Emerson Bettis CBB Series Installation instructions

Service Instructions

VA001-196-30 Rev. 1

October 2015

CBB Double-Acting Series Pneumatic Actuators

Disassembly and Reassembly

Service Instructions

VA001-196-30 Rev. 1

Table of Contents

October 2015

ITable of Contents

Table of Contents

Section 1: Introduction

1.1 General Service Information.......................................................................... 1

1.2 Denitions .................................................................................................... 2

1.3 General Safety Information ........................................................................... 2

1.4 Bettis Actuator Reference Materials............................................................... 3

1.5 Service Support Items................................................................................... 3

1.6 Lubrication Requirements ............................................................................. 3

1.7 General Tool Information .............................................................................. 3

1.8 Actuator Weight ........................................................................................... 3

1.9 Actuator Storage........................................................................................... 4

1.10 Actuator Installation ..................................................................................... 4

1.11 Actuator Start-up .......................................................................................... 4

1.12 Actuator Operation....................................................................................... 5

Section 2: Actuator Disassembly

2.1 General Disassembly ..................................................................................... 6

2.2 Pneumatic Cylinder Disassembly ................................................................... 6

2.3 Housing Disassembly .................................................................................... 8

Section 3: Actuator Reassembly

3.1 General Reassembly .................................................................................... 10

3.2 Actuator Reassembly per CBB Models Listed in Step 3.1.5.1 ........................ 10

3.3 Actuator Reassembly per CBB Models Listed in Step 3.1.5.2 ........................ 14

Section 4: Actuator Testing

4.1 Actuator Testing ......................................................................................... 20

Section 5: Troubleshooting

5.1 Fault Insertion ............................................................................................. 22

5.2 Operational Test.......................................................................................... 23

Section 6: Removal and Decommissioning

6.1 Removal and Decommissioning .................................................................. 24

Section 7: Document Revision ��25

Appendix A: List of Tables ��26

Appendix B: List of Drawings ��27

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 1: Introduction

Introduction

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 CBB double-acting series actuators. The following is a list of

general CBB model numbers.

Table 1� CBB Model Numbers

MODEL (1) MODEL (2) MODEL (3)

315 315-M3 315-M3HW

420 420-M3 420-M3HW

520 520-M3 520-M3HW

525 525-M3 525-M3HW

725 725-M3 725-M3HW

 (1)Alsoincludesactuatormodelswith–10and–11asasufx

NOTE:

Whentheactuatormodelnumberhas“-S”asasufxthentheactuatorisspecialandmay

have some differences that may not be included in this procedure.

1�1�2 Normalrecommendedserviceintervalforthisactuatorseriesisve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�1�4 Remove all piping and mounted accessories that will interfere with the module(s)

that are to be worked on.

1�1�5 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 When removing seals from seal grooves, use a commercial seal removing tool or a

small screwdriver with sharp corners rounded off.

1�1�8 Use a non-hardening thread sealant on all pipe threads.

CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS

Apply the thread sealant per the manufacturer’s instructions.

1�1�9 Emerson recommends that disassembly of the actuator should be done in a clean

area on a workbench.

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 1: Introduction

Introduction

1�2 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.

NOTE:

Thisproductisonlyintendedforuseinlarge-scalexed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).

ES: Extendedstopscrew(fortravelstopadjustmentoverafull100°degreetravelrange).

ES is not intended for use as a manual override.

M3: Manual jackscrew override

1�3 General Safety Information

1�3�1 Products supplied by Emerson, 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: FOLLOW WARNING AND CAUTION SIGNS

For 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 COMPANY SAFETY PROCEDURES

This procedure should not supersede or replace any customer’s plant safety or work

procedures.Ifaconict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 Emerson/Bettis representative.

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 1: Introduction

Introduction

1�4 Bettis Actuator Reference Materials

1�4�1 CBBXXX Assembly Drawing use part number VA001-005-72-4.

1�4�2 CBBXXX-M3HW Assembly Drawing use part number VA001-005-73-3.

1�5 Service Support Items

1�5�1 Bettis service kit

1�5�2 Commercial leak testing solution

1�5�3 Non-hardening thread sealant

1�6 Lubrication Requirements

1�6�1 The actuator should be relubricated at the beginning of each service interval using

the following recommended lubricants.

NOTE:

Lubricants other than those listed in steps 1.6.2 should not be used without prior written

approval of Emerson product engineering. The lubricant item number on some assembly

drawings is item (5) while the Bettis service kits lubricant item number is item number (500).

1�6�2 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 and

the tubes are marked ESL-4, 5 and 10 lubricant.

1�7 General Tool Information

1�7�1 AllthreadsonCBBSeriesactuatorsareInchUniedandNPT.

1�7�2 Alltools/HexagonsareAmericanStandardinch.Twoadjustablewrenches,Allen

wrench set, small standard screwdriver with sharp edges rounded off, medium size

standardscrewdriver,diagonalcuttingpliers,externalsnapringpliers,atle,drive

ratchet / deep well socket set and torque wrench (up to 2,000 lbf-in / 226 N-m).

1�8 Actuator Weight

Table 2� Actuator Weight

Actuator

Model Approximate weight (1) Actuator

Model Approximate weight (1)

CBB LB KG CBB LB KG

315 20 9.1 520-M3HW 38 17.2

315-M3 23.2 10.5 525 44 20

315-M3HW 25 11.3 525-M3 50 22.7

420 22 10 525-M3HW 56 25.4

420-M3 29.4 13.4 725 68 31

420-M3HW 33 15 725-M3 75 34

520 28 12.7 725-M3HW 81 37

520-M3 34.4 15.7

(1) Weight is for bare actuator without accessories or valve adaptation.

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 1: Introduction

Introduction

1�9 Actuator Storage

For applications where the actuator is not put into immediate service, it's recommended

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.

Also, actuators should not be stored in an atmosphere harmful to resilient seals. For

extendedstorage,contactthemanufacturer'srepresentative.

1�10 Actuator Installation

1�10�1 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 guess work out of installation.

1�10�2 Actuators are shipped from the factory with the travel stops adjusted for

approximatelyninetydegreerotation.Generallyitisnecessarytomakeslight

travel stop adjustments once the actuator is installed on the valve. Refer to the

valvemanufacturer'srecommendationsforspecicrequirements.Whenthevalve

has internal stops, the actuator should be adjusted at the same points.

NOTE:

The actual "stopping" should be done by the actuator. If the valve does not have internal

stops, adjust the actuator to the full open position. Using this as a reference point, rotate

thevalveclosedandadjusttothevalvemanufacturer'sspecicationsfortotalrotation.

1�10�3 Good instrument practices are also recommended. Clean/dry regulated

pneumatic pressure is essential for long service life and satisfactory operation.

It should be noted that new pneumatic lines often have scale and other debris in

them and these lines should be purged of all foreign material.

NOTE:

Scale and debris can damage control valves, solenoids, seals, etc.

1�11 Actuator Start-up

1�11�1 Prestart-up checks

1. Unithasbeenmountedonvalveproperly.Gearangemountingbolts,

stem key, setscrew(s) installed and secured.

2. No tubing damaged or accessories dislodged during shipping or

installation.

3. Indicatedpositionconrmsvalveposition.

4. All switching valves in normal operating position as per Schematic/

Instructions.

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 1: Introduction

Introduction

1�11�2 Check Connections:

1. Pneumatic/hydraulic components connected as per schematic enclosed

or in service manual supplied.

2. Pneumaticsupplyconnectedtoidentiedports.

3. Electrical connections terminals are secure.

4. Wiring as per enclosed diagram or service manual supplied.

1�11�3 Whenactuatorisrstputintoserviceitshouldbecycledwithregulated

pneumatic pressure. This is necessary because the seals have been stationary,

causing them to take a "set". Therefore, the actuator should be operated through

severalcycles,exercisingtheseals,resultinginaservicereadycondition.

1�11�4 The actuator speed of operation is determined by a number of factors including:

1. Power supply line length

2. Power supply line size

3. Power supply line pressure

4. Controlvalveandttingoricesize

5. Torque requirements of the valve

6. Size of the actuator

7. Setting of speed controls

1�11�5 Duetotheinteractionofthesevariablesitisdifculttospecifya"normal"

operating time. Faster operating times may be obtained by using one or more of

the following:

1. Larger supply lines

2. Larger control valve

3. Higher supply pressure*

4. Quickexhaustvalves

 *Nottoexceedmaximumoperatingpressureofactuatororcontrolcomponents

1�11�6 Sloweroperatingtimesmaybeobtainedbyusingowcontrolvalvestometerthe

exhaust.Excessiveexhaustowmeteringmaycauseerraticoperation.Normally,

incoming supply should not be metered.

1�12 Actuator Operation

1�12�1 Controlled Operation: Controlled operation is accomplished by pressurizing and/or

depressurizing the appropriate cylinder inlet(s) of a double-acting.

Do not exceed pressures indicated on actuator nameplate�

1�12�2 Manual Operation: All pressure must be vented or equalized on both sides of the

pneumatic piston prior to manual operation.

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 2: Actuator Disassembly

Actuator Disassembly

Section 2: Actuator Disassembly

2�1 General Disassembly

WARNING: DANGEROUS GAS AND/OR LIQUIDS

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.

CAUTION: DO NOT EXCEED OPERATING PRESSURE

Pressureappliedtotheactuatorisnottoexceedthemaximumoperatingpressurerating

listed on the actuator name tag.

NOTE:

Before starting the general disassembly of the actuator it is a good practice to operate

actuator with the pressure used by the customer to operate the actuator during normal

operation. Notate and record any abnormal symptoms such as jerky or erratic operation.

2�1�1 Remove all operating pressure from actuator.

2�1�2 Record the settings of stop screw or M3 jackscrews (1-70) and (4-30) before stop

screws are loosened or removed.

NOTE:

InplaceofstopscrewstheactuatormaybeequippedwithoneortwoES(ES=Extended

Stops) or M3/M3HW (1-70) located on outboard end of housing (1-10) and M3/M3HW (4-

30) on the end cap (4-20).

2�2 Pneumatic Cylinder Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.2 before proceeding with cylinder disassembly.

2�2�1 Removehexnut(4-40)asfollows:CBB315throughCBB725standardendcapstop

screworextendedstop(ES)usestep2.2.1.1.CBB315throughCBB725with-M3or

-M3HW use step 2.2.1.2.

2�2�1�1 For CBB315 through 725:endcapstopscreworextendedstopscrew(ES)

2�2�1�1�1 Loosenandremovehexnut(4-40)andwasher(4-90)from

stop screw (4-30) located in end cap (4-20).

2�2�1�1�2 Remove stop screw (4-30) from the end cap (4-20).

October 2015

Service Instructions

VA001-196-30 Rev. 1

Section 2: Actuator Disassembly

Actuator Disassembly

2�2�1�2 For CBB315/420/520/525/725-M3 or M3HW:

2�2�1�2�1 Remove retainer ring (12-30) and groove pin (12-20) from

optionalhexdrivehuborfromhandwheel(12-10).

2�2�1�2�2 Removeoptionalhexdrivehuborhandwheel(12-10)fromM3

jackscrew (1-70).

2�2�1�2�3 Loosenandremovehexnut(4-40)fromM3jackscrew(1-70).

NOTE:

CBB315/420/520/525/725-M3 or M3HW models the M3 jackscrew (1-70) cannot be

removed now. The M3 used in these models can be removed later in this procedure using

step 2.2.8.

ES (4-30), stop screw (4-30) or CBB315-M3 (1-70) does not require removal from end cap

(4-20) unless replacing with a new ES, stop screw or M3.

2�2�2 Removehousingsidehexnut(8-20)fromcenterbar(8-10).

2�2�3 Remove outer end cap (4-20) with center bar (8-10) from outboard end of

cylinder (4-10).

2�2�4 While holding housing torque shaft (1-30) pull cylinder (4-10) away from

housing (1-10).

2�2�5 Slide cylinder (4-10) over piston seal (5-40) and remove.

2�2�6 Remove piston (4-50) from housing (1-10).

NOTE:

Piston (4-50) is an assembly made up of one roll pin and one yoke pin; do not attempt to

disassemble the piston assembly.

2�2�7 OnactuatormodelsCBB415/520/725removecylinderadapter(4-15)fromange

of housing (1-10).

2�2�8 M3 Jackscrew Removal From End Cap (4-20).

2�2�8�1 CBB315/415 with a M3 remove M3 jackscrew (4-30) from the backside of

end cap (4-20).

2�2�8�2 CBB420/520/525/725 with a M3 jackscrew remove per following steps.

2�2�8�2�1 Remove retainer ring (5-60) from M3 adapter (4-55).

2�2�8�2�2 Remove M3 adapter (4-55) from end cap (4-20).

NOTE:

The M3 adapter will be removed from backside of end cap (4-20) with the M3 jackscrew.

ES (4-30), stop screw (4-30) or CBB315-M3 jackscrew (1-70) does not require removal from

end cap (4-20) unless replacing with a new ES, stop screw or M3.

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