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Emerson Process Management G01 Automobile Parts User Manual

1. 5 2 15 1 Make sure hex cap screws are tightened to their specified torque 5 2 15 2 Using required lengths of 31 diameter Monel wire as provided in the Module ordered When replacing Monel wire use the following table for wire length requirements MODEL LENGTH MODEL LENGTH Inch mm Inch Mm G01 SR 36 914 4 G5 SR 66 1676 4 G2 SR 44 1117 6 G7 SR 79 2006 6 G3 SR 48 1219 2 G8 SR 88 2235 2 G4 SR 55 1397 0 G10 SR 110 2794 0 5 2 15 3 Twist the end of both wires together and insert one through the drilled hole in the hex cap screw head pass the second wire over the screw head and twist it three 3 times around the first wire at a location where the first wire exits the screw head 5 2 15 4 Repeat the procedure until the second wire is twist tied to the screw head through wire of the last screw head Bettis P N 124840E Revision B Page 36 of 46 5 2 15 5 Attach caution tag and twist tie the wires from the last screw head to the twisted wires of the first screw head See following for illustration 5 2 16 5 2 17 5 2 18 5 2 19 5 2 20 If removed install stop screw nuts 1 190 onto stop screws 1 180 If removed install o ring 2 90 onto stop screws 1 180 If removed install two stop screws 1 180 into two stop screw holes on the front of housing 1 10 Adjust both stop screws 1 180 back to settings recorded earlier in Section 5 Tighten both stop screw nuts 1 190 securely 5 3 5 4 Bettis P
2. 1e Bettis P N 124840E Revision B Page 2 of 46 1 1 Bettis P N 124840E Revision B Page 3 of 46 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 GO1XXX G2XXX G3XXX G4XXX G5XXX G7XXX G8XXX G10XXX G13XXX Double Acting and Spring Return Series Single Power Module Pneumatic Actuators This procedure can also be used on Bettis GXX2XX Double Acting Series Twin Power Modules Pneumatic Actuators 1 1 2 Normal recommended service interval for this actuator series is five years NOTE Storage time is counted as part of the service interval 1 1 3 This procedure is applicable with the understanding that all electrical power and pneumatic pressure has been removed from the actuator 1 14 Remove all piping and mounted accessories that will interfere with the module s that are to be worked on 1 15 This procedure should only be implemented by a technically competent technician who should take care to observe good workmanship practices 1 1 6 Numbers in parentheses indicate the bubble number reference number used on the Bettis Assembly Drawing and Actuator Parts List 1 1 7 This procedure is written using the stop screw side of the housing 1 10 as a reference and this side will be considered the front side of the actuator The housing cover 1 20 will be the top of the actuator 1 18 Actuator Module
3. 1 1 8 Hex Cap Screws Socket Socket Open End 34 1 Tensionrd__________ MaleDrive G10 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE Hex Cap Screws 1 160 9 16 8 HexCapScrews Socket 33100 1516 8 HexCapScrews Socket Allen 520 1 1 8 8 HexCapScrews Socket 1 0 lo S4 1 Tensonrd Male Drive 6 10 G13 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 3 100 1 11 16 8 HexCapScrews Socket 0 Allen 00 00 0 3 130 3 16 Socket Cap Screws Allen Bettis P N 124840E Revision B Page 46 of 46 1413 6 8 Hex Cap Screws 11 8 8 HexCapScrews Socket 12 1 1 Breather Assembly 12 Vent Check Assembl Open End fee i ECN Released 17787 DATE REV BY 3 September 1998 A COMPILED B Cornelius 17 December 2001 B CHECKED B Cornelius APPROVED R Smith Signatures on file Bettis Waller Texas Tension rod Male Drive DATE 17 December 2001 17 December 2001 17 December 2001
4. 3 3 24 Install tie bar nuts 3 90 onto tie bars 3 20 Torque tighten tie bar nuts alternately in 100 foot pound N m increments until a final lubricated torque as listed in the following table has been achieved TIE BAR NUTS TORQUE HOUSING TORQUE 5 Percent MODEL 5 Percent N m FT Ib N m G7 G8 Gta 3 4 3 3 25 3 3 26 NOTE 3 3 27 3 3 28 3 3 29 NOTE 3 3 30 3 3 31 3 3 32 3 3 33 NOTE Bettis P N 124840E Revision B Page 22 of 46 Install lockwashers 3 140 onto socket cap screws 3 130 Install and tighten socket cap screws 3 130 with lockwashers 8 140 into outer end cap 3 80 If the outer end cap 3 80 has an ES stop screw completed steps 3 3 27 through 3 3 29 If not already removed then remove hex nut 3 190 and old o ring seal 4 100 Install new o ring seal 4 100 onto the ES stop screw and up against outer end cap 3 80 Install hex nut 3 140 on to ES After adjusting to proper position tighten ES stop screw Step 3 3 30 is not required if the Power Module is equipped with an ES stop screw or a M3 jackscrew If removed using pipe dope install pipe plug 8 120 into outer end cap 3 80 Apply sufficient pneumatic pressure to outer end cap 3 80 pressure inlet port to move the piston to its full inboard position next to inner end cap Remove pneumatic pressure from outer end cap 3 80 Insta
5. 3 Lbs Ca 15s e iere NA Wa WA NA e Da Power Kg LNA 61 66 76 134 NA NA NA NA Module Kg NA NA 107 118 138 265 T N A N A Module 3 Lbs AA O NA NR ode Power Kg N A N A 154 186 334 413 N A N A Module Kg VA NA NA 229 268 367 556 508 N A Module 3 Lbs N A 977 1100 1260 Kg N A 443 499 572 Module 3 Lbs VA N A N A NA 1243 1400 1525 1755 36 Dia Power Kg NA NA NA NA 564 653 692 796 N A Module Bettis P N 124840E Revision B Page 41 of 46 6 1 CONTINUED MODULE WEIGHTS BY ITEM NUMBER AND ACTUATOR HOUSING SIZE ITEM Goi G2 G3 G4 65 a7 G8 G10 G13 MODULE NO WT WT WT WT WT WT WT WT DESCRIPTION 3 Lbs VA NA NA NA NA NA 1975 2205 40 Dia Power Kg 1000 Module 44 Dia Power Module 48 Dia Power Module 52 Dia Power Module SR1 Spring Module SR2 Spring Module SR3 Spring Module SR4 Spring Module SRA5 Spring Module SRA6 Spring Module SRF1 Spring Module SRF2 Spring Module SRF3 Spring Module SRF4 Spring Module SRF5 Spring 3 Les N A 3120 Kg N A 1415 Xe ENA ENA LNA LNA LNA NACA LWA Kg N A N A N A N A N A N A N A N A 3 Lbs N A 4130 Kg N A 1873 ge usce rss oso ponto ona orones peers aba Kg 73 102 145 256 442 1243 1608 2257 4541 5 Lbs 4515 9275 Kg 72 98 141 249 445 1193 1
6. 11 2 2 12 2 2 13 NOTE NOTE Bettis P N 124840E Revision B Page 8 of 46 2 2 8 1 2 Remove o ring seals 4 80 from the inboard end of tie bars 3 20 2 2 8 2 3 Remove tie bars 3 20 by pulling the tie bars out and through piston 3 30 NOTE G4 models have flats on outboard end of tie bars 3 20 for wrench placement NOTE G5 through G13 models have a female square on the out board end of tie bars 3 20 for wrench placement 2 2 8 2 Remove G4 through G13 tie bars 8 20 as follows Unscrew and remove tie bars 3 20 from inner end cap 3 10 and piston 3 30 Remove piston as follows On early G2 and G3 models equipped with outboard and inboard tie bar nuts skip this step and go to step 2 2 11 2 2 9 1 Refer to assembly drawing page 2 of 2 Detail D Remove two split ring halves 3 50 and one retainer ring 3 60 from outboard side of piston 3 30 NOTE Piston 3 30 acts as the retainer for inboard split ring halves 3 50 When removing the piston be careful to not lose inboard split ring halves 3 50 2 2 9 2 Remove piston 3 30 and two split ring halves 3 50 from piston rod 3 40 Steps 2 2 10 is used only on early G2 and G3 models equipped with outboard and inboard tie bar nuts Remove early model G2 and G3 pistons as follows 2 2 10 1 Refer to assembly drawing page 2 of 2 Detail D Remove two split ring halves 3 50 and one retainer ring 3 60 from inboard side of piston 3 30 NO
7. 124840E Revision B Page 21 of 46 3 3 23 2 2 Install the jackscrew 3 290 through the outboard side of the outer end cap 3 80 3 3 23 2 3 Apply a light coating of lubricant to threads of jackscrew 3 290 3 3 23 2 4 Screw jackscrew adapter 3 280 onto jackscrew 3 290 NOTE The small round end of the M3 adapter will install on the jackscrew pointing to the inboard end of the jackscrew 3 3 23 2 5 Position the jackscrew with the inboard end of the jackscrew located with the needle bearing thrust washer assembly 3 340 up against or near the jackscrew adapter 3 280 3 3 23 2 6 Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70 3 3 23 2 7 Install tie bar nuts 3 90 onto tie bars 3 20 NOTE Do not tighten nuts 3 3 23 2 8 Install two socket cap screws 3 320 through jackscrew adapter 3 280 and tighten into the outer end cap 3 80 3 3 23 2 9 Lightly lubricate o ring seal 4 150 and install onto the outboard end of the jackscrew Push the o ring 4 150 down the jackscrew until it contacts the jackscrew adapter 3 280 3 3 23 2 10 Install flat hex nut 3 300 onto jackscrew 3 290 Rotate the flat hex nut 3 300 until it is up against the o ring seal 4 150 3 3 23 2 11 Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70 Continue at step 3 3 24 3 3 23 3 STANDARD OUTER END CAP INSTALLATION Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70
8. 2 6 3 2 through 2 6 3 4 2 6 3 2 Unscrew and remove hex flat nut 7 50 from M3 jackscrew assembly 7 40 2 6 3 3 Remove retainer ring 7 55 from M3 adapter 7 45 2 6 3 4 Remove M3 jackscrew assembly 7 40 from M3 SR adapter plate 7 10 G2 AND G3 SR M3 JACKSCREW DISASEMBLY FROM SR M3 ADAPTER PLATE 2 6 4 1 Remove M3 handwheel or M3 hex drive hub per Section 2 5 NOTE See 2 6 note before proceeding with step 2 6 4 2 through 2 6 4 4 2 7 3 1 Bettis P N 124840E Revision B Page 13 of 46 2 6 4 2 Unscrew and remove hex flat nut 7 50 from M3 jackscrew assembly 7 40 2 6 4 3 Unscrew and remove two socket cap screws 7 120 from M3 adapter 7 40 2 6 4 4 Remove M3 jackscrew 7 40 from M3 SR adapter plate 7 10 2 6 5 M3 THRUST BEARING DISASEMBLY FROM M3 JACKSCREW ASSEMBLY 2 6 5 1 Remove M3 bearing retainer 5 110 7 110 from inboard end of M3 jackscrew assembly 5 50 7 40 2 6 5 2 Remove needle roller thrust bearing 5 100 7 100 from M8 bearing retainer 5 110 7 110 2 6 5 3 Remove retainer ring 5 90 7 90 from M3 jackscrew assembly 5 50 7 40 EXTENDED STOP BLIND END CAP DISSASSEMBLY 2 7 1 Unscrew and remove hex nut 5 60 from ES stop screw 5 50 2 7 2 Remove ES stop screw 5 50 from ES blind end cap 5 10 SECTION 3 ACTUATOR REASSEMBLY GENERAL REASSEMBLY CAUTION Only new seals which are still within the seal s expectant shelf life should be installed into the actuato
9. N 124840E Revision B Page 37 of 46 PNEUMATIC POWER MODULE REMOVAL CAUTION Due to the weight and size of power module heavy duty support equipment 5 3 1 5 3 2 5 3 3 will be required when removing power module from the actuator housing Refer to section 6 for Pneumatic Power Module weights Standard Outer end cap with pipe plug use step 5 3 1 1 outer end cap with extended stop ES use step 5 3 1 2 G2 or G3 outer end cap with M3 or M3HW use step 5 3 1 3 and G01 outer end cap with M3 or M3HW use step 5 3 1 4 5 3 1 1 Standard outer end cap Remove pipe plug 3 120 from outer end cap 3 80 5 3 1 2 ES outer end cap 5 3 1 2 1 Loosen ES nut 3 190 5 3 1 2 2 Unscrew ES 3 180 and remove from outer end cap 3 80 5 3 1 3 G2 or G3 M3 M3HW outer end cap 5 3 1 3 1 Remove socket cap screws 3 320 from M3 adapter 3 280 5 3 1 3 2 Remove M3 adapter 3 280 from outer end cap 3 80 5 3 1 4 GO1M3 M3HW outer end cap 5 3 1 4 1 Remove socket cap screw 3 130 from M3 keeper 3 360 5 3 1 4 2 Remove M3 keeper 3 360 from M3 adapter 3 360 and outer end cap 3 80 5 3 1 4 3 Remove M3 jackscrew 3 290 with M3 adapter 3 360 from outer end cap 3 80 Using a male square drive extension go through outer end cap 8 80 and unscrew piston rod 3 40 from the drive module Remove hex cap screws 3 100 with lockwashers 3 110 from housing 1 10 NOTE When removing power module from housing 1 10 be careful n
10. P N 124840E Revision B Page 12 of 46 2 6 M3 JACKSCREW DISSASSEMBLY NOTE The jackscrew bearing retainer 7 110 5 110 needle bearing thrust washer assembly 2 6 1 2 6 2 2 6 3 2 6 4 7 100 5 100 or retainer ring 7 90 5 90 does not require disassembly from the jackscrew assembly 7 40 5 50 except for the need to replace worn parts For disassembly of these items refer to step 2 6 7 Remove M3 handwheel or M3 hex drive hub per Section 2 5 G01 M3 JACKSCREW DISASEMBLY FROM BLIND END CAP 2 6 1 1 Remove M3 handwheel or M3 hex drive hub per Section 2 5 NOTE See note 2 6 before proceeding with step 2 6 1 2 through 2 6 1 4 2 6 1 2 Unscrew and remove socket cap screw 5 120 with lockwasher 5 130 from keeper 5 140 2 6 1 3 Remove keeper 5 140 from blind end cap 5 10 2 6 1 4 Remove M3 jackscrew 5 50 from blind end cap 5 10 G2 M3 and G3 M3 JACKSCREW DISASEMBLY FROM BLIND END CAP 2 6 2 1 Remove M3 handwheel or M3 hex drive hub per Section 2 5 NOTE See 2 6 note before proceeding with step 2 6 2 2 through 2 6 2 4 2 6 2 2 Unscrew and remove hex flat nut 5 60 from G2 G3 M3 jackscrew 2 6 2 3 Unscrew and remove two socket cap screws 5 120 from G2 G3 M3 adapter 2 6 2 4 Remove M3 jackscrew 5 50 from blind end cap 5 10 G01 SR M3 JACKSCREW DISASEMBLY FROM SR M3 ADAPTER PLATE 2 6 3 1 Remove M3 handwheel or M3 hex drive hub per Section 2 5 NOTE See 2 6 note before proceeding with step
11. SRF unscrew and remove pipe plug 7 10 from spring cartridge assembly 5 10 Skip steps 5 1 2 5 1 3 and start at step 5 1 4 WARNING If an M3 M3HW jackscrew or extended stop ES is mounted in the spring 5 1 2 module cover plate 7 10 the M3 M3HW or ES should not contact the end of the spring module tension rod Unscrew hex cap screws 7 20 with lockwashers 7 30 from cover plate 7 10 or if spring module has a M3 SR adapter plate 7 10 or a SR ES adapter plate remove safety wire from hex cap screws 7 20 and then remove hex cap screws 7 20 Bettis P N 124840E Revision B Page 32 of 46 5 1 3 Remove the cover plate 7 10 from spring cartridge assembly 5 10 5 1 4 Apply pneumatic pressure to inner end cap 2 40 port A to compress the spring enough to move the yoke off the stop screw on the spring module side of the drive module 5 1 5 Loosen the stop screw nut 1 190 located on the stop screw that is closest to or next to Spring Module 5 1 6 Unscrew stop screw 1 180 that is closest to or next to Spring Module unscrew or back out until the load is removed from the stop screw 5 1 7 Remove pneumatic pressure from pressure inlet port of inner end cap 3 10 CAUTION Due to the weight and size of spring cartridge assembly 5 10 heavy duty support equipment will be required when removing spring cartridge assembly from the actuator housing Refer to section 6 for spring cartridge module weights
12. assembly 1 140 NOTE During yoke cover installation be careful not to damage o ring seal 2 70 and rod wiper 2 80 Place lockwashers 1 170 onto hex cap screws 1 160 Install and tighten hex cap screws 1 160 with lockwashers through yoke cover 1 150 and into housing cover 1 20 Vent check assembly installation as follows 2 3 43 1 G01 G2 and G3 housing 1 10 using pipe sealant install one vent check assembly 13 into the front of housing 1 10 2 3 43 2 G01 G2 and G3 housing 1 10 using pipe sealant install one vent check assemble 13 into the top area of housing cover 1 20 2 3 43 3 G4 through G13 housing 1 10 using pipe sealant install two vent check assemblies 13 into the front of housing 1 10 NOTE Refer to Section 2 step 2 3 3 for correct position indicator placement Install position indicator 1 220 over the exposed shaft of position indicator assembly 1 140 Install stop screw nuts 1 190 onto stop screws 1 180 Install o ring 2 90 onto stop screws 1 180 Install two stop screws 1 180 into two stop screw holes on the front of housing 1 10 3 3 Bettis P N 124840E Revision B Page 18 of 46 3 2 48 Adjust both stop screws 1 180 back to settings recorded earlier in Section 2 at step 2 3 2 3 2 49 Tighten both stop screw nuts 1 190 securely PNEUMATIC POWER MODULE REASSEMBLY NOTES T For early model G2 and G3 actuators with double nuts on the power module use secti
13. bars 3 20 and into the o ring grooves provided Insert the tie bars through inner end cap 3 10 and screw hex nuts 3 90 onto inboard end of the tie bars NOTE Screw the tie bars through the hex nuts 3 90 until one complete thread is exposed Refer to assembly drawing page 2 of 2 Detail E Install two tie bar o ring seals 4 80 onto the outboard end of tie bars 3 20 and into the o ring grooves provided Apply lubricant to one o ring seal 4 40 and install into the outer diameter o ring groove of outer end cap 3 80 Apply lubricant to the bore of cylinder 3 70 3 5 Bettis P N 124840E Revision B Page 24 of 46 CAUTION If needed when installing the cylinder hammer on the end of the cylinder 3 4 17 NOTE 3 4 18 3 4 19 3 3 20 3 4 21 3 4 22 only with a non metallic object Install lubricated cylinder 3 70 over piston 3 30 and onto inner end cap 3 10 When installing the cylinder over the piston seal tilt cylinder 15 to 30 degrees to piston rod If the Power Module is equipped with a M3 jackscrew pre assemble the M3 jackscrew to the outer end cap 3 80 per Section 3 6 Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70 NOTE The pressure inlet port should be positioned in the same position as recorded in section 2 2 step 2 2 1 Install tie bar nuts 3 90 onto tie bars 3 20 Torque tighten tie bar nuts alternately in 100 foot pound increments unti
14. can be held in place by installing a screw into the 375 16UNC tapped hole in the upper end of yoke pin 1 80 Install yoke pin 1 80 by inserting into the upper yoke arm upper yoke guide block bushing guide block lower yoke guide block bushing lower yoke arm and resting on lower yoke pin thrust bearing 2 10 Install guide bar 1 90 into either side of housing 1 10 by inserting through the housing through guide block and then insert the guide bar into the other side of housing 1 10 Refer to assembly drawing page 2 of 2 Section A A Install spring pin 1 100 into the top of yoke 1 70 Install position indicator assembly 1 140 onto the top of yoke 1 70 and over spring pin 1 100 NOTE Refer to Section 2 step 2 3 7 for correct installation position Install o ring 2 50 into housing cover 1 20 Install o ring seal 2 60 into housing cover 1 20 Install housing cover 1 20 being careful not to damage o ring seals 2 50 and 2 60 Place lockwashers 1 115 onto hex cap screws 1 110 On G7 through G13 model actuators apply thread adhesive Locktite 242 to threads of hex cap screws 1 110 Reference assembly drawing note number 8 Install hex cap screws 1 110 with lockwashers 1 115 through housing cover 1 20 and into housing 1 10 NOTE Leave hex cap screws 1 110 finger tight do not tighten NOTE Do this step only if groove pins 1 130 have been pulled or if the pins are being replaced Drive
15. two spherical washers 9 40 and one extension rod assembly 9 50 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 3 2 10 3 2 11 3 2 12 3 2 13 NOTE 3 2 14 3 2 15 NOTE 3 2 16 NOTE 3 2 17 3 2 18 NOTE 3 2 19 3 2 20 3 2 21 Bettis P N 124840E Revision B Page 15 of 46 Install second spherical washer 9 40 over threaded end of extension rod assembly 9 50 NOTE The spherical side of the washer will go on the extension rod assembly facing the head of the extension rod assembly Install extension rod assembly 9 50 into guide block 1 30 and up against the first spherical washer 9 40 Install extension retainer nut 9 60 over extension rod assembly 9 50 and screw into guide block 1 30 Tighten extension retainer nut assembly 9 60 until extension rod assembly 9 50 can not move Back off the extension retainer nut assembly 9 60 just enough to allow for extension rod assembly 9 50 to move freely Steps 3 2 14 and 3 2 15 are to be completed when the actuator is Double Acting and equipped with a Blind end cap extended stop screw Install guide block stop plug 5 50 into guide block 1 30 Install and tighten rod extension retainer nut assembly 5 80 over guide block stop plug 5 50 and screw into guide block 1 30 Consult Waller Texas Bettis Servi
16. weights are listed in Section 6 Table 6 1 1 1 9 When removing seals from seal grooves use a commercial seal removing tool or a small screwdriver with sharp corners rounded off 1 1 10 Use a non hardening thread sealant on all pipe threads CAUTION Apply the thread sealant per the manufacture s instructions 1 1 11 Bettis recommends that disassembly of the actuator modules should be done in a clean area on a workbench 1 2 1 3 1 4 15 DEFINITIONS WARNING CAUTION NOTE ES M3 Bettis P N 124840E Revision B Page 4 of 46 If not observed user incurs a high risk of severe damage to actuator and or fatal injury to personnel If not observed user may incur damage to actuator and or injury to personnel Advisory and information comments provided to assist maintenance personnel to carry out maintenance procedures Extended stop screw for travel stop adjustment over a full 100 degree travel range ES is not intended for use as a manual override Manual jackscrew override GENERAL SAFETY INFORMATION Products supplied by Bettis in its as shipped condition are intrinsically safe if the instructions contained within this Service Instruction are strictly adhered to and executed by well trained equipped prepared and competent personnel WARNING WARNING For the protection of personnel working on Bettis actuators this procedure should be reviewed and implemented for safe disassembly and re
17. 064 2048 4207 mom a oeste gaps onto goes 096 55098 Kg 153 98 295 534 925 2410 3085 4095 8060 5 Lbs 3735 7325 Kg 1694 3323 5 Lbs N A N A Kg N A N A 5 Lbs N A N A N A Kg N A 82 N A N A N A N A Ce Na foo tat na NA T NA WA CWA T NA Kg N A 100 141 N A N A N A 5 Lbs N A N A Kg N A N A 5 Lbs N A N A Kg N A N A 5 Lbs N A N A Kg N A N A N A N A Kg 5 7 N A N A Module Los VA 185 NA NA NA NA NA N A N A SRF6 Spring Kg VA 8 NA NA NA NA NA NA NA Module Bettis P N 124840E Revision B Page 42 of 46 G01 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE Male Drive Male Drive Hex Cap Screws Socket Socket Open End S Sq 1 Tensionrod Male Drive G2 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1 10 ene 6 HexCapScrews Socket 520 9 16 6 HexCapScrews Socket 1 1 S e Sq 1 Tensonrd Male Drive Bettis P N 124840E Revision B Page 43 of 46 G3 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1410 ge 8 HexCapScrews Socket Male Drive 3 100 96 6 HexCapScrews Soket O 520 9 16 6 HexCapScrews Socket e r i Breather Assembly Sekt S Sqg 1 Tensionrdd_____ MaleDrive___ G4 TOOL STYLE A
18. 17 3 3 18 3 3 19 3 3 20 3 3 21 Bettis P N 124840E Revision B Page 19 of 46 Place lockwashers 3 110 onto hex cap screws 3 100 Install and tighten hex cap screws 3 100 with lockwashers through housing 1 10 and into inner end cap 3 10 Refer to assembly drawing page 2 of 2 Detail D Install one o ring seal 4 70 into the seal groove in piston rod 3 40 Apply lubricant to two sets of rod T seal components 4 50 The T seal is composed of one rubber seal and two split skive cut back up rings 3 3 12 1 Install two sets of rod T seals 4 50 into the internal diameter seal grooves of piston 3 30 3 3 12 2 Install a back up ring on each side of the T seal 3 3 12 3 When installing the back up rings do not align the skive cuts 3 3 12 4 If the back up rings are too long and the rings overlap beyond the skive cuts then the rings must be trimmed with a razor sharp instrument 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 Install two split ring halves 3 50 into the piston rod in front of the piston installed in the previous step and retain with retainer ring 8 60 Install one o ring seal 4 40 onto the outer diameter seal groove of inner end cap 3 10 Coat one D ring seal 4 60 with lubricant and install into the piston external sea
19. 4 for installation NOTE Skip step 4 2 3 when working on G01 SR models and continue at step 4 2 4 4 2 8 Install the SR Powr Swivl Module per Section 5 6 4 2 4 Install the Spring Module per Section 5 2 CONVERTING SPRING RETURN ACTUATOR TO DOUBLE ACTING 4 3 1 Remove the Spring Cartridge per Section 5 1 4 3 2 f Pneumatic Power Module needs to be relocated due to fail mode requirements fail counter clockwise use Section 5 3 for removal and Section 5 4 for installation NOTE Skip step 4 3 3 when working on G01 SR models and continue at step 4 3 4 4 3 8 Remove the Spring Cartridge Powr Swivl Module per Section 5 5 4 3 4 Install the Blind End Cap Module per Section 3 5 ADD AN M3 JACKSCREW TO BLIND END CAP MODULE 4 4 4 Remove blind end cap module per Section 2 4 4 4 2 If new M3 blind end cap module is not pre assembled with the M3 then assembly M3 to the blind end cap 5 10 per Section 3 6 steps 3 6 1 or 3 6 2 4 4 3 Install the assembled M3 blind end module per Section 3 5 4 4 A Toinstall the M3 Handwheel or M3 drive hub refer to Section 3 7 ADD AN M3 JACKSCREW TO POWER MODULE OUTER END CAP 4 5 1 Remove outer end cap 3 80 per Section 2 2 steps 2 2 5 and 2 2 6 4 6 4 7 4 8 4 9 4 5 2 4 5 3 4 5 4 Bettis P N 124840E Revision B Page 30 of 46 If new M3 outer end cap 3 80 is not pre assembled with the M3 then assembly M3 to the outer end cap 3 80 per Section 3 3 steps 3 3 23 1 or 3 3 23 2 I
20. 5 1 8 The spring cartridge pre load must be removed before spring cartridge assembly 5 10 is removed from housing 1 10 Refer to steps 5 1 4 through 5 1 6 for spring cartridge pre load removal 5 1 9 Remove breather assembly 12 from outer end cap 3 80 port B CAUTION The maximum pressure to be applied in step 5 1 10 is 25 PSIG 5 1 10 Apply pneumatic pressure not to exceed the maximum as indicated in the above CAUTION to the pressure inlet port B of outer end cap 3 80 to move the spring cartridge tension rod hex nut out of it s cast hex seat NOTE If pneumatic pressure is not available to apply to the pressure inlet port B located in outer end cap 3 80 then remove pipe plug 3 120 or if equipped with an extended stop ES remove the ES Using a long rod go through the outer end cap pipe plug or ES vacant port hole and push on the piston rod so as to move the spring cartridge tension rod hex nut out of it s cast hex seat 5 1 11 Unscrew the spring cartridge tension rod from the Drive Module The tension rod can be rotated for removal by going through the open end of spring cartridge assembly with a square male drive extension 5 1 12 Remove hex cap screws 5 20 with lockwashers 5 30 from housing 1 10 5 1 13 Remove spring cartridge assembly 5 10 from actuator housing 1 10 WARNING Under no circumstances should the spring cartridge assembly 5 10 be cut apart as the spring is pre loaded and the spr
21. 9 4 1 Joint between inner end cap 3 10 and cylinder 3 70 This checks cylinder to inner end cap o ring seal 3 9 4 2 The port hole in the outer end cap 3 80 This checks the piston D seal to cylinder 3 70 o ring seal 4 70 and rod T seal 4 50 NOTE If excessive leakage across the piston remains the actuator must be disassembled and the cause of leakage must be determined and corrected 3 9 4 3 The vent check port hole in housing This checks Polypak seal 4 30 that seals piston rod 3 40 to inner end cap 3 10 3 9 4 4 Remove pressure from the pressure inlet port 3 9 5 If an actuator was disassembled and repaired the above leakage test must be performed again SECTION 4 FIELD CONVERSIONS FAIL MODE REVERSAL CW TO CCW OR CCW TO CW 4 1 1 Remove Spring Module per Section 5 1 4 2 4 3 4 4 45 Bettis P N 124840E Revision B Page 29 of 46 4 1 2 Remove Pneumatic Power Module per Section 5 3 4 1 3 Re install the Spring Module onto the opposite end of housing 1 10 as it was previously located per Section 5 2 4 1 4 Re install the Pneumatic Power Module onto the opposite end of housing 1 10 as it was previously located per Section 5 4 CONVERTING DOUBLE ACTING ACTUATOR TO SPRING RETURN 4 29 0 Remove the Blind End Cap Module per Section 2 4 4 2 2 f Pneumatic Power Module needs to be relocated due to fail mode requirements fail counter clockwise use Section 5 3 for removal and Section 5
22. Instruction Manual Form 5653 February 2007 Bettis Actuators G01 through G13 Bettis Service Instructions for Models G01 through G13 Pneumatic Actuators The following instruction manual is for the Bettis Actuator This instruction manual was prepared by Bettis a member of the Valve Automation Division of Emerson Process Management Please contact Bettis to ensure that the following instruction manual is the most recent one available Do not install operate or maintain this product without first e being fully trained and qualified in valve actuator and accessory installation operation and maintenance and e carefully reading and understanding the contents of this manual Emerson Process Management is not responsible for the content of this manual If you have any questions about these instructions contact the actuator manufacturer before proceeding Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use and maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user CS T V a y EMERSON www Fisher com Process Management D102754X012 Instruction Manual Form 5653 Bettis Actuators GO1 through G13 February 2007 Fisher and Bettis are marks owned by the Emerson Process Management business division of Emerson Electric Co Emerson Process Mana
23. M3 JACKSCREW REASSEMBLY TO M3 SR ADAPTER PLATE 3 6 4 1 Apply a light coating of lubricant to the threads of jackscrew assembly 7 40 3 6 4 2 Install jackscrew adapter 7 45 onto the none bearing end of M3 assembly 7 40 3 6 4 3 Install jackscrew adapter 7 45 through adapter plate 7 10 3 6 4 4 Install two socket cap screws 7 120 through jackscrew adapter 7 45 and tighten into adapter plate 7 10 M3 THRUST BEARING REASSEMBLY TO JACKSCRES ASSEMBLY 3 6 5 1 Apply a coating of lubricant to the internal hole located on the inboard end of M3 assembly 5 40 7 50 3 6 5 2 Install the wire retainer ring 5 90 7 90 into the internal hole of M3 assembly until retainer ring opens up into its groove inside the M3 assembly 3 6 5 3 Pre assemble the needle bearing thrust washer assembly 5 100 7 100 as follows 3 6 5 3 1 Apply lubricant to one thrust washer and install onto bearing retainer 5 110 7 110 3 6 5 3 2 Apply lubricant to needle bearing and install onto bearing retainer 7 110 and up against thrust washer installed in step 3 6 5 3 1 3 7 3 8 Bettis P N 124840E Revision B Page 27 of 46 3 6 5 3 3 Apply lubricant to the remaining thrust washer and install onto bearing retainer 5 110 7 110 and up against the needle bearing installed in step 3 6 1 3 2 3 6 5 4 Install the pre assembled needle bearing thrust washer assembly 5 100 7 100 into the open hole located on the inboard en
24. Mark stop screws 1 180 left and right The setting of stop screws 1 180 should be checked and setting recorded before stop screws are loosened or removed NOTE Stop screws will be removed later in this procedure 2 3 2 1 Hold stop screw cover 1 195 in place and remove pipe plug 1 260 2 3 2 2 Hold submerged stop screw 1 180 in place and remove stop screw cover 1 195 NOTE For steps 2 3 3 through 2 3 10 refer to assembly drawing page 2 of 2 Section A A Detail F on drawing part number 115674 and Detail G on drawing part number 116422 2 3 3 Before removing position indicator 1 220 record or mark it s position Remove position indicator 1 220 NOTE Step 2 3 4 is used only on G01 G2 and G3 Drive Modules Drive Modules G4 through G13 will skip steps 2 3 4 and continue with step 2 3 5 2 3 4 Remove one vent check assembly 13 from top of housing cover 1 20 2 3 5 Unscrew and remove hex cap screws 1 160 with lockwashers 1 170 from yoke cover 1 150 2 3 6 Remove yoke cover 1 150 from housing cover 1 20 2 3 7 Mark and record the orientation of the position indicator assembly 1 140 in relation to the top of yoke 1 70 2 3 8 Remove position indicator assembly 1 140 from top of yoke 1 70 2 3 9 Remove spring pin 1 100 from top of yoke 1 70 2 3 10 Remove hex cap screws 1 110 with lockwashers 1 115 from housing cover 1 20 NOTE Steps 2 3 11 and 2 3 12 are used only on G7 G8 and G10 Drive
25. Modules Drive Modules G01 G2 G3 G4 and G5 will skip steps 2 3 11 and 2 3 12 and continue with step 2 3 13 2 3 11 Remove hex cap screws 1 120 with lockwashers 1 115 from housing cover 1 20 2 3 12 NOTE 2 3 13 NOTE 2 3 14 2 3 15 2 3 16 2 3 17 2 3 18 2 3 19 2 3 20 2 3 21 2 3 22 NOTE 2 3 23 2 3 24 Bettis P N 124840E Revision B Page 10 of 46 Using hex cap screws 1 110 install into holes vacated by hex cap screws 1 120 Use these hex cap screws to jack the housing cover up for removal Alternately rotate the hex cap screws clockwise until housing cover 1 20 is clear of housing 1 10 G01 G2 G3 and G4 model housing cover will have cast tabs for placing prying tools to aid in cover removal Remove housing cover 1 20 from housing 1 10 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 Refer to assembly drawing page 2 of 2 Detail B Remove guide bar 1 90 from housing 1 10 Remove top yoke pin thrust bearing 2 10 from top of yoke pin 1 80 Rotate the arms of yoke 1 70 to the center position of housing 1 10 Remove yoke 1 70 with yoke pin 1 80 guide block 1 30 and two yoke guide block bushings 2 30 by lifting yoke up and out of the housing 1 10 Remove bottom yoke p
26. ND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1 110 e 8 HexCapScrews Socket Male Drive 3 100 6 HexCapScrews Socket 3 120 5 8 Sq 1 PipePlug S Open End or Adjustable 3 130 3 16 2 SocketCapScrews Alen 0 1 520 6 HexCapScrews Socket 7 20 9 16 4 HexCapScrews Socket L 34 1 Tensionrod Male Drive Bettis P N 124840E Revision B Page 44 of 46 6 6 G5 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1 310 34 8 HexCapScrews Socket 1 160 9 16 6 HexCapScrews Socket Open End or Adjustable 2 ae 1 PistonHod MaleDrive 2 Standard Hex Nuts Socket Socket Tie Bar flats Open End or Adjustable 6 7 G7 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1 310 34 8 HexCapScrews Socket 1 160 9 16 8 HexCapScrews Socket Male Drive 3 100 15 16 8 HexCapScrews Socket 5 10 5 20 15 6 8 HexCapScrews Socket 7 20 9 16 8 HexCapScrews Socket L 34 1 Tensinrd MaleDrve Bettis P N 124840E Revision B Page 45 of 46 G8 TOOL STYLE AND WRENCH SIZE NO SIZE QTY DESCRIPTION TOOL STYLE 1 160 9 16 8 HexCapScrews Socket Male Drive Male Drive 3 100 1 1 8 8 Hex Cap Screws Socket O 5 20 1 1 8 8 HexCapScrews Socket O 7 20
27. S lt a A ei ALA nete Rees 4 1 3 General Safety Information c ccccceeeeeeceeeeeceeeeeeeaeeeeneeseeeeseaeeeeaeesneees 4 1 4 Bettis Reference Materials sssseen enne 4 1 5 Service Support Items sse 4 1 6 Lubrication Requirements sseseeene enne 5 1 7 General Tool Information sse 5 SECTION 2 0 ACTUATOR DISASSEMBLY 2 1 General Disassembly comcoccccnccononcnononnnanoconnncn ronca nora cnn nennen 5 2 2 Pneumatic Power Module Disassembly eese 6 2 3 Drive Module Disassembly sene 9 24 Blind End Cap Module Disassembly ssseeeeeee 11 2 5 M3 Handwheel or M3 Hex Drive Hub Removal sesser 11 2 6 M3 Jackscrew Disassembly sssseeee enne 12 2 7 Extended Stop Blind End Cap Disassembly sssssssss 13 SECTION 3 0 ACTUATOR REASSEMBLY 3 1 General Reassembly sse ener enne 13 3 2 Drive Module Reassembly coooccccococcccconoccccnononccncnnoncnnnnnancnn nano nn nennen 14 3 3 Pneumatic Power Module Reassembly seseeee 18 3 4 Early G2 And G3 Pneumatic Power Module Reassembly 22 3 5 Blind End Cap Module Reassembly sse 24 3 6 M3 Jackscrew Reassembly ssssessseseeeeeneen 25 3 7 M3 Handwheel or M3 Hex Drive Hub Installation 27 3 8 Ex
28. TE Piston 3 30 acts as the retainer for outboard split ring halves 3 50 2 2 10 2Slide piston 3 30 toward the inner end cap 3 10 until the out board split ring halves is exposed enough for removal Remove outboard split ring halves from piston rod 3 40 2 2 10 3 Remove piston 3 30 and two split ring halves 3 50 from piston rod 3 40 Remove o ring seal 4 70 from piston rod 3 40 Remove hex cap screws 3 100 with lockwashers 3 110 from housing 1 10 Remove inner end cap 3 10 off of piston rod 3 40 On early model G2 and G3 actuators remove two hex nuts 3 90 from housing 1 10 These two nuts will be loose after tie bars 3 20 are removed in step 2 2 8 1 and will be located in the area where the piston rod passes through the housing 1 10 The piston rod 3 40 removal as outlined in step 2 2 14 is only required when the piston rod is being replaced or when the Drive Module is to be disassembled 2 3 Bettis P N 124840E Revision B Page 9 of 46 2 2 14 Unscrew and remove piston rod 3 40 from drive module DRIVE MODULE DISASSEMBLY NOTE Review Section 2 steps 2 1 1 through 2 1 5 General Disassembly before proceeding with Drive Module Disassembly 2 3 1 If not already removed remove piston rod 3 40 from drive module NOTE If the actuator is equipped with submerged stop screws with stop screw covers 1 195 then proceed to and complete steps 2 3 2 1 and 2 3 2 2 prior to doing step 2 3 2 2 3 2
29. ack up rings 3 4 5 1 Install two sets of rod T seals 4 50 into the internal diameter seal grooves of piston 3 30 3 4 5 2 Install a back up ring on each side of the T seal 3 4 5 3 When installing the back up rings do not align the skive cuts 3 4 5 4 f the back up rings are too long and the rings overlap beyond the skive cuts then the rings must be trimmed with a razor sharp instrument Coat one D ring seal 4 60 with lubricant and install into the piston external seal groove NOTE The flat side of the D ring seal goes down into the seal groove Install piston 3 30 onto piston rod 3 40 NOTE The cast rib side of the piston is to be facing away from the outboard side of inner end cap 3 10 or position piston 3 30 on the piston rod so that the retainer grooves are on the out board side of the piston Refer to assembly drawing page 2 of 2 Detail D Install o ring seal 4 70 into the seal groove in the outboard end of piston rod 3 40 Install two split ring halves 3 50 into the outer most groove in piston rod 3 40 and retain by installing the recessed area of piston 3 30 over the two split halves 3 50 Install two split ring halves 3 50 into the piston rod in back of the piston and retain with retainer ring 3 60 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 Install two tie bar o ring seals 4 80 onto the inboard end of tie
30. assembly Close attention should be noted to the WARNINGS CAUTIONS and NOTES contained in this procedure This procedure should not supersede or replace any customer s plant safety or work procedures If a conflict arises between this procedure and the customer s procedures the differences should be resolved in writing between an authorized customers representative and an authorized Bettis representative BETTIS REFERENCE MATERIALS 1 41 Assembly Drawing for G01 through G13 Double Acting One Power Module Pneumatic Series Actuators use part number 116422 1 4 2 Assembly Drawing for G01 through G13 Double Acting Twin Power Module Pneumatic Series Actuators use part number 115678 1 43 Assembly Drawing for G01 through G13 Spring Return One Power Module Pneumatic Series Actuators use part number 115674 SERVICE SUPPORT ITEMS 1 5 4 Bettis Module Service Kit 1 5 2 For rod extension retainer nut tool part number refer to the following table NOTE These tools are required only when extension rod assembly 1 50 or 9 50 is removed or when a new extension rod assembly is installed 1 5 3 1 5 4 Bettis P N 124840E Revision B Page 5 of 46 ACTUATOR BETTIS PART ACTUATOR BETTIS PART MODEL NUMBER MODEL NUMBER G5 G7 117369 123616 G8 G10 117368 G3 G4 117370 122849 Commercial leak testing solution Non hardening thread sealant 1 6 LUBRICATION REQUIREMENTS NOTE Lubricants other than listed in step 1 6 1 should n
31. block 1 30 Install second spherical washer 1 40 over threaded end of extension rod assembly 1 50 NOTE The spherical side of the washer will go on the extension rod assembly facing the head of the extension rod assembly Bettis P N 124840E Revision B Page 40 of 46 5 6 5 Install extension rod assembly 1 50 into right of guide block 1 30 and up against the first spherical washer 1 40 5 6 6 Install extension retainer nut assembly 1 60 over extension rod assembly 1 50 and screw into guide block 1 30 5 6 7 Tighten extension retainer nut assembly 1 60 until extension rod assembly 1 50 can not move Back off the extension retainer nut assembly 1 60 just enough to allow for extension rod assembly 1 50 to move freely SECTION 6 ACTUATOR SUPPORT INFORMATION 6 1 MODULE WEIGHTS BY ITEM NUMBER AND ACTUATOR HOUSING SIZE ITEM G01 G2 G3 G4 G5 G7 G8 G10 G13 MODULE NO WT WT WT WT WT WT WT WT WT DESCRIPTION 1 Lbs 83 110 162 280 545 1025 1495 2550 4625 Drive Module Kg 38 127 247 465 678 1157 2098 Kg N A NA N A N A N A NA NA N A Module A O A Sere Kg 30 5 N A NA NA NA N A NA N A Module Fra aras e NA NA NAT NA TNA NA Mode Kg N A NA NA NA NA N A Module 3 Lbs 5 HE ee NA O e na Power Kg 39 39 47 59 NA N A NA NA N A Module Kg 44 44 51 66 N A Module
32. ce Coordinator for yoke bearing yoke pin bearing or yoke guide block bushing installation information If the two yoke bearings 2 40 are being replaced install new bearing into housing cover 1 20 and housing 1 10 The yoke bearing 2 40 must be pressed into housing 1 10 and housing cover 1 20 Install the yoke bearings with the bearing seam located 45 5 degrees from the yoke arm slot when yoke 1 70 is rotated to its full clockwise position If the two yoke pin bearings 2 10 are being replaced install new bearing into housing cover 1 20 and housing 1 10 Lubricate two yoke guide block bushings 2 30 and install onto top and bottom sides of guide block 1 30 The guide block 1 30 should be already pre assembled with extension rod assembly and associated parts assembled in the guide block Install guide block 1 30 with yoke guide block bearings 2 30 between arms of yoke 1 70 Install one o ring seal 2 50 into inner diameter seal groove in the bottom of housing 1 10 Coat the bearing surfaces of yoke 1 70 with lubricant and install into housing 1 10 3 2 22 NOTE 3 2 23 3 2 24 3 2 25 3 2 26 3 2 27 3 2 28 3 2 29 3 2 30 NOTE 3 2 31 3 2 32 3 2 33 Bettis P N 124840E Revision B Page 16 of 46 Align hole in guide block 1 30 with the matching holes in the two yoke guide block bushings 2 30 and the slots in the arms of yoke 1 70 The yoke pin
33. d 5 1 3 If new ES G SR adapter plate 7 10 is not pre assembled with the ES then assembly ES to the G SR cover plate as follows 4 9 2 1 Install ES stud 7 40 into adapter plate 7 10 4 9 3 Bettis P N 124840E Revision B Page 31 of 46 4 9 2 2 Install o ring seal 6 30 onto outboard end of ES 7 40 and up against outboard side of adapter plate 7 10 4 9 2 3 Install stop screw nut 7 50 onto outboard end of ES 7 40 Install the assembled ES adapter plate 7 10 onto the spring cartridge out end per Section 5 2 steps 5 2 11 through 5 2 15 SECTION 5 MODULE REMOVAL AND INSTALLATION NOTE When the Spring Module is to be removed it should be removed from the drive Module prior to the Pneumatic Power Module removal or disassembly WARNING WARNING 5 1 DO NOT REMOVE SPRING MODULE WHILE SPRING IS COMPRESSED ACTUATORS EQUIPPED WITH A SPRING CARTRIDGE MOUNTED M3 JACKSCREW OR AN EXTENDED STOP ES READ WARNING TAG WIRED TO THE SPRING CARTRIDGE COVER PLATE SPRING MODULE REMOVAL WARNING DO NOT REMOVE SPRING MODULE WHILE SPRING IS COMPRESSED NOTE NOTE NOTE 5 1 1 Review section 2 1 General Disassembly before proceeding with Spring Module Disassembly The setting of stop screws 1 180 should be checked and setting recorded before stop screws are loosened or removed G2 SRF and G3 SRF use step 5 1 1 G01 SHR G2 SR G3 SR through G13 skip step 5 1 1 and start at step 5 1 2 G2 SRF and G3
34. d of M3 assembly 5 50 7 40 NOTE Press or push the bearing retainer 5 110 7 110 into the M3 assembly forcing the retainer ring 5 90 7 90 onto the neck of the bearing retainer 5 110 7 110 M3 HANDWHEEL OR M3 HEX DRIVE HUB INSTALLATION 3 7 1 3 7 2 M3 HANDWHEEL OR HEX DRIVE HUB INSTALLATION TO M3 JACKSCREW 3 7 1 1 Install handwheel or hex drive hub 10 10 onto M3 jackscrew 7 40 3 7 1 2 Install two grooved pins 10 20 and 10 30 through handwheel hub or hex drive hub 10 10 and through M3 jackscrew 7 40 EARLY MODEL G2 amp G3 M3 HANDWHEEL AND HEX NUT INSTALLATION 3 7 2 1 Screw the slotted nut onto the outboard end of the M3 jackscrew with the slot facing toward the cylinder end cap Screw the nut until one of the slots in the nut is aligned with the cross drilled through hole in the stud CAUTION When aligning the slot and the cross drilled hole make certain that the back of the slot is at least one thread from being aligned with the hole 3 7 2 2 Insert the spiral pin through the slotted nut and through the jackscrew stud making sure that equal amounts of the spiral pin is exposed on both sides of the slotted nut and the jackscrew stud 3 7 2 3 For actuators equipped with a M3 jackscrew and require an optional handwheel install handwheel using the following procedure 3 7 2 3 1 Place the handwheel onto M3 jackscrew and over the pinned slotted nut NOTE The hub of handwheel has a cast hexagon h
35. e blind end cap 5 10 Install the M3 jackscrew assembly 5 50 through the inboard side of the blind end cap 5 10 Apply a light coating of lubricant to threads of M3 assembly 5 50 Screw M3 adapter 5 45 onto M3 jackscrew assembly 5 50 NOTE The small round end of the M3 adapter will install on the M3 assembly pointing to the inboard end of the M3 assembly Position the M3 assembly with the inboard end of the M3 located with the needle bearing thrust washer assembly 5 100 up against or near the M3 adapter 5 45 3 6 3 3 6 4 3 6 5 Bettis P N 124840E Revision B Page 26 of 46 3 6 2 6 Install two socket cap screws 5 120 through jackscrew adapter 5 45 and tighten into blind end cap 5 10 3 6 2 7 Lightly lubricate o ring seal 6 30 and install onto the outboard end of the M3 jackscrew assembly Push the o ring 6 30 down the M3 until it contacts the M3 adapter 5 45 3 6 2 8 Install flat hex nut 5 60 onto M3 assembly 5 50 Rotate the flat hex nut 5 60 until it is up against the o ring seal 6 30 G01 SR M3 JACKSCREW REASSEMBLY TO M3 SR ADAPTER PLATE 3 6 3 1 Apply a light coating of lubricant to the threads of jackscrew assembly 7 40 3 6 3 2 Install jackscrew adapter 7 45 onto the none bearing end of jackscrew assembly 7 40 3 6 3 3 Install jackscrew adapter 7 45 through M3 adapter plate 7 10 3 6 3 4 Retain jackscrew adapter 7 45 with retainer ring 7 55 G2 M3 amp G3 SR
36. e smaller round end of the jackscrew adapter will install on the jackscrew pointing to the outboard end of the jackscrew 3 6 23 1 3 Position the jackscrew with the inboard end of the jackscrew located with the needle bearing thrust washer assembly 3 350 up against or near the jackscrew adapter 3 280 3 6 23 1 4 Lightly lubricate o ring seal 6 20 and install into o ring groove on the outboard side of the jackscrew adapter 3 280 3 6 23 1 5 Insert jackscrew 3 290 through inboard side of the outer end cap 3 80 3 3 23 1 6 Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70 3 3 23 1 7 Install tie bar nuts 3 90 onto tie bars 3 20 NOTE Do not tighten nuts 3 3 23 1 8 Install the jackscrew adapter keeper 3 360 into the groove exposed on the outboard side of the jackscrew adapter 3 280 3 3 23 1 9 Lightly lubricate o ring seal 6 30 and install onto the outboard end of the jackscrew Push the o ring 6 30 down the jackscrew until it contacts the jackscrew adapter 3 280 3 3 23 1 10 Install flat hex nut 3 300 onto jackscrew 3 290 Rotate the flat hex nut 3 290 until it is up against o ring seal 6 30 3 3 23 1 11 Install outer end cap 3 80 over tie bars 3 20 and into cylinder 3 70 Continue at step 3 3 24 3 3 23 2 G2 8 G3 M3 OUTER END CAP INSTALLATION 3 3 23 2 1 Lightly lubricate o ring seal 6 10 and install into o ring groove in the M3 hole in the outer end cap 3 80 Bettis P N
37. emoved it should be removed from the Drive Module prior to the Pneumatic Power Module removal or disassembly 2 2 2 1 5 Bettis P N 124840E Revision B Page 6 of 46 The Pneumatic Power Module can be disassembled while still attached to the Drive Module or the Pneumatic Power Module can be removed from the Drive Module and disassembled separate to the actuator refer to Section 5 Module Removal And Installation To ensure correct re assembly that is with Pneumatic Power Module or Spring Module on same end of Drive Module as was mark or tag right or left and mark mating surfaces For Spring Module removal refer to Section 5 step 5 1 PNEUMATIC POWER MODULE DISASSEMBLY NOTE 1 Review Section 2 steps 2 1 1 through 2 1 5 General Disassembly before proceeding with Pneumatic Power Module Disassembly 2 If the actuator model is a GXX2XX Series two same size power modules with one module mounted on each side of the drive module then do the following steps on both Power Modules simultaneously or complete one power module and then repeat section 2 2 on the second Power Module WARNING If not already removed disconnect all operating pressure from actuator power cylinders WARNING If the actuator is spring return then the spring cartridge must be checked to 2 2 1 NOTE 2 2 2 2 2 3 NOTE 2 2 4 verify that the spring s are in their extended position before the Pneumatic Power Module is disassembled fro
38. gement Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability We reserve the right to modify or improve the designs or specifications of such products at any time without notice Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use and maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user Emerson Process Management Marshalltown lowa 50158 USA d Cernay 68700 France s Sao Paulo 05424 Brazil b Singapore 128461 www Fisher com EM ERSON Fisher Controls International LLC 2004 2007 All Rights Reserved Printed in USA Process M a nagement ENGLISH LANUAGE BETTIS SERVICE INSTRUCTIONS FOR MODELS G01 THROUGH G13 PNEUMATIC ACTUATORS PART NUMBER 124840E REVISION B DATE 17 December 2001 Bettis P N 124840E Revision B Page 1 of 46 CONTENTS SECTION 1 0 INTRODUCTION PAGE 1 1 General Service Information ssssssssssseseeeeene 3 1 2 Definitiori
39. groove pins 1 130 through housing cover 1 20 and into housing 1 10 The groove pins should be flush with the cover Torque tighten hex cap screws 1 110 until a final lubricated torque as listed in the following table has been achieved HOUSING COVER SCREW QUANTITY AND TORQUE TABLE MODEL QTY TORQUE MODEL QTY TORQUE 5 Percent 5 Percent FT Ib N m FT LB Nm G7 8 100 136 G8 12 100 136 G10 16 100 136 G13 20 340 461 NOTE 3 2 34 3 2 35 3 2 36 3 2 37 3 2 38 3 2 39 3 2 40 3 2 41 3 2 42 3 2 43 3 2 44 3 2 45 3 2 46 3 2 47 Bettis P N 124840E Revision B Page 17 of 46 Complete step 3 2 34 on G5 through G13 model actuators For GO1 through G4 model actuators skip step 3 2 34 and proceed to step 3 2 35 On G5 through G13 models 3 2 34 1 Place lockwashers 1 115 onto hex cap screws 1 120 NOTE Hex cap screw 1 120 are only used as hole fillers and to protect threads from environment 3 2 34 2Install and tighten hex cap screws 1 120 with lockwashers 1 115 Install thrust bearing 2 110 onto position indicator 1 140 Install o ring seal 2 100 onto position indicator 1 140 Install upper bearing 2 120 into yoke cover 1 150 Install rod wiper 2 80 into yoke cover 1 150 Install o ring seal 2 70 into yoke cover 1 150 Install yoke cover 1 150 onto housing cover 1 20 and over position indicator
40. he hole where the blind end cap was removed and pushing on the guide block 5 5 2 Refer to assembly drawing page 2 of 2 Detail B Use Bettis tool part number as listed in chart in section 1 step 1 2 1 to remove retainer nut assembly 1 60 from the guide block 1 30 CAUTION When removing rod extension assembly from guide block be careful not to drop one of the spherical washers inside the housing 5 5 3 Remove rod extension assembly 1 50 from guide block 1 30 NOTE One spherical washer 1 40 will be removed from guide block 1 30 when extension rod assembly is removed 5 5 4 Remove the remaining spherical washer 1 40 from guide block 1 30 G2 THRU G13 POWR SWIVL MODULE INSTALLATION WARNING The actuator must be in the appropriate over travel position Confirm over travel position by observing the guide block 1 30 is against the inner wall of housing 1 10 CAUTION While step 5 6 1 is in progress be sure to maintain guide bar retention when 5 6 1 5 6 2 5 6 3 5 6 4 moving the guide block Push the guide block to the required side of the housing 1 10 NOTE The guide block can be moved by inserting a long rod through either end of the housing and pushing on the guide block Lubricate two spherical washers 1 40 and one extension rod assembly 1 50 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
41. in thrust bearing 2 10 from inside bottom of housing 1 10 Remove yoke pin 1 80 by inserting 3 8 16 UNC screw into top of the yoke pin and pull straight up and out Remove guide block 1 30 from between the arms of yoke 1 70 Remove yoke guide block bushing 2 30 from top of guide block 1 30 Remove yoke guide block bushing 2 30 from the top of the lower yoke arm of yoke 1 70 G01 model actuators skip steps 2 3 23 through 2 3 25 and continue disassembly at step 2 3 26 Refer to assembly drawing page 2 of 2 Detail B Use Bettis tool part numbers 117368 G8 G10 117369 G5 G7 117370 G3 G4 122849 G13 or 123616 G2 and remove retention retainer nut assemblies 1 60 from guide block 1 30 On spring return actuators also remove retention retainer nut assemblies 9 60 Remove rod extension assembly 1 50 from guide block 1 30 On spring return actuators also remove rod extension assembly 9 50 2 4 2 5 NOTE 2 3 25 2 3 26 2 3 27 2 3 28 2 3 29 Bettis P N 124840E Revision B Page 11 of 46 One spherical washer 1 40 will be removed from guide block 1 30 when extension rod assembly is removed On spring return actuators also one spherical washer 9 40 will be removed from guide block 1 30 Remove the remaining spherical washer 1 40 from guide block 1 30 On spring return actuators also remove the remaining spherical washer 9 40 from guide block 1 30 Unscrew and remo
42. ing cartridge is a weld assembly 5 2 Bettis P N 124840E Revision B Page 33 of 46 SPRING MODULE INSTALLATION CAUTION 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 For the approximate weight of the spring cartridge refer to Section 6 WARNING ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION Refer to detail A on warning tag attached to Spring Module access hole cover or to Bettis drawing part number 130084 for G01 models or part number 123650 for G2 through G13 models Confirm over travel position by observing the guide block 1 30 is against the inner wall of housing 1 10 NOTE The setting of stop screws 1 180 should be checked and setting recorded before stop 5 2 1 5 2 2 5 2 3 5 2 4 screws are loosened or removed On stop screw 1 180 that is located on the same side of the housing as spring cartridge 5 10 loosen stop screw nut 1 190 Unscrew or back out stop screw 1 180 to achieve over travel as illustrated in detail A on warning tag attached to Spring Module cover plate or to Bettis drawing part number 123650 Install o ring seal 6 20 into the o ring groove in the inboard end of spring cartridge assembly 5 10 Using lifting equipment move Spring Module up to housing 1 10 and align spring cartridge tension rod with extension rod assembly 9 50 for G2 thro
43. ing into guide block 1 30 The guide bar bearing 2 20 must be pressed into guide block guide bar bore with the seam located 5 degrees of the top or bottom centerline as shown in section A A G01 model actuators skip steps 3 2 2 through 3 2 13 and continue reassembly at step 3 2 14 Lubricate guide block 1 30 two spherical washers 1 40 and one extension rod assembly 1 50 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 Install second spherical washer 1 40 over threaded end of extension rod assembly 1 50 NOTE The spherical side of the washer will go on the extension rod assembly facing the head of the extension rod assembly Install extension rod assembly 1 50 into guide block 1 30 and up against the first spherical washer 1 40 Install extension retainer nut assembly 1 60 over extension rod assembly 1 50 and screw into guide block 1 30 Tighten extension retainer nut assembly 1 60 until extension rod assembly 1 50 can not move Back off the extension retainer nut assembly 1 60 just enough to allow for extension rod assembly 1 50 to move freely Steps 3 2 8 through 3 2 13 are to be completed when the actuator is equipped with a Spring Module If the actuator is Double Acting then skip steps 3 2 8 through 3 2 13 and continue actuator reassembly starting with step 3 2 14 Lubricate
44. l a final lubricated torque as listed in the following table has been achieved TIE BAR NUTS HOUSING TORQUE HOUSING TORQUE MODEL 5 Percent MODEL 5 Percent FT Ib N m G2 G3 150 203 Install lockwashers 3 140 onto socket cap screws 3 130 Install and tighten socket cap screws 3 130 with lockwashers 8 140 into outer end cap 3 80 Install Pneumatic Power Module per Section 5 steps 5 4 BLIND END CAP MODULE INSTALLATION NOTE 3 5 1 3 5 2 NOTE 3 5 3 3 5 4 If the blind end cap has an M3 jackscrew or ES stop screw that has been removed from the blind end cap then pre assemble the M3 or ES into the blind end cap per Section 3 6 or 3 8 Install o ring seal 6 10 into the o ring groove in blind end cap 5 10 Install lockwashers 5 30 onto hex cap screws 5 20 Verify that steps 3 2 14 and 3 2 15 have been completed prior to commencing with step 3 5 3 Install blind end cap 5 10 onto end of housing 1 10 Install and tighten hex cap screws 5 20 with lockwashers 5 30 through housing 1 10 and into blind end cap 5 10 3 6 Bettis P N 124840E Revision B Page 25 of 46 M3 JACKSCREW ASSEMBLY NOTE 1 NOTE 2 3 6 1 3 6 2 This section is to be completed when the M3 jackscrew has been disassembled from the blind end cap or from the SR M3 adapter plate 7 10 If the thrust bearing assembly has been disassembled from the M3 jackscrew st
45. l groove NOTE The flat side of the D ring seal go down into the seal groove 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 Screw tie bars 3 20 into inner end cap 3 10 and tighten until the threads bottom out Refer to assembly drawing page 2 of 2 Detail E Coat two o ring seals 4 80 with lubricant and install into outer end cap 3 80 Apply lubricant to one o ring seal 4 40 and install into the outer diameter o ring groove of outer end cap 8 80 Apply lubricant to the bore of cylinder 8 70 CAUTION If needed when installing the cylinder hammer on the end of the cylinder only with a non metallic object 3 3 22 3 3 23 NOTE Bettis P N 124840E Revision B Page 20 of 46 Install lubricated cylinder 3 70 over piston 3 30 and onto inner end cap 3 10 When installing the cylinder over the piston seal tilt cylinder 15 to 30 degrees to piston rod OUTER END CAP 3 80 INSTALLATION AS FOLLOWS G01 M3 use step 3 3 23 1 G2 M3 and G3 M3 use step 3 3 23 2 and standard outer end cap use step 3 3 23 3 The outer end cap 3 80 pressure inlet port should be positioned in the same position as recorded in Section 2 2 step 2 2 1 3 3 23 1 G01 M3 OUTER END CAP INSTALLATION 3 6 23 1 1 Apply a light coating of lubricant to threads of jackscrew 3 290 3 6 23 1 2 Screw jackscrew adapter 3 280 onto jackscrew 3 290 NOTE Th
46. ll breather assembly 12 in outer end cap 3 80 Individual actuators may not have reducer bushing 14 depending on port and breather size G2 AND G3 EARLY MODEL PNEUMATIC POWER MODULE REASSEMBLY NOTES 1 Early G2 and G3 pneumatic power modules where equipped with tie bars that had nuts on both ends of the tie bars 3 20 double nuts 2 Refer to Section 2 step 2 1 4 for the correct installation location for piston rod 3 40 3 THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION Confirm over travel position by observing the guide block 1 30 is against the inner wall of housing 1 10 3 4 1 Refer to assembly drawing page 2 of 2 Detail C Install one rod wiper 4 10 into inner end cap 3 10 3 4 2 Install one rod bushing 4 20 into inner end cap 3 10 3 4 3 Coat one Polypak seal 4 30 with lubricant and install lip first into inner end cap 3 10 CAUTION Install the Polypak seal with energizer ring facing outboard side of inner end cap 3 10 3 4 4 3 4 5 NOTE 3 4 6 3 4 7 3 4 8 3 4 9 3 4 10 3 4 11 3 4 12 3 4 13 3 4 14 3 4 15 3 4 16 Bettis P N 124840E Revision B Page 23 of 46 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 Apply lubricant to two sets of rod T seal components 4 50 The T seal is composed of one rubber seal and two split skive cut b
47. m the Drive Module refer to Section 5 1 through step 5 1 6 Mark and record location of the ports on outer end cap 8 80 and inner end cap 3 10 If actuator is equipped with a Spring Module complete step 2 2 2 If actuator is a Double Acting model skip step 2 2 2 and go to step 2 2 3 Remove breather assembly 12 from outer end cap 3 80 Refer to assembly drawing page 2 of 2 Detail E Remove two socket cap screws 3 130 with lockwasher 3 140 from outer end cap 3 80 If the Power Module is equipped with an M3 jackscrew remove the M3 jackscrew using Section 2 6 5 for G01 models and Section 2 6 6 for G2 and G3 models Outer end cap 3 80 removal as follows 2 2 4 1 G01 through G13 standard end cap 3 80 removal Continue at step 2 2 5 2 2 4 2 G01 M3 JACKSCREW DISASEMBLY FROM OUTER END CAP 3 80 2 2 4 2 1 Remove M3 handwheel or M3 hex drive hub from M3 3 290 per Section 2 5 2 2 4 2 2 2 2 4 2 3 2 2 4 2 4 2 2 4 2 5 Bettis P N 124840E Revision B Page 7 of 46 Refer to assembly drawing page 2 of 2 Detail E If not already removed unscrew and remove two socket cap screws 3 130 with lockwasher 3 140 from outer end cap 3 80 Remove socket cap screw 3 130 with lockwasher 3 140 from keeper 3 360 Remove keeper 3 360 from outer end cap 3 80 Push jackscrew 3 290 back into the outer end cap far enough so that the jackscrew adapter 3 280 will not interfere with the removal of he
48. nstall the assembled M3 outer end cap 3 80 per Section 3 3 steps 3 3 23 2 11 or 3 3 23 3 11 and 3 3 24 through 3 3 26 To install the M3 Handwheel or M3 drive hub refer to Section 3 7 ADD AN M3 JACKSCREW TO SPRING MODULE 4 6 1 4 6 2 4 6 3 4 6 4 Remove G SR 7 10 adapter plate per Section 5 1 steps 5 1 2 and 5 1 3 If new M3 G SR adapter plate 7 10 is not pre assembled with the M3 then assembly M3 to the G SR cover plate 7 10 per Section 3 steps 3 6 3 or 3 6 4 Install the assembled M3 adapter plate 7 10 onto the spring cartridge out end per Section 5 2 steps 5 2 11 through 5 2 15 To install the M3 Handwheel or M3 drive hub refer to Section 3 7 ADD AN EXTENDED STOP ES TO BLIND END CAP MODULE 4 7 1 4 7 2 4 2 3 Remove blind end cap module per Section 2 4 If new ES blind end cap module is not pre assembled with the ES then assembly ES to the blind end cap per Section 3 8 Install the assembled ES blind end module per Section 3 5 ADD AN EXTENDED STOP ES TO POWER MODULE OUTER END CAP 4 8 1 4 8 2 4 8 3 Remove outer end cap per Section 2 2 steps 2 2 5 and 2 2 6 If new ES outer end cap is not pre assembled with the ES then assembly ES to the end cap per Section 3 8 Install the assembled ES outer end 3 80 per Section 3 3 steps 3 3 23 3 3 3 24 through 3 3 26 ADD AN EXTENDED STOP ES TO SPRING MODULE 4 9 1 4 9 2 Remove G SR 7 10 adapter plate per Section 5 1 steps 5 1 2 an
49. ole that fits over the pinned slotted nut 3 7 2 3 2 Place lockwasher onto M3 jackscrew up against handwheel hub 3 7 2 3 3 Install and tighten hex nut onto M3 jackscrew and screw nut up against the lockwasher EXTENDED STOP BLIND END CAP REASSEMBLY 3 8 1 3 8 2 Apply a light coating of lubricant to the threads of ES stop screw 5 50 Install hex nut 5 60 onto the ES stop screw 5 50 3 9 4 1 Bettis P N 124840E Revision B Page 28 of 46 3 8 3 Install ES stop screw 5 50 through ES blind end cap 5 10 ACTUATOR TESTING 3 9 1 Leakage Test All areas where leakage to atmosphere may occur are to be checked using a commercial leak testing solution CAUTION Pressure applied to the actuator is not to exceed the maximum operating pressure rating listed on the actuator name tag Test the actuator using a properly adjusted self relieving regulator with gauge 3 9 2 Cycle the actuator five time at the nominal operating pressure NOP as listed on the actuator name tag or the customers normal actuator supply pressure If excessive leakage across the pistons is noted generally a bubble which breaks three seconds or less after starting to form cycle the actuator five times as this will allow the seals to seek their proper service condition 3 9 3 Apply NOP pressure to the pressure port in inner end cap 3 10 and allow the actuator to stabilize 3 9 4 Apply a commercial leak testing solution to the following areas 3
50. on 3 4 for reassembly 2 Refer to Section 2 step 2 1 4 for the correct installation location for piston rod 3 40 3 THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION Confirm over travel position by observing the guide block 1 30 is against the inner wall of housing 1 10 3 3 1 Lubricate piston rod 3 40 and insert through the side of housing 1 10 3 3 1 1 G2 through G13 screw piston rod 3 40 onto extension rod assembly 1 50 3 3 1 2 G01 only screw piston rod 3 40 onto guide block 1 30 3 3 2 Torque tighten piston rod 3 40 to the lubricated torque as listed in the following table PISTON ROD TORQUE INFORMATION TORQUE TORQUE 5 Percent 5 Percent N m FT LB N m 3 3 3 Refer to assembly drawing page 2 of 2 Detail C Install one rod wiper 4 10 into inner end cap 3 10 3 3 4 Install one rod bushing 4 20 into inner end cap 3 10 3 3 5 Coat one Polypak seal 4 30 with lubricant and install lip first into inner end cap 3 10 CAUTION Install the Polypak seal with energizer ring facing outboard side away from housing 3 3 6 Install one o ring seal 4 90 into seal groove located on the inboard face of inner end cap 3 10 3 3 7 Install inner end cap 3 10 on to housing 1 10 NOTE The pressure inlet port should be positioned in the same position as recorded in section 2 2 step 2 2 1 3 3 8 3 3 9 3 3 11 3 3 12 NOTE 3 3 13 3 3 14 3 3 15 3 3 16 3 3
51. ot be used without prior written approval 1 6 1 of Bettis Product Engineering All temperature services 50 F to 350 F 45 5 C to 176 6 C use Bettis ESL 5 lubricant ESL 5 lubricant is contained in the Bettis Module Service Kit in tubes or cans and they are marked ESL 4 5 amp 10 lubricant 1 7 GENERAL TOOL INFORMATION 1 7 1 Tools All tools Hexagons are American Standard inch Imperial Large adjustable wrench two 2 large screwdrivers Allen wrench set set of open box end wrenches rubber or leather mallet torque wrench up to 1600 foot pounds 2169 N m breaker bar and a drive socket set For recommended tool and wrench sizes refer to Section 6 Tables 6 2 through 6 10 SECTION 2 ACTUATOR DISASSEMBLY 2 1 GENERAL DISASSEMBLY WARNING WARNING WARNING It is possible that the actuator may contain a dangerous gas and or liquids 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 is written to either completely disassemble the entire actuator or can be used to disassemble individual Modules as needed Pneumatic Power Module or Drive module ect DO NOT REMOVE SPRING MODULE WHILE SPRING IS COMPRESSED ACTUATORS EQUIPPED WITH A SPRING CARTRIDGE MOUNTED M3 JACKSCREW OR AN EXTENDED STOP ES READ WARNING TAG WIRED TO THE SPRING CARTRIDGE COVER PLATE When the Spring Module is to be r
52. ot to loose o ring seal 4 90 5 3 4 Remove power module from actuator housing 1 10 POWER MODULE INSTALLATION 5 4 1 Check to verify that o ring seal 4 90 is properly seated in its seal groove located on the housing side of inner end cap 3 10 NOTE G2 and G3 models older models confirm that the two inboard hex nuts 3 90 flats are aligned to fit into the slot located in the end of housing 1 10 5 4 2 5 4 3 Bettis P N 124840E Revision B Page 38 of 46 Using lifting equipment move the power module up to the drive module and align piston rod 3 40 as follows 5 4 2 1 G2 through G13 models align piston rod 3 40 with power module extension rod assembly 1 50 5 4 2 2 G01 models align piston rod 3 40 with the drive module guide block 1 30 Using a male square drive extension go through outer end cap 3 80 and install piston rod 3 40 as follows 5 4 3 1 G2 through G13 screw piston rod 3 40 onto extension rod assembly 1 50 5 4 3 2 G01 only screw piston rod 3 40 onto guide block 1 30 CAUTION When screwing piston rod into the G2 through G13 extension rod assembly 5 4 4 5 4 5 5 4 6 5 4 7 1 50 or G01 guide block 1 30 make certain that the piston rod and extension rod assembly guide block threads do not cross thread Torque tighten piston rod 3 40 Refer to Section 3 step 3 3 2 for correct torque value Install lock washers 3 110 onto hex cap screws 3 100 Ins
53. ough housing 1 10 and into spring cartridge assembly 5 10 and tighten Install o ring seal 6 10 into the o ring groove in the outboard end of spring cartridge assembly 5 10 G2 SRF and G3 SRF use step 5 2 10 G01 SR G2 SR G3 SR through G13 SR skip step 5 2 10 and start at step 5 2 11 Using pipe sealant on the threads install pipe plug 7 10 in the vacant hole in out board end of spring cartridge assembly 5 10 Skip steps 5 2 10 through 5 2 13 and start at step 5 2 14 Install lockwashers 7 30 onto hex cap screws 7 20 Install the cover plate 7 10 or install M3 adapter plate 7 10 onto the outboard end of spring cartridge assembly 5 10 Install and tighten hex cap screws 7 20 with lockwashers 7 30 through cover plate 7 10 and into spring cartridge assembly 5 10 Torque tighten hex cap screws 7 20 until a final lubricated torque as listed in the following table has been achieved Bettis P N 124840E Revision B Page 35 of 46 HEX CAP SCREWS 7 20 TORQUE TABLE HOUSING TORQUE 5 Percent MODEL TORQUE 5 Percent FT Ib FT Ib 5 2 15 On M3 M3HW and ES models install Monel wire 6 130 through each hex cap screw 7 20 per the following steps NOTE The following steps provides guidelines for wire locking hex cap screws to discourage screw loosening and removal in applications where screw removal could be hazardous
54. r being refurbished 3 1 1 Remove and discard all old seals and gaskets 3 1 2 All parts should be cleaned to remove all dirt and other foreign material prior to inspection 3 1 3 All parts should be thoroughly inspected for excessive wear stress cracking galling and pitting Attention should be directed to threads sealing surfaces and areas that will be subjected to sliding or rotating motion Sealing surfaces of the cylinder tie bars and piston rod must be free of deep scratches pitting corrosion and blistering or flaking coating CAUTION Actuator parts that reflect any of the above listed characteristics should be replaced with new parts 3 1 4 Before installation coat all moving parts with a complete film of lubricant Coat all seals with a complete film of lubricant before installing into seal grooves 3 2 NOTE 3 1 5 Bettis P N 124840E Revision B Page 14 of 46 The parts and seals used in the actuator will be assembled using lubricant as identified in section 1 step 1 6 1 For Spring Module Installation refer to Section 5 step 5 2 DRIVE MODULE REASSEMBLY NOTE NOTE 3 2 1 NOTE NOTE 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 3 2 7 NOTE 3 2 8 3 2 9 Review section 3 1 General Reassembly before proceeding with Drive Module Reassembly Refer to assembly drawing page 2 of 2 Detail B for section drawing of guide block If guide bar bearing 2 20 is being replaced install new bear
55. tall hex cap screws 3 100 with lockwashers 3 110 through housing 1 10 and screw into inner end cap 3 10 Standard Outer end cap with pipe plug use step 5 4 7 1 outer end cap with extended stop ES use step 5 4 7 2 G2 or G3 outer end cap with M3 or M3HW use step 5 4 7 3 and G01 outer end cap with M3 or M3HW use step 5 4 7 4 5 4 7 1 Standard outer end cap Using pipe dope install pipe plug 3 120 into outer end cap 3 80 5 4 7 2 ES outer end cap 5 4 7 2 1 Screw ES 3 180 into outer end cap 3 80 5 4 7 2 2 Install ES nut 3 190 on to ES 3 180 5 4 7 3 G2 or G3 M3 M3HW outer end cap 5 4 7 3 1 Install M3 adapter 3 280 into outer end cap 3 80 5 4 7 3 2 Install socket cap screws 3 320 through M3 adapter 3 280 and into outer end cap 3 80 5 3 1 4 GO1M3 M3HW outer end cap 5 3 1 4 1 Remove socket cap screw 3 130 from M3 keeper 3 360 5 3 1 4 2 Remove M3 keeper 3 360 from M3 adapter 3 360 and outer end cap 3 80 5 5 5 6 Bettis P N 124840E Revision B Page 39 of 46 5 3 1 4 3 Remove M3 jackscrew 3 290 with M3 adapter 3 360 from outer end cap 3 80 G2 THRU G13 POWR SWIVL REMOVAL CAUTION While step 5 5 1 is in progress be sure to maintain guide bar retention when moving the guide block 5 5 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 non metallic rod through t
56. tended Stop Blind End Cap Reassembly ssssssssss 27 3 9 Actuator Testing codicia ea ar tede tee DER Pe Pee idad 28 SECTION 4 0 FIELD CONVERSIONS 4 1 Fail Mode Reversal CW to CCW ect sse 28 4 2 Convert Double Acting to Spring Return sessssssss 29 4 3 Convert Spring Return to Double Acting ssseseesse 29 4 4 Add An M3 Jackscrew To Blind End Cap Module 29 4 5 Add An M3 Jackscrew To Power Module Outer End Cap 29 4 6 Add An M3 Jackscrew To Spring Module sss 30 4 7 Add An Extended Stop Es To Blind End Cap Module 30 4 8 Add An Extended Stop Es To Power Module Outer End Cap 30 4 9 Add An Extended Stop Es To Spring Module ssss 30 Contents Continued next page CONTENTS SECTION 5 0 MODULE REMOVAL AND INSTALLATION 5 1 Spring Module Removal 5 3 Pneumatic Power Module Removal 5 4 Pneumatic Power Module Installation 5 5 G2 Through G13 Powr Swivl Module Removal 5 6 G2 Through G13 Powr Swivl Module Installation SECTION 6 0 ACTUATOR SUPPORT INFORMATION 6 1 Module Weight Table 6 2 G01 Tool Table 6 3 G2 Tool Table 6 4 G3 Tool Table 6 5 G4 Tool Table 6 6 G5 Tool Table 6 7 G7 Tool Table 6 8 G8 Tool Table 6 9 G10 Tool Table 6 10 G13 Tool Table 5 2 Spring Module Installation
57. ud then pre assemble the thrust bearing assembly to the M3 jackscrew stud per Section 3 6 5 G01 M3 JACKSCREW REASSEMBLY TO M3 BLIND END CAP 3 6 1 1 3 6 1 2 3 6 1 3 3 6 1 4 3 6 1 5 3 6 1 6 3 6 1 7 3 6 1 8 Apply a light coating of lubricant to threads of M3 assembly 5 50 Screw M3 adapter 5 45 onto M3 assembly 5 50 NOTE The smaller round end of the M3 adapter will install on the M3 assembly pointing to the outboard end of the M3 assembly Position the M3 assembly with the inboard end of the M3 located with the needle bearing thrust washer assembly 5 100 up against or near the M3 adapter 5 45 Lightly lubricate o ring seal 6 20 and install into o ring groove on the outboard side of the M3 adapter 5 45 Insert M3 assembly 5 50 through inboard side of the M3 blind end cap 5 10 Install the jackscrew adapter keeper 5 140 into the groove exposed on the outboard side of the M3 adapter 5 45 Lightly lubricate o ring seal 6 30 and install onto the outboard end of the M3 jackscrew assembly Push the o ring 6 30 down the M3 until it contacts the M3 adapter 5 45 Install flat hex nut 5 60 onto M3 assembly 5 50 Rotate the flat hex nut 5 60 until it is up against the o ring seal 6 30 G2 M3 amp G3 M3 JACKSCREW REASSEMBLY TO M3 BLIND END CAP 3 6 2 1 3 6 2 2 3 6 2 3 3 6 2 4 3 6 2 5 Lightly lubricate o ring seal 6 10 and install into o ring groove in the M3 hole in th
58. ugh G13 models or G01 models align spring cartridge with tapped hole in guide block 1 30 WARNING COMPLETE STEP 5 2 5 TO AVOID SEVER INJURY TO PERSONNEL OR 5 2 5 INCUR MAJOR DAMAGE TO THE ACTUATOR SPRING CARTRIDGE TENSION ROD TO ROD EXTENSION INSTALLATION AS FOLLOWS 5 2 5 1 Using a male square drive extension go through the open end of Spring Module 5 10 and rotate the tension rod nut until initial thread engagement is achieved NOTE Confirm initial thread engagement of rod extension 9 50 to tension rod 5 2 5 2 After confirming initial thread engagement rotate tension rod into extension rod assembly 9 50 per the following table Bettis P N 124840E Revision B Page 34 of 46 WARNING After initial thread engagement the tension rod must be rotated clockwise the minimum number of turns listed in the following table MODEL UNITS ALA NO TURNS WARNING When screwing tension rod into extension rod assembly 9 50 make certain 5 2 6 5 2 7 5 2 8 5 2 9 NOTE 5 2 10 5 2 11 5 2 12 5 2 13 5 2 14 that the tension rod and extension rod assembly threads do not cross thread Torque tighten the spring cartridge tension rod as listed in the following table HOUSING TORQUE 5 Percent HOUSING TORQUE 5 Percent MODEL MODEL FT Lb N m G7 240 325 MA E PEN Install lock washers 5 30 onto hex cap screws 5 20 Install hex cap screws 5 20 with lockwashers 5 30 thr
59. ve two stop screw nuts 1 190 from stop screws 1 180 Unscrew and remove two stop screws 1 180 from front of housing 1 10 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 2 3 28 2 G4 through G13 housing 1 10 unscrew and remove two vent check assembly s 13 from the front of housing 1 10 The following items do not need to be removed from their assembled locations unless being replaced by new items Two guide bar bearings two yoke bearings 2 40 yoke pin bearing and yoke pin thrust bearing 2 10 BLIND END CAP MODULE REMOVAL 2 4 1 2 4 2 Remove hex cap screws 5 20 with spring lockwashers 5 30 from blind end cap 5 10 Remove blind end cap 5 10 from end of housing 1 10 M3 HANDWHEEL OR M3 HEX DRIVE HUB REMOVAL 2 5 1 2 5 2 M3 HANDWHEEL OR HEX DRIVE HUB REMOVAL FROM M3 STUD 2 5 1 1 Using pin punch drive out two grooved pins 10 20 and 10 30 from handwheel hub or hex drive hub 10 10 2 5 1 2 Remove handwheel or hex drive hub 10 10 from M3 stud 5 50 EARLY MODEL G2 amp G3 M3 HANDWHEEL AND HEX NUT REMOVAL FROM JACKSCREW 2 5 2 1 Remove hex nut lockwasher from M3 jackscrew 2 5 2 2 Remove handwheel from M3 jackscrew 2 5 2 3 Using pin punch drive out spiral pin from outboard end of M3 jackscrew 2 5 2 4 Remove hex nut from M3 jackscrew and handwheel Bettis
60. x nuts 3 90 Continue at step 2 2 5 2 2 4 8 G02 amp G3 M3 JACKSCREW DISASEMBLY FROM OUTER END CAP 3 80 2 2 4 3 1 2 2 4 3 2 2 2 4 3 3 2 2 4 3 4 Remove M3 handwheel or M3 hex drive hub from M3 3 290 per Section 2 5 Unscrew and remove hex flat nut 3 300 from G2 G3 M3 jackscrew 3 290 Unscrew and remove two socket cap screws 3 320 from G2 G3 M3 adapter 3 280 Remove M3 jackscrew 3 290 from outer end cap 3 80 Continue at step 2 2 5 2 2 5 Remove two tie bar hex nuts 3 90 from outboard side of outer end cap 3 80 2 2 6 The fit between cylinder 3 70 and outer end cap 3 80 is very tight Break end cap free by tapping with a breaker bar on lip provided on the end cap Remove outer end cap 3 80 from cylinder 3 70 CAUTION Do not damage o ring groove when removing end cap from cylinder NOTE When removing cylinder 3 70 off of piston 3 30 tilt the cylinder 15 to 30 degrees with respect to actuator centerline 2 2 7 Remove cylinder 3 70 from inner end cap 3 10 CAUTION Do not use pipe wrench to remove tie bars 2 2 8 TIE BAR REMOVAL NOTE G01 G2 and G3 models have flats on outboard end of tie bars 3 20 for wrench placement 2 2 8 1 Remove G01 G2 and G3 tie bars 3 20 as follows 2 2 8 1 1 Unscrew tie bars 3 20 from inner end cap 3 10 Pull the tie bars out of the inner end cap far enough to expose the o ring seals 4 80 2 2 9 NOTE 2 2 10 2 2

Emerson Process Management G01 Automobile Parts User Manual

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