Emerson Fisher 1078 User manual

www.Fisher.com

Fisher™1078 Declutchable Manual Actuator

Contents

Introduction 1.................................

Scope of Manual 1.............................

Description 2.................................

Specifications 3...............................

Educational Services 3.........................

Installation 5..................................

Converting An Existing Power Actuator for use

with the Fisher 1078 Manual Actuator 6........

Installing the Manual Actuator 6.................

Installing the Manual Actuator on a 1061

Size 30, 40, 60, 68, 80, or 100 and

1052 Size 70 7..........................

Installing the Manual Actuator on a 2052

Size 1, 2, or 3 7..........................

Operation 7...................................

Engaging and Disengaging the Manual Actuator 8..

Engaging the Manual Actuator 8.............

Disengaging the Manual Actuator 8..........

Maintenance 8.................................

Lubrication 9.................................

Parts Ordering 10...............................

Parts List 10...................................

Manual Actuator Assembly 10...................

Field Mounting Parts 10........................

For 1061; and 1052 Size 70 Actuators 10......

Figure 1. Fisher 1078 Manual Actuator Mounted on

a 2052 Size 1 Actuator

X0178

Introduction

Scope of Manual

This instruction manual includes installation, operation, and maintenance information for the Fisher 1078

declutchable manual actuator (figure 1). Refer to separate instruction manuals for instructions covering the power

actuator and control valve.

Do not install, operate, or maintain a 1078 declutchable manual actuator without being fully trained and qualified in

valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage,

it is important to carefully read, understand, and follow all the contents of this manual, including all safety cautions

and warnings. If you have any questions about these instructions, contact your Emerson sales office or Local Business

Partner before proceeding.

Instruction Manual

D101329X012

1078 Actuator

June 2017

Instruction Manual

D101329X012

1078 Actuator

June 2017

Table 1. Specifications

Available Configurations

Direct and reverse acting; see Handwheel Rotation in

this specification table

Actuator Sizes

See tables 2, 3, and 4

Acceptable Coupling Shaft Diameters

See tables 2, 3, and 4

Power Actuator Compatibility

See tables 2, 3, and 4

Output Torque

See tables 2, 3, and 4

Wheel‐Rim Force

See tables 2, 3, and 4

Handwheel Turns Required For Full Rotation

See tables 2, 3, and 4

Handwheel Rotation

Direct Acting Construction: Clockwise handwheel

rotation closes the valve (produces clockwise valve

shaft rotation)

Reverse Acting Construction: Clockwise handwheel

rotation closes the valve (produces counterclockwise

valve shaft rotation)

Decide whether Direct or Reverse Action is required

by referring to the appropriate valve or power

actuator instruction manual and determining valve

rotation.

Maximum Output Rotation

90 degrees; limited by travel stops in the power

actuator

Standard Mounting Positions

1052 (size 70)(1):handwheel down (std) or

handwheel right‐hand or left‐hand mount (optional)

1061 (sizes 30, 40, 60, 68, 80, and 100)(1):

handwheel down (std) or handwheel right‐hand or

left‐hand mount (optional)

2052 (sizes 1, 2, and 3)(1):handwheel down (std) or

handwheel right-hand or left-hand mount (optional)

Approximate Weights without Handwheel

Size AAA: 2.7 kg (6 lb)

Size AA: 6.8 kg (15 lb)

Size A: 9.5 kg (21 lb)

Size 2A: 13.6 kg (30 lb)

Size 1A: 15.9 kg (35 lb)

Size B: 23.1 kg (51 lb)

Size C: 29.9 kg (66 lb)

Size D: 63.5 kg (140 lb)

Size II‐FA: 81.6 kg (180 lb)

Handwheel Weight

6‐inch: 1.8 kg (4 lb)

8‐inch: 2.3 kg (5 lb)

12‐inch: 3.2 kg (7 lb)

16‐inch: 6.8 kg (15 lb)

24‐inch: 5.4 kg (12 lb)

30‐inch: 6.4 kg (14 lb)

36‐inch: 7.3 kg (16 lb)

1. If a positioner is used, the right‐hand or left‐hand mounting option will be limited to the side away from the positioner.

Description

The 1078 manual actuator, shown in figures 1 and 2, is a declutchable unit for manual operation of control valves and

equipment that use power actuators. The 1078 manual actuator mounts directly to Fisher 1052 size 70; 1061 sizes 30,

40, 60, 68, 80, and 100; and to all sizes of 2052 actuators. The 1078 manual actuator can be engaged to allow manual

operation of the valve when the power actuator is not in use. It can be disengaged to allow automatic operation of the

valve by the power actuator. The mechanism used allows manual actuator engagement at any point of power actuator

rotation.

Instruction Manual

D101329X012

1078 Actuator

June 2017

Figure 2. Fisher 1078 Declutchable Manual Actuator Mounted on a 2052 Size 1 Actuator and V300 Valve with

FIELDVUE™ DVC6200 Digital Valve Controller

X0177

Specifications

1078 manual actuator specifications are given in table 1. Specifications for a control valve assembly as it comes from

the factory appear on a nameplate attached to the power actuator.

Educational Services

For information on available courses for Fisher 1078 manual actuators, as well as a variety of other products, contact:

Emerson Automation Solutions

Educational Services - Registration

Phone: 1-641-754-3771 or 1-800-338-8158

E-mail: [email protected]

emerson.com/fishervalvetraining

Instruction Manual

D101329X012

1078 Actuator

June 2017

Table 2. Fisher 2052 Actuator Size Selection and Specifications for Sizes AAA, A, and C

MANUAL

ACTUATOR

SIZE

SHAFT SIZE POWER

ACTUATOR

STANDARD

HANDWHEEL

DIAMETER

MAXIMUM

TORQUE

WHEEL‐RIM‐FORCE

HANDWHEEL

TURNS FOR

ROTATION

For Maximum

Torque

For Less Than Maximum

Torque Degrees

mm Inch Type Size mm Inch NSm LbfSin N Pounds N Pounds 60 90

AAA

(2400 in•lbs)

12.7 1/2

2052 1 203 8

131 1156 144 32 Divide NSm

req'd by

0.91

Divide lbfSin

req'd by 36 4 6

14.2x15.9

15.9

9/16x5/8

5/8 211 1866 232 52

19.1 3/4 271 2400 298 67

(8000 in•lbs)

14.3x15.9

15.9

9/16x5/8

5/8

2052 2 406 16

489 4326 204 45

Divide NSm

req'd by 2.4

Divide lbfSin

req'd by 96 5.3 8

19.1 3/4 590 5221 246 54

22.2

25.4

7/8

1818 7241 341 75

28.6x31.8

31.8

1-1/8x1-1/4

1-1/4 904 8000 377 83

(18000

in•lbs)

19.1 3/4

2052 3 610 24

1338 11842 279 61

Divide NSm

req'd by 4.8

Divide lbfSin

req'd by 194 9 13.5

22.2

25.4

7/8

11566 13862 326 71

28.6x31.8

31.8

38.1

39.7x44.5

44.5

50.8

1-1/8x1-1/4

1-1/4

1-1/2

1-9/16x1-3/4

1-3/4

2034 18000 424 93

Table 3. Fisher 1052 Actuator Size Selection and Specifications for Sizes 2A, 1A, B, and C

MANUAL

ACTUATOR

SIZE

(max output

torque)

SHAFT SIZE POWER

ACTUATOR(1) GEAR

RATIO

HANDWHEEL

DIAMETER

MAXIMUM

TORQUE(2)

WHEEL‐RIM‐FORCE

HANDWHEEL

TURNS FOR

ROTATION

For Maximum

Torque

For Less Than

Maximum Torque Degrees

mm Inch Type Size mm Inch NSm LbfSin N Pounds N Pounds 60 90

(8200 in•lbs)

31.8,

28.6x

31.8

1‐1/4,

1‐1/8x

1‐1/4

1052 70 32:1 610 24 929 8200 378 85 Divide NSm

req'd by 2.4

Divide

lbfSin req'd

by 96

5.3 8

38.1

31.8x

38.1

1‐1/2,

1‐1/4x

1‐1/2

(44.4,

50.8),

39.7

x44.5

(1‐3/4,

2),

1‐9/16

x1‐3/4

(12,000

in•lbs)

31.8 1‐1/4

1052 70 40:1 610 24 1356 12,000 369 83 Divide NSm

req'd by 3.6

Divide

lbfSin req'd

by 144

6.7 10

38.1,

(44.4,

50.8)

1‐1/2,

(1‐3/4,

(18,000

in•lbs)

31.8 1‐1/4

1052 70 54:1 610 24 2034 18,000 414 93 Divide NSm

req'd by 4.8

Divide

lbfSin req'd

by 194

9 13.5

(44.4,

50.8)

(1‐3/4,

1. Field conversion of actuators for F and G mounting adaptations requires installation of new parts.

2. Compare table value with torque requirements of the valve plus the torque required to compress the power actuator spring (from Fisher Catalog 14). Note that dynamic torque of the valve

may have a positive or negative effect on total torque required.

Instruction Manual

D101329X012

1078 Actuator

June 2017

Table 4. Fisher 1061 Actuator Size Selection and Specifications for Sizes 2A, 1A, B, C, D, and II‐FA

MANUAL

ACTUATOR

SIZE

(max output

torque)

SHAFT SIZE POWER

ACTUATOR GEAR

RATIO

HANDWHEEL

DIAMETER

MAXIMUM

TORQUE(1)

WHEEL‐RIM‐FORCE

HANDWHEEL

TURNS FOR

ROTATION

For Maximum

Torque

For Less Than Maximum

Torque Degrees

mm Inch Type Size mm Inch NSm LbfSin N Pounds N Pounds 60 90

(4800 in.lbs)

12.7 1/2

1061 30 34:1

152 6

58 515 89 20 Divide NSm

req'd by

0.66

Divide lbfSin

req'd by 26

5.7 8.5

15.9,

14.3x

9.5

5/8,

9/16x

5/8

138 1225 214 48

19.1 3/4(3) 203 8 239 2120 276 62

Divide NSm

req'd by

0.86

Divide lbfSin

req'd by 34

(22.2,

25.4) (7/8, 1) 305 12 467(4) 4140(4) 360 81 Divide NSm

req'd by 1.3

Divide lbfSin

req'd by 51

31.8 1‐1/4 541 4800 416 94

(8200 in.lbs)

(22.2,

25.4) (7/8, 1)

1061 40,

60, 68 32:1

305 12 467 4140 382 86 Divide NSm

req'd by 1.2

Divide lbfSin

req'd by 48

5.3 8

31.8,

28.6x

31/8

1‐1/4,

1‐1/8x

1‐1/4

610 24 929 8200 378 85 Divide NSm

req'd by 2.4

Divide lbfSin

req'd by 96

38.1

31.8x

38.1

1‐1/2,

1‐1/4x

1‐1/2

(44.4,

50.8),

39.7

x44.5

(1‐3/4,

2),

1‐9/16

x1‐3/4

(12,000 in.lbs)

31.8 1‐1/4

1061 40,

60, 68 40:1 610 24

1109 9815 308 68

Divide NSm

req'd by 3.6

Divide lbfSin

req'd by

144

6.7 10

38.1,

(44.4,

50.8)

1‐1/2,

(1‐3/4,

1356 12,000 377 83

(18,000 in.lbs)

31.8 1‐1/4

1061 40,

60, 68 54:1 610 24

1109 9815 231 51 Divide NSm

req'd by 4.8

Divide lbfSin

req'd by

194

9 13.5

(44.4,

50.8)

(1‐3/4,

2) 2034 18,000 424 93

(30,000 in.lbs)

(44.4,

50.8)

(1‐3/4,

1061 80,

100 64:1

762 30 2658 23,524 369 82 Divide NSm

req'd by 7.2

Divide lbfSin

req'd by

287

10.7 16

54,

63.5

57.2x

63.5

2‐1/8,

2‐1/2,

2‐1/4x

2‐1/2

914 36 3390 30,000 394 87 Divide NSm

req'd by 8.6

Divide lbfSin

req'd by

345

II‐FA

(60,000 in.lbs)

54,

63.5

2‐1/8,

2‐1/2 1061 80,

100 288:1(2) 406 16 6301 55,762 400 90

Divide NSm

req'd by

15.7

Divide lbfSin

req'd by

619

48 72

1. Compare table value with torque requirements of the valve plus the torque required to compress the power actuator spring (from Fisher Catalog 14). Note that dynamic torque of the valve

may have a positive or negative effect on total torque required.

2. Has spur gear.

3. 2A 3/4 inch shaft will also mount on the 1061 size 40, 60, and 68.

4. Maximum torque of connection between power and manual actuator.

Installation

WARNING

Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal

injury.

Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

Instruction Manual

D101329X012

1078 Actuator

June 2017

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this

instruction manual.

The 1078 manual actuator is normally shipped mounted on a power actuator. If the manual actuator has been shipped

separately for installation on a power actuator, or if the manual actuator was removed for maintenance, mount the

manual actuator by following the instructions presented in this section.

Converting An Existing Power Actuator For Use With The Fisher 1078

Manual Actuator

Field conversion of a power actuator for use with the 1078 manual actuator may require replacement and/or removal

of some parts. The procedures which follow apply only to power actuators which were not ordered specifically for use

with the 1078 manual actuator. Proceed as appropriate:

Installing the Manual Actuator

WARNING

Avoid personal injury from sudden release of process pressure or bursting of parts. Before performing any maintenance

operations:

D Do not remove the actuator from the valve while the valve is still pressurized.

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

D Disconnect any operating lines providing air pressure, electric power, or a control signal to the power actuator. Be sure

the actuator cannot suddenly open or close the valve.

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure

on both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power actuator loading pressure and relieve any actuator spring precompression.

D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.

D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the

pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when

loosening the packing box pipe plug.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

CAUTION

Undertravel or overtravel of the valve ball or disk, especially at the closed position, may result in poor valve performance

and/or damage to the equipment. Make certain that the power actuator travel stops are properly set before installing and

adjusting the manual actuator. Refer to the instruction manuals for the valve and the power actuator for information about

setting travel stops.

1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the

process media from both sides of the valve. Also shut off all pressure lines to the power actuator and release all

Instruction Manual

D101329X012

1078 Actuator

June 2017

pressure from the power actuator. Use lock‐out procedures to be sure that the above measures stay in effect while

you work on the equipment.

2. Make certain that the power actuator travel stops have been properly set according to the caution given above.

3. For spring‐return power actuators, allow the power actuator to remain in the position where the spring is relaxed.

For double‐acting power actuators, apply supply pressure as appropriate to position the valve disk or ball in either

the open or closed position.

4. Note whether the valve disk or ball is in the open or closed position.

5. Rotate the handwheel to move the drive sleeve gear and travel indicator to the position that corresponds with the

position of the valve disk or ball. For both direct and reverse acting manual actuators, clockwise handwheel rotation

sets the manual actuator to the closed position. Counterclockwise handwheel rotation sets the manual actuator to

the open position.

Installing the Manual Actuator on a 1061 Size 30, 40, 60, 68, 80, or 100 and 1052 Size 70

For manual actuator installation on 1061 sizes 30, 40, 60, 68, 80, and 100; and 1052 size 70, remove the actuator

cover (key 34) and attached parts from 1061 or 1052. Replace with 1078. Most assemblies require installation of a new

lever and splined adaptor to complete the installation. When used, the splined adaptor slides inside the new lever and

the lever is then clamped onto the splined adaptor. See figure 5.

1. Remove the lever and add a new lever and splined adaptor when needed. See figure 5.

The splined adaptor slides inside the new lever and the lever is then clamped onto the splined adaptor.

2. Disengage the manual actuator.

3. Install the manual actuator.

4. Tighten the cap screws to the final torque value.

5. For double‐acting power actuators, be certain the power actuator is equipped with a bypass valve. Operating the

handwheel mechanism against the force of differential cylinder pressures will be difficult or impossible.

Installing the Manual Actuator on a 2052 Size 1, 2, or 3

1. Remove the travel scale and travel indicator. They will no longer be required since the 1078 has it's own scale and

indicator.

2. Mount the manual actuator on the surface where the travel scale was.

3. Position the manual actuator on the 2052 so that the drive square fits into the quad square spline of the 2052 lever.

4. Bolt the manual actuator onto the 2052.

Operation

After the travel indicator pointer has been adjusted and the control valve assembly installed, the manual actuator is

ready for operation.

CAUTION

Applying too much torque to the actuator and valve parts could cause damage to the parts. To avoid such damage, do not

exceed the maximum allowable torques listed in table 2, 3, or 4 or any other torque limitation of internal valve parts. Also,

do not use wrenches or other devices on the handwheel or handwheel shaft to increase operating force.

If the force required to rotate the handwheel exceeds the wheel‐rim force listed in tables 2, 3, and 4, refer to the

maintenance procedure.

Instruction Manual

D101329X012

1078 Actuator

June 2017

Engaging and Disengaging the Manual Actuator

Engaging the Manual Actuator

1. Shut off the supply pressure to the power actuator.

2. Pull the ring on the detent mechanism to unlock the lever. Move the lever into the engaged position until it is

against the stop pin and locked in position by the detent mechanism. (Note that stop pins are not available on 1078

size II‐FA actuators.)

3. If applicable, open the power actuator bypass valve.

Disengaging the Manual Actuator

CAUTION

Disengaging the manual actuator when forces such as spring compression, cylinder pressure, and dynamic torque are

present may cause sudden, extreme movement of all control valve components. This can result in damage to equipment

and violent disturbance of the process. Before disengaging the manual actuator, take appropriate steps to ensure that the

return to automatic operation will not result in an extreme repositioning of control valve components. Procedures to

determine approximate system balance are given in the following steps.

1. Before disengaging the manual actuator, approximate system balance should be achieved. The system is in balance

when the actual valve ball or disk position is approximately the same as the position requested by the automatic

control system. Under balanced system conditions, the manual actuator disengaging lever moves freely without

use of excessive force. If after releasing the detent mechanism, the lever does not move freely toward the

disengaged position, some system force is causing an imbalance. A forced return to automatic operation under

these conditions can cause serious damage to the equipment and violent disturbance of the process.

2. If possible, determine whether the automatic control system is tending to open or close the valve ball or disk, and

rotate the handwheel in the appropriate direction until friction in the manual operator is reduced and the lever can

be easily moved by hand. As an alternate approach, local manipulation of the supply pressure to the power actuator

may bring the set point of the automatic system closer to the actual valve ball or disk position.

3. If a smooth transition from manual to automatic operation cannot be ensured, isolate the valve from the process.

Position the manual actuator so that it matches the position of the ball or disk when no supply pressure is applied to

the power actuator.

4. Pull the ring on the detent mechanism to unlock the lever. Push the lever into the disengaged position until it is

against the stop pin and locked in position by the detent mechanism. (Note that stop pins are not available on 1078

size II‐FA actuators.)

5. Close the bypass valve and return supply pressure to the power actuator.

Maintenance

If the force required to rotate the handwheel exceeds the wheel‐rim force listed in tables 2, 3, and 4, check for the

following conditions:

D Insufficient lubrication,

D Seized actuator parts,

Instruction Manual

D101329X012

1078 Actuator

June 2017

D Excessive pressure drop across the valve body, or

D Obstruction to the valve disk or ball rotation.

If the manual actuator does not seem to control the process fluid, the worm or drive sleeve gear teeth may be broken,

the pin (key 3) may be sheared, or the internal power actuator or valve parts may be broken. Purchase a replacement

manual actuator if necessary. Refer to the power actuator and valve instruction manuals if power actuator or valve

maintenance is needed.

Lubrication

The interior parts of the 1078 manual actuator should be lubricated on a regular schedule with a quality gear lubricant.

The interior parts should also be lubricated whenever difficulty in handwheel rotation indicates a need for lubrication.

WARNING

Avoid personal injury from sudden release of process pressure or uncontrolled movement of parts. Before performing any

maintenance operations:

D Do not remove the actuator from the valve while the valve is still pressurized.

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

D Disconnect any operating lines providing air pressure, electric power, or a control signal to the power actuator. Be sure

the actuator cannot suddenly open or close the valve.

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure

from both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power actuator loading pressure and relieve any actuator spring precompression.

D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.

D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the

pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when

loosening the packing box pipe plug.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the

process media from both sides of the valve. If using a power actuator, also shut off all pressure lines to the power

actuator, release all pressure from the actuator. Use lock‐out procedures to be sure that the above measures stay in

effect while you work on the equipment.

2. Mark the position of the travel indicator pointer on the indicator dial. The travel indicator pointer must be returned

to its original position when assembling the manual actuator. Remove the machine screws and the travel indicator

pointer.

3. Remove the manual actuator cover screws.

4. Remove the travel indicator scale and the gearbox cover plate. Coat the worm, the drive sleeve gear teeth, and the

bearing surfaces of the gearbox housing and worm with a quality gear lubricant.

5. Install the cover plate and the travel indicator scale on the gearbox.

6. Replace the manual actuator cover screws.

Instruction Manual

D101329X012

1078 Actuator

June 2017

Parts Ordering

When corresponding with your Emerson sales office or Local Business Partner, indicate the type number and size of the

power actuator and the mounting adaptation used. If the manual actuator was shipped separately (not attached to a

power actuator), give the serial number of the unit, which is shown on a tag attached to the manual actuator.

For 1052 (size 70), and 1061 (sizes 30, 40, 60, 68, 80, and 100), indicate valve shaft size.

WARNING

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions should

not, under any circumstances, be used in any Fisher valve, because they may void your warranty, might adversely affect the

performance of the valve, and could cause personal injury and property damage.

Parts List

Note

Contact your Emerson sales office or Local Business Partner for Part

Ordering information.

Manual Actuator Assembly

(figures 3 and 4)

Key Description

1 Actuator

2 Handwheel

3 Pin, steel

Note

A new lever and splined adaptor (figure 5) are needed on most

assemblies for field installation of the 1078 onto the 1052 size 70, and

1061 sizes 30, 40, 60, 68, 80, & 100 actuators.

Key Description

4 Travel Indicator scale, stainless steel

5 Travel Indicator Pointer, stainless steel

6 Machine Screw, steel (2 required)

9 Shaft Adaptor

Field Mounting Parts

For 1061; and 1052 Size 70 Actuators

Note

Most assemblies require installation of a new lever to complete the

installation. Contact your Emerson sales office.

Description

Lever

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