For actuators shipped separately or whenever the actuator pressure connections are installed use the following steps 1 Connect the loading pressure piping to the NPT internal connection at the side of the diaphragm casing 2 Cycle the actuator several times to be sure that the valve stem travel is correct when the correct pressure ranges are applied to the diaphragm 3 If valve stem travel appears to be incorrect refer to the travel stop adjustment procedures at the beginning of this section Do not place the valve in service if it is not reacting correctly to diaphragm loading pressure changes Maintenance Actuator parts are subject to normal wear and must be inspected and replaced when necessary The frequency of inspection and replacement depends on the severity of service conditions WARNING Avoid
25. ce with a manual torque wrench CAUTION Over tightening the diaphragm cap screws and nuts keys 45 and 46 can damage the diaphragm Do not exceed 16 Nem 12 Ibf ft torque Note Do not use lubricant on these bolts and nuts Fasteners must be clean and dry 3025 Actuator Instruction Manual May 2011 0251402 012 27 Align the diaphragm casings and diaphragm holes Be sure the vent and air connection on the diaphragm casings are still diametrically opposed Install the cap screws and nuts keys 45 and 46 Tighten the diaphragm cap screws and nuts in the following manner 28 The first four bolts tightened should be diametrically opposed and 90 degrees apart Tighten these four bolts to 8 Nem 6 Ibfeft 29 Tighten the remaining bolts in a clockwise crisscross pattern to 8 Nem 6 Ibfeft 30 Repeat this procedure by tightening four bolts diametrically opposed and 90 degrees apart to a torque of 16 Nem 12 Ibfeft 31 Tighten the remaining bolts in a clockwise crisscross pattern to 16 Nem 12 Ibfeft 32 After the last bolt is tightened to 16 Nem 12 Ibfeft all of the bolts should be tightened again to 16 Nem 12 Ibfeft in a circular pattern around the bolt circle 33 Once completed no more tightening is recommended 34 Place the gasket 71 and the lifting lug cap 40 onto one of the diaphragm casings according to the actuator action air to close key 1 air to open key 3 Insert the cap screws key 44 and tighten t
26. e Mounted Handwheel 8 898 88888686 I Dees 22 RE AEN y j 4 j d d 3 d 3 i 7 i 02 C APPLY LUBRICANT 36 3025 Actuator Instruction Manual D251402X012 May 2011 Figure 15 Fisher 3025 Size P460 200 Side Mounted Handwheel 8888 6666 P 8 e 998899 j 888808 C APPLY LUBRICANT 37 3025 Actuator Instruction Manual May 2011 0251402 012 Figure 16 Fisher Driving Shaft Assembly for all Side Mounted Handwheel Sizes DOO e 69 69 a phe ER E ex PR gt m SN SOLD Ecc c os C APPLY LUBRICANT 38 Instruction Manual D251402X012 3025 Actuator May 2011 39 3025 Actuator Instruction Manual May 2011 D251402X012 Fisher is a mark owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks
27. e following sequence with a manual torque wrench CAUTION Over tightening the diaphragm cap screws and nuts keys 45 and 46 can damage the diaphragm Do not exceed 16 Nem 12 Ibf ft torque Note Do not use lubricant on these bolts and nuts Fasteners must be clean and dry 11 Align the diaphragm casings and diaphragm holes Be sure the vent and air connection on the diaphragm casings are still diametrically opposed Install the cap screws and nuts keys 45 and 46 Tighten the diaphragm cap screws and nuts in the following manner 12 The first four bolts tightened should be diametrically opposed and 90 degrees apart Tighten these four bolts to 8 Nem 6 Ibfeft 13 Tighten the remaining bolts in a clockwise crisscross pattern to 8 Nem 6 Ibfeft 14 Repeatthis procedure by tightening four bolts diametrically opposed and 90 degrees apart to a torque of 16 Nem 12 Ibfeft 15 Tighten the remaining bolts in a clockwise crisscross pattern to 16 Nem 12 Ibfeft 16 After the last bolt is tightened to 16 Nem 12 Ibfeft all of the bolts should be tightened again to 16 Nem 12 Ibfeft in a circular pattern around the bolt circle 17 Once completed no more tightening is recommended 18 Coatthe thread of the four cap screws key 32 and the internal threads of the diaphragm casing key 3 with anti seize lubricant key 202 Be sure that the cap screw beds into the spring seat are still aligned with the internal threads of the d
28. g the diaphragm cap screws and nuts keys 45 and 46 can damage the diaphragm Do not exceed 16 Nem 12 Ibf ft torque Note Do not use lubricant on these bolts and nuts Fasteners must be clean and dry Instruction Manual 3025 Actuator D251402X012 May 2011 13 Align the diaphragm casings and diaphragm holes Be sure the vent and air connection on the diaphragm casings are still diametrically opposed Install the cap screws and nuts keys 45 and 46 Tighten the diaphragm cap screws and nuts in the following manner 14 The first four bolts tightened should be diametrically opposed and 90 degrees apart Tighten these four bolts to 8 Nem 6 Ibfeft 15 Tighten the remaining bolts in a clockwise crisscross pattern to 8 Nem 6 16 Repeat this procedure by tightening four bolts diametrically opposed and 90 degrees apart to a torque of 16 Nem 12 Ibfeft 17 Tighten the remaining bolts a clockwise crisscross pattern to 16 Nem 12 Ibfeft 18 After the last bolt is tightened to 16 Nem 12 Ibfeft all of the bolts should be tightened again to 16 Nem 12 Ibfeft in a circular pattern around the bolt circle 19 Once completed no more tightening is recommended 20 Coat the thread of three cap screws key 32 and the internal threads of the diaphragm casing key 3 with anti seize lubricant key 202 Be sure that the cap crew beds into the spring seat are still aligned with the internal threads of the diaphragm casing Then inst
29. he cap screws key 122 For the size P460 200 remove the bolts keys 122 and 132 Then lift the actuator and handwheel assembly off the yoke 6 Unscrew the protective cover cap screws key 120 remove the washers key 128 and the protective covers key 119 7 Remove the stem connector cap screws key 125 or 137 For the sizes P460 and P462 loosen the stem connector screws and nuts keys 130 and 131 and unscrew the connector half For the sizes P900 and P460 200 unscrew the stem connector locknut key 136 and then the connector half key 124 8 Remove the cap screws key 77 then lift the actuator off the handwheel Note To disassemble the actuator refer to the Actuator Disassembly procedures in the Actuator Maintenance section from step 8 Following steps describe only how the side mounted handwheel can be completely disassembled 9 Remove the travel scale indicator key 113 by loosening the cap screw that maintain it or for the size P460 200 by unscrewing the two nuts key 129 10 Forthe size P460 200 remove the two bellows keys 133 134 and 135 11 Turn clockwise the handwheel to unscrew the upper threaded shaft key 111 12 Remove the lower threaded shaft and shaft connector assembly keys 109 and 110 Remove the upper threaded shaft and bridge keys 111 and 112 For the size P460 200 if required disassemble the upper threaded shaft by removing the pin key 127 and unscrewing the bridge key 112 1
30. hem 35 If removed place the travel stop and the lock nut keys 41 and 42 into the lifting lug cap 36 If the actuator is equipped with a side mounted handwheel it is necessary to adjust the actuator travel stop before mounting the actuator onto the side mounted handwheel Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section Then refer to the Side Mounted Handwheel Assembly procedures in the Side Mounted Handwheel Maintenance section to complete the actuator assembly from step 9 37 Lift the actuator and place it onto the yoke Insert the cap screws key 77 and tighten them 38 If removed screw the vents key 49 into the diaphragm casings keys 2 and 3 39 Mount the actuator onto the valve in accordance with the procedures in the Installation section Side Mounted Handwheel Maintenance Instructions are given below for complete disassembly and assembly of a side mounted handwheel Perform the disassembly only as far as necessary to accomplish the required maintenance then begin the assembly at the appropriate step If it is only necessary to separate the actuator from the side mounted handwheel perform the eight first steps of the following Side Mounted Handwheel Disassembly procedure Then to mount the actuator on the side mounted handwheel begin at the step 9 of the Side Mounted Handwheel Assembly procedure Key numbers refer to figures 13 14 15 and 16 unless otherwise indicated
31. iameter of that stem Damage to threads on either stem or in the stem connector can cause the parts to be replaced prematurely 6 Perform one of the following procedures as appropriate a For an air to open actuator Slowly decrease the diaphragm pressure and line up the stem connector halves b For an air to close actuator Slowly increase the diaphragm pressure and line up the stem connector halves 7 Install the cap screws key 87 with the lock washers if used and tighten them 8 For sizes P460 P462 and P460 200 install the cap screws key 80 and the nuts key 81 and tighten them For the size P900 screw the valve and actuator stem locknuts against the stem connector halves 9 Slowly increase and decrease pressure several times stroking the valve from the lower bench set pressure to the upper pressure 10 Adjust the travel indicator scale key 74 to correspond with the travel indicator Stroke the valve full travel to ensure that the travel matches the valve travel on the travel indicator plate If travel is not correct repeat the stem connector procedure 3025 Actuator Instruction Manual May 2011 0251402 012 11 If the actuator is equipped with a side mounted handwheel insert the screw key 139 and the nut key 140 into the stem connector half key 78 Then screw the nut against the stem connector half Adjust the handwheel travel indicator key 113 to correspond with the screw key 139 used as neutral position indi
32. iaphragm casing Then install and screw alternately and slowly the four cap screws to compress the spring 19 Place the retaining ring key 59 onto the stem Install the ring key 61 and slide the retaining ring and bend it on the ring 20 Place the gasket key 72 and the flange key 34 Insert the cap screws key 36 and tighten them 21 If used screw travel stop on the stem keys 66 22 Place the spacer if used key 67 the gasket key 71 and the lifting lug cap key 40 onto one of the diaphragm casings according to the actuator action air to close key 1 air to open key 3 Insert the cap screws key 44 and tighten them 23 If removed place the travel stop key 41 into the lifting lug cap 24 If the actuator is equipped with side mounted handwheel it is necessary to adjust the actuator travel stop before mounting the actuator onto the side mounted handwheel Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section Then refer to the Side Mounted Handwheel Assembly 3025 Actuator Instruction Manual May 2011 0251402 012 procedures in the Side Mounted Handwheel Maintenance section to complete the actuator assembly from step 9 25 Lift the actuator and place it onto the yoke Insert the cap screws key 77 and tighten them 26 If removed screw the vent key 49 into the diaphragm casing key 3 27 Mount the actuator onto the valve in accordance with the procedures in the I
33. ing key 1 Take care when pushing the actuator stem through the diaphragm casing so that the threads do not damage the bushing O ring or wiper ring 9 Place the actuator springs key 30 and 31 10 Install the diaphragm casing key 3 so that the vent and air connection are diametrically opposed Take care when lowering the casing around the stem so that the thread do not damage the bushing Apply lithium grease to the washer key 53 and place it 11 Apply anti seize lubricant key 202 on the nut internal thread key 16 and screw it slowly to compress the springs Note When you replace actuator diaphragms in the field take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage but not crush the material Perform the following sequence with a manual torque wrench CAUTION Over tightening the diaphragm cap screws and nuts keys 45 and 46 can damage the diaphragm Do not exceed 16 Nem 12 Ibf ft torque Note Do not use lubricant on these bolts and nuts Fasteners must be clean and dry 3025 Actuator Instruction Manual May 2011 0251402 012 12 Align the diaphragm casings and diaphragm holes Be sure the vent and air connection on the diaphragm casings are still diametrically opposed Install the cap screws and nuts keys 45 and 46 Tighten the diaphragm cap screws and nuts in the following manner 13 The first four bolts tightened should be diametrically opposed and 90 degrees apart
34. is shipped separately or the actuator has been removed from the valve it is necessary to mount the actuator on the valve before placing the valve in the pipeline Refer to the actuator mounting procedures before placing the valve in service Positioner If a positioner is installed or is to be installed on the actuator refer to the positioner instruction manual for installation During the adjustment procedures it will be necessary to provide a temporary loading pressure to the actuator diaphragm CAUTION The 3025 diaphragm actuators are designed to mount on push down to close valves Do not mount these actuators on any other type of valve without first contacting your Emerson Process Management sales office Mounting the Actuator on the Valve CAUTION If the valve stem is allowed to remain in the up position towards the actuator during mounting it can interfere with the actuator mounting possibly damage valve stem threads or bend the valve stem Be sure the valve stem is pushed down into the valve body away from the actuator while mounting CAUTION If the actuator is equipped with a side mounted handwheel during mounting it can interfere with the valve stem even if the valve stem is pushed completely down into the valve body possibly damage valve stem threads or bend the valve stem Be sure the actuator stem is sufficiently retracted into the side mounted handwheel away from the valve while mounting If not the actuator
35. ize P460 figure 5 and 6 the size P462 figure 7 and 8 the size P460 200 and figures 9 through 12 illustrate the size P900 It may be necessary to apply a temporary loading pressure to the actuator during the disassembly Size P460 Actuator Size P460 Actuator Disassembly 1 Bypass the control valve Reduce the loading pressure to atmospheric and remove the tubing or piping from the diaphragm casing key 1 2 If the actuator is equipped with a side mounted handwheel refer to the Side Mounted Handwheel Disassembly procedures in the Side Mounted Handwheel Maintenance section to separate the actuator and handwheel steps 2 to 7 Then continue the Size P460 Actuator Disassembly procedure from the step 8 For an air to open actuator only slightly pressurize the actuator diaphragm until movement of the actuator stem is detected and the spring force applied to the stem connector is relieved WARNING To avoid personal injury due to sudden uncontrolled movement of parts do not loosen yoke locknut screws and do not remove parts of the stem connector when the stem connector has spring force applied to it UJ Remove the stem connector cap screws key 87 the anti rotator key 85 the spacer if used key 86 and the travel scale indicator key 84 Loosen the stem connector halves cap screws and nuts keys 80 and 81 Remove the stem connector halves 4 For an air to open actuator only slowly exhaust the diaphragm pre
36. l 3025 Actuator D251402X012 May 2011 6 To separate the actuator from the valve body remove the yoke locknut or the bolts and then lift off the actuator 7 Remove the yoke to actuator cap screws key 77 then lift the actuator off the yoke 8 Remove the lifting lug cap screws key 44 the lifting lug key 40 and the gasket key 71 If required loosen the locknut key 42 and remove the travel stop key 41 9 Unscrew the cap screws key 35 and remove the flange key 34 and gasket key 72 10 Unbend the ring retaining key 59 and slide towards the casing Remove the 2 ring halves key 61 and then the ring retaining WARNING avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator relieve the spring compression step 11 below and carefully remove casing cap screws and nuts keys 45 and 46 steps 12 and 16 below 11 Relieve the spring compression by unscrewing alternately and slowly the three cap screws key 32 Note The size P900 is a double stacked diaphragm casings actuator First disassemble the stack composed of two short diaphragm casings keys 1 and 2 Then disassemble the stack made of one short and one long diaphragm casings keys 1 and 3 12 Remove all the cap screws and nuts keys 45 and 46 of the short diaphragm casings assembly keys 1 and 2 If required remove the vent key 49 13 Lift off the diaphragm casing key 1 14 Unscrew
37. n for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Actuator Assembly figures 3 through 12 Key Description Lower Diaphragm Casing Upper Diaphragm Casing Upper Diaphragm Casing Wiper Ring Size P460 Size P462 Size P460 200 Size P900 5 Seal Retainer 6 O Ring Size P460 Size P462 Size P460 200 Size P900 7 Bushing 8 Retaining Ring 9 Stem 10 Nut 2 parts 11 Retaining Ring 12 Spring Wave Washer 13 Tab Washer 14 Travel Stop LO 15 Travel Stop 16 Nut 17 Ring 18 Hex Socket Cap Screw 19 Spring Lock Washer 20 O Ring Size P900 21 Hex Socket Cap Screw 22 Hex Socket Cap Screw 23 Spring Lock Washer 24 Back Up Plate 25 Hex Head Cap Screw 26 Diaphragm Plate 27 Diaphragm Plate 28 Groove Pin 29 Spring Seat 30 Spring 31 Spring 32 Hex Head Cap Screw ER Bushing 34 Flange 35 Hex Head Cap Screw 36 Hex Socket Cap Screw 39 Disc 22 Part Number 1269208 0161080 1234722 1230174 1269224 1269666 0156922 1230212 0277711 See following table See following table Key 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 56 57 58 99 60 61 62 64 65 66 67 68 69 70 72 Instruction Manual D251402X012 Description Part Number Lifting Lug Cap Hex Head Cap Screw Jam Hex Nut Cap Size P460 and P462 0296759 Hex Head Cap Screw Hex Head Cap Screw Hex Nut Diaphragm Size P460 0161420 Size P462 1269
38. nstallation section Size P460 200 Actuator Size P460 200 Actuator Disassembly 1 Bypass the control valve Reduce the loading pressure to atmospheric and remove the tubing or piping from the diaphragm casing key 1 2 If the actuator is equipped with a side mounted handwheel refer to the Side Mounted Handwheel Disassembly procedures in the Side Mounted Handwheel Maintenance section to separate the actuator and handwheel steps 2 to 7 Then continue the Size P460 200 Actuator Disassembly procedure from the step 8 UJ Foran air to open actuator only slightly pressurize the actuator diaphragm until movement of the actuator stem is detected The spring force applied to the stem connector is relieved WARNING To avoid personal injury due to sudden uncontrolled movement of parts do not loosen yoke screws do not remove the parts of the stem connector when the stem connector has spring force applied to it 4 Remove the stem connector screws key 87 the anti rotator key 85 the spacer if used key 86 and the travel scale indicator key 84 Loosen the stem connector halves cap screws and nuts keys 80 and 81 Remove the stem connector halves For an air to open actuator only slowly exhaust the diaphragm pressure To separate the actuator from the valve body remove the yoke locknut or the bolts and then lift off the actuator Remove the yoke cap screws key 77 then lift the act
39. personal injury or property damage from sudden release of process pressure or bursting of parts Before performing any maintenance operations Donot remove the actuator from the valve while the valve is still pressurized 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 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 Vent the power actuator loading pressure and relieve any actuator spring precompression Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment When performing maintenance procedures isolate the control valve from the process line pressure from both sides of the valve Use the lock out procedures to be sure that the above measures stay in effect while you are working on the actuator Actuator Maintenance This procedure describes how the actuator can be completely disassembled and assembled When inspection or repairs are required disassemble only those parts necessary to accomplish the job then start the assembly at the appropriate step Instruction Manual 3025 Actuator D251402X012 May 2011 Key numbers refer to figures 3 through 12 unless otherwise indicated Figure 3 and 4 show the s
40. ppage part key 121 into the two holes Rotate the connector half so that the distance between the bridge and the connector half is equal to the valve travel Be sure that the actuator stem threads are engaging the threads of the stem connector by the distance of at least one diameter of the stem Then slowly decrease the diaphragm pressure until the connector half is contacting the bridge and line up the stem connector half b For an air to close actuator position the bridge key 112 at the upper location and wedge it by inserting the stoppage part key 121 into the two holes Rotate the connector half so that it is contacting the bridge and line it up 14 Install the cap screws key 125 or 137 and tighten them 15 Forthe sizes P460 and P462 install the cap screw and nut key 130 and 131 and tighten them For the sizes P900 and P460 200 screw the actuator stem locknut against the stem connector half 16 Foran air to open actuator only slightly pressurize the actuator diaphragm until movement of actuator stem is detected WARNING avoid personal injury due to sudden uncontrolled movement of parts do not remove the stoppage part of the bridge when the connector has spring force applied to it 17 Remove the stoppage part from the bridge and install it into the protective cover for the sizes P460 P462 and P900 or into the top holes of the handwheel yoke for the size P460 200 18 For the size P460 200 only Place the two
41. ssure To separate the actuator from the valve body remove the yoke locknut or the bolts and then lift off the actuator Remove the yoke cap screws key 77 and then lift the actuator off the yoke Remove the lifting lug cap screws key 44 the lifting lug key 40 and the gasket key 71 If required remove the cap key 43 and the travel stop key 41 WARNING avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator carefully remove casing cap screws and nuts keys 45 and 46 step 9 below and then relieve the spring compression by unscrewing the nut key 16 step 11 below CON O 9 Remove all the diaphragm casing cap screws and nuts keys 45 and 46 If required remove the vent key 49 10 Remove the set screws key 57 and if used the travel stop and locknut keys 65 and 66 11 Relieve the spring compression by unscrewing slowly the nut key 16 12 Remove the washer key 53 then lift off the diaphragm casing key 3 13 Remove the actuator springs keys 30 and 31 14 Lift off the stem and diaphragm plate assembly 15 Unscrew the travel stop key 54 remove ring key 17 the wave washers key 12 the tube key 51 the diaphragm plate key 26 the diaphragm key 47 the O ring key 6 the washers if used key 64 and the travel stop key 14 Unbend the tab washer key 13 remove the retaining ring key 11 and the two nut halves key 10
42. stem can be retracted by turning counterclockwise the handwheel Be sure the actuator stem does not rotate while turning the handwheel use the anti rotator to prevent rotation 1 Provide a vise or some other method of supporting the valve and the weight of the actuator during assembly Push the valve stem down away from the actuator while mounting the actuator 3025 Actuator Instruction Manual May 2011 0251402 012 2 Lift or hoist the actuator onto the valve bonnet a For the 3 9 16 yoke boss Slowly lower the actuator down onto the valve As the yoke passes over the end of the valve stem place the yoke locknut over the valve stem Once the actuator is in place screw the yoke locknut onto the valve bonnet and tighten the locknut b Forall other yoke bosses Slowly lower the actuator down onto the valve Once the actuator is in place insert the cap screws and tighten the hex nuts securing the actuator to the bonnet Travel Stop Adjustment The actuator is normally shipped adjusted at the factory and you may refer directly to the Installing the Stem Connector Assembly procedures If the actuator has been disassembled it is necessary to adjust the travel stop You may perform the following procedure before connecting the actuator stem to the valve stem WARNING When moving the actuator stem with loading pressure applied exercise caution to keep hands tools out of the actuator stem travel path If the loading pressure
43. sure The actuator should show movement at the lower bench set pressure Adjust the travel stop key 41 so that it touches the actuator stem Then lock the travel stop by replacing the cap key 43 or tightening the locknut key 42 4 Stroke the actuator and check that the actuator is capable of the travel shown on the travel indicator scale key 74 If the travel span is correct travel stop adjustment is complete Proceed to the Installing the Stem Connector Assembly subsection Instruction Manual 3025 Actuator D251402X012 May 2011 5 If the travel span is not correct a wrong or damaged spring has been installed in the actuator To obtain the correct spring sizing information refer to Fisher Catalog 14 Actuator Sizing and Sample Calculations to determine the correct spring selection for your application Or contact your Emerson Process Management sales office for assistance After replacing the spring repeat the steps above Installing the Stem Connector Assembly When installing the stem connector assembly the actuator and valve stem threads should engage the threads of the stem connector by a distance of the diameter of the stem 1 If necessary push the valve stem down so that it is touching the seat ring 2 For an air to open actuator only set the diaphragm loading pressure to approximately 0 5 bar over the upper bench set pressure The actuator stem should be contacting the upper travel stop 3 For the size P900 only scre
44. t the threads of the stem key 9 with anti seize lubricant key 202 5 Place the two ring halves key 61 and the retaining ring key 60 Slide the travel stop key 14 the O ring key 6 the diaphragm key 47 the diaphragm plate key 26 the tube key 51 the wave washers key 12 and the retaining ring key 11 6 Coat the internal thread of the 2 nut halves key 10 with anti seize lubricant key 202 and tighten them until the wave washers are completely compressed 7 Slide the travel stop key 52 and tighten the set screw key 57 8 Place this stem assembly into the diaphragm casing key 1 Take care when pushing the actuator stem through the diaphragm casing so that the threads do not damage the bushing O ring or wiper ring 9 Place the actuator spring key 30 Apply anti seize lubricant key 202 into the four cap screw beds of the spring seat Place the spring seat key 29 so that the cap screw beds will be aligned with the internal threads of the diaphragm casing key 3 Instruction Manual 3025 Actuator D251402X012 May 2011 10 Install the diaphragm casing key 3 so that the vent and air connection are diametrically opposed Take care when lowering the casing around the stem so that the threads do not damage the bushing Note When you replace actuator diaphragms in the field take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage but not crush the material Perform th
45. the nut key 10 Remove the ring retaining key 11 the washer key 55 the O ring key 20 the diaphragm key 48 the diaphragm plate key 27 the lock washer key 50 the ring retaining key 11 and the two nut halves key 10 15 Remove the cap screws the washers keys 22 and 23 and the diaphragm casing key 2 16 Remove all the cap screws and nuts keys 45 and 46 of the long diaphragm casings assembly keys 1 and 3 If required remove the vent key 49 17 Lift off the diaphragm casing key 3 18 Remove the spring seat with the discs keys 29 and 39 and actuator spring key 30 19 Lift off the stem and diaphragm plate assembly 20 Unscrew the set screw key 57 and remove the travel stop key 52 Loosen the nut key 10 Remove the ring retaining key 11 the wave washer key 50 the tube if used key 51 the diaphragm plate and diaphragm assembly keys 24 25 26 and 47 the O ring key 6 the travel stop assembly keys 14 15 18 and 19 the retaining key 11 and the two nut halves key 10 21 Unscrew the cap screws key 25 disassemble the ring key 24 the diaphragm key 47 and the diaphragm plate key 26 22 If required remove the cap screws key 18 lock washers key 19 and disassemble the travel stop keys 14 and 15 23 Unscrew the cap screws key 21 remove the wiper ring and the seal retainer keys 4 and 5 and the O ring key 6 24 If required remove the casing bushings keys 7 and 33
46. tion Manual D251402X012 S 9 999909980009998 0900906099996 1 A N LJ N N 2 2 23 AU LEIDI A e BW N VAI WAP esse S TT d 27 027 CN x A N S N MNA m VEEE Sn nln 172 Se 5 Ex NA pg VL 22 4 Le C APPLY LUBRICANT 25 Instruction Manual 3025 Actuator May 2011 D251402X012 Figure 4 Fisher 3025 Size P460 Air to Close Actuator AAT ANEN arni af ar alan ar ar F m 21248 GEM de s BN ia ij b E NN x aa E S e C SAAE TNN a T ES A d 26 LL n eR pep A 1 GEN ZS KZ E H v TI Ad AI KE L NN D tir Se N ae S p ER C CH S 51 1 4 eg S ur a rA ad VE E EE E o S IR 9 9 9G 0G C APPLY LUBRICANT 26 3025 Actuator 2011 27 C4 e C 3 _ 50000666 PENSE E E mm ON ONES E
47. tor travel stop before mounting the actuator onto the side mounted handwheel Perform the Travel Stop Adjustment in accordance with the procedures in the Installation section Then refer to the Side Mounted Handwheel Assembly procedures in the Side Mounted Handwheel Maintenance section to complete the actuator assembly from step 9 24 Lift the actuator and place it onto the yoke Insert the cap screws key 77 and tighten them 25 If removed screw the vent key 49 into the diaphragm casing key 3 26 Mount the actuator onto the valve in accordance with the procedures in the Installation section Size P462 Actuator Size P462 Actuator Disassembly 1 Bypass the control valve Reduce the loading pressure to atmospheric and remove the tubing or piping from the diaphragm casing key 1 2 If the actuator is equipped with a side mounted handwheel refer to the Side Mounted Handwheel Disassembly procedures in the Side Mounted Handwheel Maintenance section to separate the actuator and handwheel steps 2 to 7 Then continue the Size P462 Actuator Disassembly procedure from the step 8 3 For an air to open actuator only slightly pressurize the actuator diaphragm until movement of the actuator stem is detected The spring force applied to the stem connector is relieved WARNING To avoid personal injury due to sudden uncontrolled movement of parts do not loosen yoke cap screws and do not remove parts of the stem connec
48. tor when the stem connector has spring force applied to it 4 Remove the stem connector cap screws key 87 the anti rotator key 85 the spacer if used key 86 and the travel scale indicator key 84 Loosen the stem connector halves cap screws and nuts keys 80 and 81 Remove the stem connector halves 5 For an air to open actuator only slowly exhaust the diaphragm pressure 6 To separate the actuator from the valve body remove the yoke locknut or the bolts and then lift off the actuator 3025 Actuator Instruction Manual May 2011 0251402 012 7 Remove the yoke screws key 77 then lift the actuator off the yoke 8 Remove the lifting lug cap screws key 44 the lifting lug key 40 the gasket key 71 and the spacer if used key 67 If required remove the cap key 43 and the travel stop key 41 9 Unscrew the cap screws key 36 and remove the flange key 34 and gasket key 72 10 Unbend the ring retaining key 59 and slide towards the casing Remove the 2 ring halves key 61 and then the ring retaining WARNING avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator relieve the spring compression step 11 below and carefully remove casing cap screws and nuts keys 45 and 46 step 12 below 11 Relieve the spring compression by unscrewing alternately and slowly the four cap screws key 32 12 Remove all the diaphragm casing cap screws and
49. travel stop assembly keys 14 15 18 and 19 the O ring key 6 the diaphragm plate assembly keys 24 25 26 and 47 the tube if used key 51 the lock washer key 50 and the ring key 11 8 Coat the internal thread of the two nut halves key 10 with anti seize lubricant key 202 and tighten them until the lock washer is completely compressed 9 Slide the travel stop key 52 and tighten the set screws key 57 10 Place this stem assembly into the diaphragm casing key 1 Take care when pushing the actuator stem through the diaphragm casing so that the threads do not damage the bushing O ring or wiper ring 11 Install the actuator springs key 30 and 31 Apply anti seize lubricant key 202 into the three cap screw beds of the spring seat Coat the disc key 39 with anti seize lubricant key 202 Install the discs into the spring seat and place the spring seat so that the cap screw beds will be aligned with the internal threads of the diaphragm casing key 3 12 Install the diaphragm casing key 3 so that the vent and air connection are diametrically opposed Take care when lowering the casing around the stem so that the threads do not damage the bushing Note When you replace actuator diaphragms in the field take care to ensure the diaphragm casing bolts are tightened to the proper load to prevent leakage but not crush the material Perform the following sequence with a manual torque wrench CAUTION Over tightenin
50. tuator 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 A DM www Fisher com Process Management 3025 Actuator Instruction Manual May 2011 0251402 012 Description The Fisher 3025 size P460 P462 P460 200 and P900 spring opposed diaphragm actuators position the valve plug in the valve body in response to varying controller or valve positioner pneumatic output signals applied to the actuator diaphragm They can be specified either direct air to close or reverse acting air to open The size P460 offers 65 mm maximum actuator travel The sizes P462 and P900 provide 120 mm maximum actuator travel The size P460 200 offers 203 mm maximum actuator travel The 3025 actuator can be equipped with a side mounted assembly It is usually used as an auxiliary manual actuator Table 1 Specifications ACTUATOR SIZE SPECIFICATION P460 2462 460 200 1800 1800 Nominal Effective Area 5 3 IL Yoke Boss Diameter 7mm IA lh ll Rom 5x J ln O Ill 3 4 16UNF ee ee 222 1 14UNS Acceptable Valve Stem Connection
51. tuator and place it onto the yoke Insert the cap screws key 77 and tighten them 25 If removed screw the vent key 49 into the diaphragm casing key 3 26 Mount the actuator onto the valve in accordance with the procedures in the Installation section Size P900 Actuator Size P900 Actuator Disassembly 1 Bypass the control valve Reduce the loading pressure to atmospheric and remove the tubing or piping from the diaphragm casings key 1 2 If the actuator is equipped with a side mounted handwheel refer to the Side Mounted Handwheel Disassembly procedures in the Side Mounted Handwheel Maintenance section to separate the actuator and handwheel steps 2 to 7 Then continue the Size P900 Actuator Disassembly procedure from the step 8 3 Foran air to open actuator only slightly pressurize the actuator diaphragm until movement of the actuator stem is detected The spring force applied to the stem connector is relieved WARNING To avoid personal injury due to sudden uncontrolled movement of parts do not loosen yoke screws do not remove the parts of the stem connector when the stem connector has spring force applied to it 4 Remove the stem connector cap screws key 87 the anti rotator key 85 and the spacer if used key 86 Loosen the stem connector halves locknuts keys 82 and 83 Remove the stem connector halves 5 For an air to open actuator only slowly exhaust the diaphragm pressure Instruction Manua
52. uator off the yoke CON On Ul Remove the bellows key 68 Remove the lifting lug cap screws key 44 the lifting lug key 40 and the gasket key 71 If required loosen the locknut key 42 and remove the travel stop key 41 A WARNING To avoid personal injury from the precompressed spring force thrusting the diaphragm casing away from the actuator carefully remove casing cap screws and nuts keys 45 and 46 step 9 below and then relieve the spring compression by unscrewing the nut key 16 step 11 below 9 Remove all the diaphragm casing cap screws and nuts keys 45 and 46 If required remove the vent key 49 10 Unscrew the locknut key 62 11 Relieve the spring compression by unscrewing slowly the nut key 16 12 Remove the washer key 53 then lift off the diaphragm casing key 3 13 Remove the actuator springs keys 30 and 31 14 Lift off the stem and diaphragm plate assembly 15 Unscrew the travel stop key 54 remove the wave washers key 12 the tube key 51 the O ring key 6 the diaphragm and diaphragm plate assembly keys 24 25 26 and 47 Remove the retaining ring key 11 and the two nut halves key 10 12 Instruction Manual 3025 Actuator D251402X012 May 2011 16 Unscrew the cap screws key 25 disassemble the ring key 24 the diaphragm key 47 and the diaphragm plate key 26 17 Unscrew the cap screws key 70 remove the wiper ring and the seal retainer key 4 and 5 and the O
53. w the actuator and valve stem locknuts away from the connector halves locations 4 Screw the two stem connectors halves keys 78 and 79 onto the valve stem and actuator stem Then place the travel indicator key 84 the spacer if used key 86 and the anti rotator key 85 on the valve stem connector half 5 To adjust the travel perform one of the following procedures as appropriate a If the actuator is equipped with a side mounted handwheel turn the handwheel so that the distance between the anti rotator and the actuator stem connector half is equal to the valve travel Be sure the actuator stem does not rotate while turning the handwheel use the anti rotator to prevent rotation Be sure that the actuator and valve stem threads are engaging the threads of the stem connectors by the distance of at least one diameter of the stem b If the actuator is not equipped with a side mounted handwheel rotate the connector halves so that the distance between the anti rotator and the actuator stem connector half is equal to the valve travel Be sure that the actuator and valve stem threads are engaging the threads of the stem connectors by the distance of at least one diameter of the stem CAUTION Incomplete engagement of the stem connector onto either the valve stem or actuator stem can result in stripped threads or improper operation Be sure that the length of the actuator stem or the valve stem in the connector is equal or greater than the d
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