Instruction Manual Form 5653 February 2007 Bettis Actuators G01 through G13 Bettisr 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 Managementt. Please contact Bettis to ensure that the following instruction manual is the most recent one available.
Instruction Manual Bettis Actuators G01 through G13 Form 5653 February 2007 Fisher and Bettis are marks owned by the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.
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 1.1 1.2 1.3 1.4 1.5 1.6 1.7 PAGE General Service Information ................................................................... Definitions ............................................................................................... General Safety Information ..................................................................... Bettis Reference Materials ..................................................................
Bettis P/N 124840E Revision “B” Page 2 of 46 CONTENTS SECTION 5.0 - MODULE REMOVAL AND INSTALLATION 5.1 5.2 5.3 5.4 5.5 5.6 Spring Module Removal .......................................................................... Spring Module Installation ....................................................................... Pneumatic Power Module Removal ........................................................ Pneumatic Power Module Installation .....................................................
Bettis P/N 124840E Revision “B” Page 3 of 46 SECTION 1 - INTRODUCTION 1.1 GENERAL SERVICE INFORMATION 1.1.1 This service procedure is offered as a guide to enable general maintenance to be performed on Bettis G01XXX, 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.
Bettis P/N 124840E Revision “B” Page 4 of 46 1.2 1.3 1.4 1.5 DEFINITIONS WARNING: If not observed, user incurs a high risk of severe damage to actuator and/or fatal injury to personnel. CAUTION: If not observed, user may incur damage to actuator and/or injury to personnel. NOTE: Advisory and information comments provided to assist maintenance personnel to carry out maintenance procedures. ES: Extended stop screw (for travel stop adjustment over a full 100° degree travel range).
Bettis P/N 124840E Revision “B” Page 5 of 46 ACTUATOR MODEL G01 G2 G3/G4 1.6 BETTIS PART NUMBER None required 123616 117370 1.5.3 Commercial leak testing solution. 1.5.4 Non-hardening thread sealant. ACTUATOR MODEL G5/G7 G8/G10 G13 BETTIS PART NUMBER 117369 117368 122849 LUBRICATION REQUIREMENTS NOTE: Lubricants, other than listed in step 1.6.1 should not be used without prior written approval of Bettis Product Engineering. 1.6.1. 1.7 All temperature services (-50°F to +350°F)/(-45.5°C to 176.
Bettis P/N 124840E Revision “B” Page 6 of 46 2.2 2.1.3 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). 2.1.4 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. 2.1.
Bettis P/N 124840E Revision “B” Page 7 of 46 2.2.4.2.2 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). 2.2.4.2.3 Remove socket cap screw (3-130) with lockwasher (3-140) from keeper (3-360). 2.2.4.2.4 Remove keeper (3-360) from outer end cap (3-80). 2.2.4.2.
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.
Bettis P/N 124840E Revision “B” Page 9 of 46 2.2.14 Unscrew and remove piston rod (3-40) from drive module. 2.3 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.
Bettis P/N 124840E Revision “B” Page 10 of 46 2.3.12 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). NOTE: G01, G2, G3 and G4 model housing cover will have cast tabs for placing prying tools to aid in cover removal. 2.3.13 Remove housing cover (1-20) from housing (1-10).
Bettis P/N 124840E Revision “B” Page 11 of 46 NOTE: 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). 2.3.25 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). 2.3.
Bettis 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 (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. 2.6.1 G01-M3 JACKSCREW DISASEMBLY FROM BLIND END CAP 2.6.1.
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.
Bettis P/N 124840E Revision “B” Page 14 of 46 NOTE: The parts and seals used in the actuator will be assembled using lubricant as identified in section 1 step 1.6.1. 3.1.5 3.2 For Spring Module Installation refer to Section 5 step 5.2. DRIVE MODULE REASSEMBLY NOTE: Review section 3.1 General Reassembly before proceeding with Drive Module Reassembly. NOTE: Refer to assembly drawing page 2 of 2 Detail "B" for section drawing of guide block. 3.2.
Bettis P/N 124840E Revision “B” Page 15 of 46 3.2.10 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. 3.2.11 Install extension rod assembly (9-50) into guide block (1-30) and up against the first spherical washer (9-40). 3.2.12 Install extension retainer nut (9-60) over extension rod assembly (9-50) and screw into guide block (1-30). 3.2.
Bettis P/N 124840E Revision “B” Page 16 of 46 3.2.22 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). NOTE: The yoke pin can be held in place by installing a screw into the .375-16UNC tapped hole in the upper end of yoke pin (1-80). 3.2.
Bettis P/N 124840E Revision “B” Page 17 of 46 NOTE: Complete step 3.2.34 on G5, through G13 model actuators. For G01 through G4 model actuators skip step 3.2.34 and proceed to step 3.2.35. 3.2.34 On G5 through G13 models 3.2.34.1Place 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). 3.2.
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. 3.3 PNEUMATIC POWER MODULE REASSEMBLY NOTES: 3.3.1 1. For early model G2 and G3 actuators with double nuts on the power module use section 3.4 for reassembly. 2. Refer to Section 2 step 2.1.4 for the correct installation location for piston rod (3-40). 3.
Bettis P/N 124840E Revision “B” Page 19 of 46 3.3.8 Place lockwashers (3-110) onto hex cap screws (3-100). 3.3.9 Install and tighten hex cap screws (3-100), with lockwashers, through housing (1-10) and into inner end cap (3-10). 3.3.11 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). 3.3.12 Apply lubricant to two sets of rod T-seal components (4-50).
Bettis P/N 124840E Revision “B” Page 20 of 46 3.3.22 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. 3.3.23 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.
Bettis P/N 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.
Bettis P/N 124840E Revision “B” Page 22 of 46 3.3.25 Install lockwashers (3-140) onto socket cap screws (3-130). 3.3.26 Install and tighten socket cap screws (3-130), with lockwashers (3-140), into outer end cap (3-80). NOTE: If the outer end cap (3-80) has an ES stop screw completed steps 3.3.27 through 3.3.29. 3.3.27 If not already removed then remove hex nut (3-190) and old o-ring seal (4-100). 3.3.28 Install new o-ring seal (4-100) onto the ES stop screw and up against outer end cap (3-80). 3.3.
Bettis P/N 124840E Revision “B” Page 23 of 46 3.4.4 Install piston rod (3-40) through inner end cap (3-10). NOTE: The piston rod end with retainer grooves to be on the outboard side of inner end cap (3-10). 3.4.5 Apply lubricant to two sets of rod T-seal components (4-50). NOTE: The T-seal is composed of one rubber seal and two split skive-cut back-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.
Bettis P/N 124840E Revision “B” Page 24 of 46 CAUTION: If needed, when installing the cylinder, hammer on the end of the cylinder only with a non metallic object. 3.4.17 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. NOTE: 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. 3.4.
Bettis P/N 124840E Revision “B” Page 25 of 46 3.6 M3 JACKSCREW ASSEMBLY NOTE: 1. 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). NOTE: 2. If the thrust bearing assembly has been disassembled from the M3 jackscrew stud then pre assemble the thrust bearing assembly to the M3 jackscrew stud per Section 3.6.5. 3.6.1 G01-M3 JACKSCREW REASSEMBLY TO M3 BLIND END CAP. 3.6.1.
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). 3.6.
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 end of M3 assembly (5-50) / (7-40).
Bettis P/N 124840E Revision “B” Page 28 of 46 3.8.3 3.9 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.
Bettis P/N 124840E Revision “B” Page 29 of 46 4.2 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 4.2.1 Remove the Blind End Cap Module per Section 2.4. 4.2.
Bettis P/N 124840E Revision “B” Page 30 of 46 4.6 4.7 4.8 4.9 4.5.2 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. 4.5.3 Install 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. 4.5.4 To install the M3 Handwheel or M3 drive hub refer to Section 3.7. ADD AN M3 JACKSCREW TO SPRING MODULE 4.6.
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). 4.9.3 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.
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.
Bettis P/N 124840E Revision “B” Page 33 of 46 5.2 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.
Bettis P/N 124840E Revision “B” Page 34 of 46 WARNING: ACTUATOR MODEL MINIMUM NO TURNS WARNING: 5.2.6 After initial thread engagement the tension rod must be rotated clockwise the minimum number of turns listed in the following table. TORQUE G01 G2 G3 G4 G5 G7 G8 G10 G13 UNITS N/A 6 10 10 10 13 14 20 25 31 When screwing tension rod into extension rod assembly (9-50) make certain that the tension rod and extension rod assembly threads do not cross-thread.
Bettis P/N 124840E Revision “B” Page 35 of 46 HOUSING MODEL G01 G2 G3 G4 G5 HEX CAP SCREWS (7-20) TORQUE TABLE TORQUE ±5 % Percent HOUSING TORQUE ±5 % Percent MODEL (FT-lb.) N-m (FT-lb.) N-m 30 41 G7 135 183 30 41 G8 240 325 30 41 G10 285 386 65 88 G13 340 461 65 88 5.2.
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 If removed install stop screw nuts (1-190) onto stop screws (1-180). 5.2.17 If removed install o-ring (2-90) onto stop screws (1-180). 5.2.18 If removed install two stop screws (1-180) into two stop screw holes on the front of housing (1-10). 5.2.
Bettis P/N 124840E Revision “B” Page 37 of 46 5.3 PNEUMATIC POWER MODULE REMOVAL CAUTION: 5.3.1 Due to the weight and size of power module, heavy duty support equipment 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.
Bettis P/N 124840E Revision “B” Page 38 of 46 5.4.2 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). 5.4.3 Using a male square drive extension, go through outer end cap (3-80) and install piston rod (3-40) as follows: 5.4.3.
Bettis P/N 124840E Revision “B” Page 39 of 46 5.3.1.4.3 5.5 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).
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.
Bettis P/N 124840E Revision “B” Page 41 of 46 6.1 CONTINUED - MODULE WEIGHTS BY ITEM NUMBER AND ACTUATOR HOUSING SIZE ITEM NO. 3 3 3 3 5 5 5 5 5 5 5 5 5 5 5 5 Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg Lbs. Kg G01 WT. N/A N/A N/A N/A N/A N/A N/A N/A 160 73 158 72 153 153 144 65 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A G2 WT.
Bettis P/N 124840E Revision “B” Page 42 of 46 6.2 G01 TOOL STYLE AND WRENCH SIZE ITEM NO. 1-110 1-160 1-180 1-190 3-20 3-40 3-90 3-100 3-120 3-130 5-20 7-20 12 13 - 6.3 WRENCH SIZE 9/16” ½” 3/8” Sq. 1-15/16” 3/8” 3/8” Sq. 1-1/8” 9/16” 5/8” Sq. 3/16” 9/16” 9/16” 1” 3/4” 3/8” Sq.
Bettis P/N 124840E Revision “B” Page 43 of 46 6.4 G3 TOOL STYLE AND WRENCH SIZE ITEM NO. 1-110 1-160 1-180 1-190 3-20 3-40 3-90 3-100 3-120 3-130 5-20 7-20 12 13 - 6.5 WRENCH SIZE 9/16” 9/16” 1/2” Sq. 1-5/16” 1/2” 3/8” Sq. 1-5/16” 9/16” 5/8” Sq. 3/16” 9/16” 9/16” 1” 3/4” 3/8” Sq.
Bettis P/N 124840E Revision “B” Page 44 of 46 6.6 G5 TOOL STYLE AND WRENCH SIZE ITEM NO. 1-110 1-120 1-160 1-180 1-190 3-20 3-40 3-90 3-100 3-120 3-130 5-20 7-20 12 13 - 6.7 WRENCH SIZE 3/4” 3/4” 9/16” 7/8” Sq. 2-3/8” 1/2” Sq. 1/2” Sq. 2” 3/4” 1-1/8” Sq.
Bettis P/N 124840E Revision “B” Page 45 of 46 6.8 G8 TOOL STYLE AND WRENCH SIZE ITEM NO. 1-110 1-120 1-160 1-180 3-20 3-40 3-90 3-100 3-120 3-130 5-20 7-20 12 13 - 6.9 WRENCH SIZE 3/4” 3/4” 9/16” 1-1/4” 3/4” Sq. 3/4” Sq. 2-3/4” 1-1/8” 1-5/16” Sq.
Bettis P/N 124840E Revision “B” Page 46 of 46 6.10 G13 TOOL STYLE AND WRENCH SIZE ITEM NO. 1-110 1-120 1-160 1-180 3-20 3-40 3-90 3-100 3-120 3-130 5-20 7-20 12 13 - ECN Released 17787 WRENCH SIZE 1-1/8” 1-1/8” 9/16” 2” Sq. 3/4” Sq. 3/4” Sq. 4-1/4” 1-11/16” 1-7/8” Sq.