G01 through G10 Spring-Return Pneumatic …

1 Service Instructions127073E Rev. CAugust 2015G01 through G10 Spring-Return Pneumatic Actuators with M11 hydraulic Override IService Instructions127073E Rev. CTable of ContentsAugust 2015 Table of ContentsTable of ContentsSection 1: Introduction General Service Information .. Definitions .. General Safety Information .. Bettis Reference Materials .. Service Support Items .. Lubrication and Fluid General Tool Information .. actuator Storage .. actuator Installation .. actuator Start-up .. actuator Operation ..5 Section 2: actuator Disassembly General Disassembly .. Pneumatic Power Module Disassembly .. Drive Module Disassembly .. G01 through G5 M11 hydraulic Override Cylinder Disassembly .. G7 through G10 M11 hydraulic Override Cylinder Disassembly.

2 12 Section 3: actuator General Reassembly .. Drive Module Reassembly .. Pneumatic Power Module Reassembly .. G2 and G3 Early Model Pneumatic Power Module G01 through G5 M11 hydraulic Override Cylinder Reassembly .. G7 through G10 M11 hydraulic Override Cylinder Reassembly .. actuator Testing ..25 Section 4: Field Fail Mode Reversal (CW to CCW, or CCW to CW) .. Converting Double-Acting actuator To Spring-Return with Override Cylinder Assembly ..27 Section 5: Module Removal and M11 Override Cylinder Removal .. M11 Override Cylinder Installation .. spring Module Removal .. spring Module Installation .. Pneumatic Power Module Removal .. Pneumatic Power Module Installation .. Powr Swivl Removal .. Powr Swivl Module Installation.

3 37 IIService Instructions127073E Rev. CTable of ContentsAugust 2015 Table of ContentsSection 6: actuator Support M11 hydraulic Override System Fluid Volume .. Module Weights by Item Number and actuator Housing Size .. G01 Tool Style and Wrench Size .. G2 Tool Style and Wrench G3 Tool Style and Wrench G4 Tool Style and Wrench G5 Tool Style and Wrench G7 Tool Style and Wrench G8 Tool Style and Wrench G10 Tool Style and Wrench Size ..43 Section 7: Fault Insertion .. Operational Test ..45 Section 8: Removal and Removal and Decommissioning ..46 Section 9: Document Revision 47 Appendix A: List of Tables 48 Appendix B: List of Drawings 49 Service Instructions127073E Rev.

4 C August 20151 Section 1: IntroductionIntroductionSection 1: Introduction 1 1 General Service Information This service procedure is offered as a guide to enable general maintenance to be performed on Bettis G01 XXX-SR, G2 XXX SR, G3 XXX SR, G4 XXX SR, G5 XXX SR, G7 XXX SR, G8 XXX SR, and G10 XXX SR Spring-Return Series Single Pneumatic Power Module Actuators with M11 or M11 S hydraulic Override Module. Normal recommended service interval for this actuator series is five : Storage time is counted as part of the service interval. This procedure is applicable with the understanding that all electrical power and Pneumatic pressure has been removed from the Remove all piping and mounted accessories that will interfere with the module(s) that are to be worked This procedure should only be implemented by a technically competent technician who should take care to observe good workmanship practices.

5 Numbers in parentheses, ( ) indicate the bubble number (reference number) used on the Bettis assembly drawing and actuator Parts 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 module weights are listed in Section 6 Table When removing seals from seal grooves, use a commercial seal removing tool or a small screwdriver with sharp corners rounded Use a non-hardening thread sealant on all pipe threads. CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS Apply the thread sealant per the manufacturer s instructions. Bettis recommends that disassembly of the actuator components should be done in a clean area on a 2 Definitions WARNINGIf not observed, user incurs a high risk of severe damage to actuator and/or fatal injury to personnel.

6 Service Instructions127073E Rev. C August 20152 Section 1: IntroductionIntroduction CAUTIONIf 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 :This product is only intended for use in large-scale fixed installations excluded from the scope of Directive 2011/65/EU on the restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS 2).1 3 General Safety Information Products supplied by Bettis, in its as shipped condition, are intrinsically safe if the instruc-tions contained within this Service Instruction are strictly adhered to and executed by well trained, equipped, prepared and competent personnel.

7 WARNING: READ WARNING SIGNSFor the protection of personnel working on Bettis actuators, this procedure should be reviewed and implemented for safe disassembly and reassembly. Close attention should be noted to the WARNINGS, CAUTIONS and NOTES contained in this procedure. WARNING: FOLLOW PLANT SAFETY PROCEDURESThis 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 customer's representative and an authorized Bettis representative. 1 4 Bettis Reference Materials Assembly Drawing for G2-SR-M11 through G5-SR-M11 model actuators with one Pneumatic Power Module and one spring Module with M11 hydraulic Override Module use part number Assembly Drawing for G7-SR-M11 through G10-SR-M11 model actuators with one Pneumatic Power Module and one spring Module with M11 hydraulic Override Module use part number M11 Manual hydraulic Override System operating instructions part number 126858 with M11 Assembly Drawing part number M11-S Manual hydraulic Override System operating instructions part number 121960 with M11 S Assembly Drawing part number Instructions127073E Rev.

8 C August 20153 Section 1: IntroductionIntroduction1 5 Service Support Items Bettis module service kits. 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 1 G-Series ModelsActuator ModelBettis Part NumberActuator ModelBettis Part NumberG01 None requiredG5/G7117369G2123616G8/G10117368G 3 Commercial leak testing solution. Non-hardening thread sealant. 1 6 Lubrication and Fluid RequirementsNOTE: Lubricants and Fluids, other than listed in step and should not be used without prior written approval of Bettis Product All temperature services (-50 F to +350 F)/( C to C) use Bettis ESL 5 lubricant.

9 ESL 5 lubricant is contained in the Bettis module service kit in tubes or cans and they are marked ESL 4, 5 and 10 M11 Manual hydraulic Override System Fluid Requirements: Standard and high temperature service (-20 F to +350 F) use Dexron II or Shell Tellus T-32 Automatic Transmission Fluid. For low temperature service (-50 F to 150 F) use Univis J13 or HVI 13 hydraulic 7 General Tool Tools: All tools/Hexagons are American Standard inch. Large adjustable wrench, two (2) large screwdrivers, Allen wrench set, set of open/box end wrenches, rubber or leather mallet, torque wrench (up to 1200 foot pounds / 1627 N-m), breaker bar, small drift punch and a drive socket set. For recommended tool and wrench sizes refer to Section 6, Tables through Instructions127073E Rev.

10 C August 20154 Section 1: IntroductionIntroduction1 8 actuator StorageFor applications where the actuator is not placed into immediate service, it is recom-mended that the actuator be cycled with regulated clean/dry Pneumatic pressure at least once per month. Indoor storage, if available, is recommended for all actuators. Care should be taken to plug all open ports on actuator and controls to keep out foreign particles and moisture. Actuators should not be stored in an atmosphere that is harmful to resilient seals. Contact factory for extended storage 9 actuator Since there are many valve and actuator combinations, it is not practical to include detailed instructions for each type. Mountings are designed to be as simple as possible to keep the guess work out of the Actuators that are shipped from the factory with the travel stops adjusted for approximately ninety degree rotation.