Emerson FISHER 657 User manual

www.Fisher.com

Fisher™657 Diaphragm Actuator

Sizes 30/30i through 70/70i and 87

Contents

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

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

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

Specifications 2...............................

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

Instructional Videos 3..........................

Installation 3..................................

Mounting the Actuator on the Valve 4............

Discussion of Bench Set 5.......................

Spring Verification 6...........................

Installing the Stem Connector Assembly 7.........

Friction Discussion 9...........................

Deadband Measurement 10.....................

Loading Connection 10.........................

Maintenance 11................................

Actuator Maintenance 11.......................

Top‐Mounted Handwheel Assembly 13...........

Side‐Mounted Handwheel for Sizes 34/34i

through 60/60i Actuators 15..................

Side‐Mounted Handwheel for Sizes 70

and 87 Actuators 17.........................

Casing‐Mounted Adjustable Travel Stops 19.......

Parts Ordering 22...............................

Parts Kits 22...................................

Kits for Side‐Mounted Handwheels 22............

Kits for Top‐Mounted Handwheels 22.............

Parts List 23...................................

Actuator Assembly (figures 6, 7, 8, 9, or 10) 23.....

Figure 1. Fisher 657 Actuator Mounted

on an easy‐e™ Valve

X1175

Top‐Mounted Handwheel (figures 11 or 12) 23.....

Side‐Mounted Handwheel (figure 13 or 17) 26.....

Casing‐Mounted Adjustable Up Travel Stops

(figures 18 or 19) 31.........................

Casing‐Mounted Adjustable Down Travel Stops

(figure 20) 32..............................

Introduction

Scope of Manual

This instruction manual provides information on installation, adjustment, maintenance, and parts ordering for the

Fisher 657 actuator in sizes 30/30i through 70/70i and size 87. The 657‐4 actuator in sizes 70/70i and 87 is also

covered. Refer to separate instruction manuals for information about the valve positioner and other accessories used

with these actuators.

Do not install, operate, or maintain a 657 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

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

Table 1. Specifications

SPECIFICATION(1) ACTUATOR SIZE

30/30i 34/34i 40/40i 45/45i 46/46i 50/50i 60/60i 70/70i(1) 87(1)

Nominal Effective Area cm2297 445 445 677 1006 677 1006 1419 1419

Inch246 69 69 105 156 105 156 220 220

Yoke Boss Diameters mm 54 54 71 71 71 90 90 90 127

Inches 2‐1/8 2‐1/8 2‐13/16 2‐13/16 2‐13/16 3‐9/16 3‐9/16 3‐9/16 5

Acceptable Valve

Stem Diameters

mm 9.5 9.5 12.7 12.7 12.7 19.1 19.1 19.1 25.4

Inches 3/8 3/8 1/2 1/2 1/2 3/4 3/4 3/4 1

Maximum Allowable

Output Thrust(4)

N 10230 10230 12010 25131 33582 25131 30246 39142 39142

Lb 2300 2300 2700 5650 7550 5650 6800 8800 8800

Maximum Travel(2) mm 19 29 38 51 51 51 51 76(3) 76(3)

Inches 0.75 1.125 1.5 2 2 2 2 3(3) 3(3)

Maximum Casing

Pressure for

Actuator Sizing(4)

Bar 8.6 4.5 4.5 3.4 2.8 3.4 2.8 3.8 3.8

Psig 125 65 65 50 40 50 40 55 55

Maximum Diaphragm

Casing Pressure(4)(5)

Bar 9.6 5.2 5.2 4.1 3.4 4.1 3.4 4.5 4.5

Psig 140 75 75 60 50 60 50 65 65

Material Temperature

Capabilities

_CNitrile Elastomers: -40 to 82_C, Silicone Elastomers: -54 to 149_C, Fluorocarbons: -18 to 149_C

_FNitrile Elastomers: -40 to 180_F, Silicone Elastomers: -65 to 300_F, Fluorocarbons: 0 to 300_F

Pressure Connections

(internal)

1/4 NPT X X X X X X X ‐ ‐ ‐ ‐ ‐ ‐

1/2 NPT ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ X X

Approximate Weights kg 16/17 22/25 23/25 37/40 49/52 42/45 53/56 107/109 116

Lb 36/38 48/54 51/56 82/84 107/114 92/99 116/125 235/240 255

1. These values also apply to the 657‐4 actuator construction.

2. Actuator travel may be less than the value listed after connecting the actuator to the valve.

3. Maximum travel for 657‐4 is 102 mm (4 inches).

4. Normal operating diaphragm pressure must not exceed maximum diaphragm casing pressure and must not produce a force on the actuator stem greater than the maximum allowable out

put thrust or the maximum allowable valve stem load. Contact your Emerson sales office or Local Business Partner with questions concerning maximum allowable valve stem load.

5. This maximum casing pressure is not to be used for normal operating pressure. Its purpose is to allow for typical regulator supply settings and/or relief valve tolerances.

Description

The 657 actuator (figure 1) and the 657‐4 actuator are direct‐acting, spring‐opposed diaphragm actuators. They

provide automatic operation of control valve body assemblies. The 657 actuator offers 76 mm (3 inches) maximum

actuator travel. The 657‐4 actuator provides 102 mm (4 inches) maximum actuator travel. Both actuators position the

valve plug in response to varying pneumatic loading pressure on the actuator diaphragm. Figure 2 shows the

operation of these actuators.

A 657 or 657‐4 actuator can be equipped with either a top‐mounted or a side‐mounted handwheel assembly. A

top‐mounted handwheel assembly is used as an adjustable up travel stop to limit actuator travel in the up direction

(see figure 2). A side‐mounted handwheel assembly is usually used as an auxiliary manual actuator. Adjustable

casing‐mounted up or down travel stops are also available for this actuator.

Note

If repeated or daily manual operation is expected, the actuator should be equipped with a side‐mounted handwheel rather than a

casing‐mounted travel stop or top‐mounted handwheel.

The side‐mounted handwheel is designed for more frequent use as a manual operator.

Specifications

Refer to table 1 for Specifications of the 657 and 657‐4 actuators. See the actuator nameplate for specific information

about your actuator.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

Figure 2. Schematic of Fisher 657 and 657‐4 Actuators

SPRING LIFTS

STEM UP

AIR PUSHES

STEM DOWN

STEM

AF3833‐A

A0792‐2

Educational Services

For information on available courses for Fisher 657 diaphragm 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

Instructional Videos

Click here or access the following QR code for a video on mounting a DVC6200 Digital Valve

Controller on a 657 actuator.

Click here or access the following QR code for a video on installing a side-mounted handwheel

on a 657 actuator.

Installation

Key number locations are shown in figures 6, 7, 8, 9, and 10, unless otherwise indicated. Also, refer to figure 3 for

location of parts.

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.

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

instruction manual.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

CAUTION

To avoid parts damage, do not use an operating pressure that exceeds the Maximum Diaphragm Casing Pressure (table 1)

or produces a force on the actuator stem greater than the Maximum Allowable Output Thrust (table 1) or the maximum

allowable valve stem load. (Contact your Emerson sales office or Local Business Partner with questions concerning

maximum allowable valve stem load.)

D Valve/Actuator Assembly: If the actuator and valve are shipped together as a control valve assembly, it has been

adjusted at the factory, and may be installed in the pipeline. After installing the valve in the pipeline, refer to the

Loading Connection procedures.

D Actuator Mounting: If the actuator is shipped separately or the actuator has been removed from the valve, the

actuator should be mounted to the valve before placing the valve in the pipeline when practical. In the case of

needing to place a weld-end body in-line, the trim will be removed from the body during the welding process. When

completed and reassembled, the actuator should then be mounted to the welded in valve assembly. Refer to the

actuator mounting procedures before placing the valve in service. You may perform the Bench Set Spring

Adjustment procedures in this section to confirm the adjustment has not changed since it was shipped from the

factory.

D Positioner: If a positioner is installed, or is to be installed on the actuator, refer to the positioner instruction manual

for installation. During the adjustment procedures, it will be necessary to provide a temporary loading pressure to

the actuator diaphragm.

Mounting the Actuator on the Valve

The 657 actuator spring loading pushes the actuator stem up towards the actuator diaphragm (see figure 2). This

spring action moves the stem away from the valve while installing the actuator.

CAUTION

If the valve stem is allowed to remain in the up position (towards the actuator) during mounting, it can interfere with the

actuator mounting, possibly damage valve stem threads or bend the valve stem. Be sure the valve stem is pushed down

(into the valve body), away from the actuator while mounting.

Provide a temporary method of applying diaphragm loading pressure to the diaphragm to extend the actuator stem

during bench set spring adjustments.

1. Provide a vise or some other method of supporting the valve and the weight of the actuator during assembly. For

direct or reverse acting valves, push the valve stem down away from the actuator while mounting the actuator.

2. Screw the stem locknuts all the way onto the valve stem. With the concave side of the travel indicator disk (key 14)

facing the valve, install the travel indicator disk on the valve stem. (Note: The travel indicator disk is not used with

size 87 actuators.)

3. Lift or hoist the actuator onto the valve bonnet:

a. For size 87 actuators, insert the cap screws and tighten the hex nuts, securing the actuator to the bonnet.

b. For all other size actuators, screw the yoke locknut onto the valve bonnet and tighten the locknut. (Note: On

small size actuators, it may be necessary to remove the indicator disk and re‐install it while lowering the actuator

on to the valve because the disk will not go through the actuator yoke opening.)

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

4. Do not connect the actuator stem to the valve stem at this time. Whenever the actuator is installed on the valve, it

is recommended to perform the Bench Set Spring Adjustment procedure to verify that the actuator is still adjusted

correctly.

Figure 3. Actuator Mounting Components for Size 30/30i through 70/70i Actuators

VALVE STEM

YOKE LOCK NUT

YOKE BOSS

DIAMETER

BONNET

TYPICAL VALVE

(REFER TO VALVE

MANUAL)

W6199-1

MATCH

LINE FOR

ACTUATOR

NPT INTERNAL CONNECTION

DIAPHRAGM CASING

DIAPHRAGM AND STEM SHOWN

IN UP POSITION

DIAPHRAGM PLATE

ACTUATOR SPRING

ACTUATOR STEM

SPRING SEAT

SPRING ADJUSTOR

STEM CONNECTOR

YOKE

TRAVEL INDICATOR DISK

INDICATOR SCALE

X1177

LOWER DIAPHRAGM CASING

X1176

SIZE 30i THROUGH 70i SIZE 30 THROUGH 70

INTEGRATED FIELDVUE™ DVC6200 AND

DVC2000 DIGITAL VALVE CONTROLLER

MOUNTING PAD

INTEGRATED

SIDE-MOUNTED

HANDWHEEL

MOUNTING

PADS (4)

Discussion of Bench Set

The bench set pressure values are used to adjust the initial compression of the actuator spring with the valve‐actuator

assembly “on the bench.” The correct initial compression is important for the proper functioning of the valve‐actuator

assembly when it is put into service and the proper actuator diaphragm operating pressure is applied.

The bench set values are established with the assumption that there is no packing friction. When attempting to adjust

the spring in the field, it is very difficult to ensure that there is no friction being applied by “loose” packing.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

Accurate adjustment to the bench set range can be made during the actuator mounting process by making the

adjustment before the actuator is connected to the valve (see the Spring Verification procedure).

Figure 4. Bench Set Adjustment

SPRING ADJUSTER

LOWER BENCH SET

LOADING PRESSURE

UPPER BENCH SET

PRESSURE MARK

VALVE

STEM

RATED VALVE

TRAVEL MEASURE

MARK

VALVE

STEM HERE

UPPER BENCH SET

LOADING PRESSURE

ACTUATOR STEM

NOTES:

THE LOWER PSIG LOADING PRESSURE (MARKED ON NAMEPLATE) WHERE THE FIRST MOVEMENT OF

ACTUATOR STEM IS DETECTED.

THE UPPER PSIG LOADING PRESSURE EXTENDS ACTUATOR STEM.

MARK THIS POINT WITH TAPE OR A MARKER.

MEASURE DISTANCE OF TRAVEL. IT SHOULD EQUAL THE TRAVEL SPAN SHOWN ON THE NAMEPLATE.

40A8715-B

B2426

Spring Verification

Ensure that the actuator stem is at the top of its travel as shown in figure 4 and not connected to the valve. (Note:

Some spring compression is required to move the diaphragm to the top of its travel.) The steps provided are the same

for push-down-to-close (direct acting) or push-down-to-open (reverse acting) valves.

WARNING

When moving the actuator stem with diaphragm loading pressure, use caution to keep hands and tools out of the actuator

stem travel path. Personal injury and/or property damage is possible if something is caught between the actuator stem and

other control valve assembly parts.

Also, provide a certified pressure gauge suitable to accurately read the diaphragm pressure from 0 through 0.3 bar (5

psig) above the upper operating range pressure marked on the nameplate. Apply loading pressure to the diaphragm.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

CAUTION

Stroke the actuator a few times to ensure that the pressure gauge is working correctly, and that the actuator is functioning

properly. To prevent actuator damage, it is important to ensure that the actuator stem is stroking smoothly and not

exhibiting binding or excessive friction. Binding or excessive friction could be an indicator of incorrect assembly or

damaged parts.

1. If not already accomplished, provide a temporary means of applying an adjustable loading pressure to the actuator

during bench set adjustments.

2. Set the diaphragm loading pressure at 0 bar (0 psig). Then, slowly raise the pressure towards the lower bench set

pressure, as indicated on the nameplate, while checking for the first linear movement of the actuator stem. The

actuator stem should show movement at the lower bench set pressure. If movement occurs before or after the

lower pressure is reached, adjust the spring adjuster (see figure 4) into or out of the yoke until the actuator stem's

movement is first detected at the lower bench set pressure.

Note

Before turning the spring adjuster on size 70/70i or 87 actuators, assemble the stem connector around the actuator stem and the

anti‐rotating lug on the yoke. Mark the actuator stem as a visual reference to verify that stem rotation does not occur. Remove the

stem connector before rechecking the bench set.

3. Be sure the spring adjuster is adjusted to meet the requirements of step 2 above.

4. Apply the upper bench set pressure, as indicated on the nameplate. This pressure extends the actuator stem down

towards the valve. At the end of the actuator stem, use a marker or a piece of tape to mark the valve stem (see

figure 4).

Note

The actuator stem may slide over the valve stem as shown in figure 4. If the actuator stem does not pass over the valve stem,

provide a method to mark this point of stem travel.

5. Slowly decrease the diaphragm loading pressure to the lower bench set pressure, as indicated on the nameplate.

6. Measure the distance between the marker or tape on the valve stem to the end of the actuator stem. The distance

should match the rated travel indicated on the nameplate.

7. If the measured travel matches the nameplate travel, bench set is complete. Proceed to the Installing the Stem

Connector Assembly subsection.

8. If the measured travel is not exact, consider the spring free-length and spring rate tolerances may produce a slightly

different bench set than specified. Contact your Emerson sales office or Local Business Partner for assistance.

Installing the Stem Connector Assembly

When installing the stem connector assembly (key 26), the actuator and valve stem threads should engage the

threads of the stem connector by the distance equal to the diameter of the stem.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

WARNING

Install the stem connector securely before a positioner is mounted to the actuator and pressurized, using only a

regulator-controlled air supply, not the positioner, to move the actuator stem.

To avoid personal injury or property damage, keep hands and tools out of the actuator stem travel path while applying

loading pressure to move the actuator stem in the following steps.

CAUTION

To avoid damaging the seating surfaces, do not rotate the valve plug while it is seated. Exercise care while installing the

stem connector assembly to avoid damage to the valve plug stem and valve stem threads.

Note

Replacement stem connectors are an assembly of two stem connector halves, cap screws, and a spacer between the connector

halves. Remove the spacer and discard, if present, before clamping the actuator and valve stems together. Use only a mated pair

of stem connector halves.

1. If necessary, push the valve stem down so that it is touching the seat ring on direct acting valves. For reverse acting

valves, push the stem down to the open position.

If necessary, screw the valve stem locknuts down, away from the connector location. For all actuators except size 87,

ensure that the travel indicator disk (key 14) is located on top of the locknuts.

2. Slowly increase the diaphragm pressure to the upper bench set pressure. This should be the same pressure used in

the Spring Verification steps, and it is marked on the nameplate.

3. Place the stem connector half with the threaded holes, approximately half way between the actuator and valve

stems, and align with the stem connector. A slight change to loading pressure may be necessary to align the

threads. Refer to figures 6, 7, 8, 9, and 10 to help locate the connector position.

CAUTION

Incomplete engagement of either the valve stem or actuator stem in the stem connector can result in stripped threads or

improper operation. Be sure that the length of each stem clamped in the stem connector is equal to or greater than one

diameter of that stem. Damage to threads on either stem or in the stem connector can cause the parts to be replaced

prematurely. Do not loosen the cap screws when the stem connector has spring or loading pressure force applied.

4. Install the other half of the stem connector and insert the cap screws and tighten them while ensuring even spacing

between the stem connector halves on all sides. If installing a positioner, also attach the feedback bracket at the

same time.

CAUTION

Over‐tightening the valve stem locknuts can make disassembly difficult.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

5. Screw the valve stem locknuts up against the stem connector for the size 87 actuator. For all other actuator sizes,

screw the valve stem locknuts up until the indicator disk contacts the bottom of the stem connector. Do not

overtighten the locknuts.

6. Slowly stroke the valve from fully open to fully closed and verify full rated travel is achieved.

Be sure that the valve is in the closed position. Loosen the screws on the travel indicator scale (key 18), and align it with

the travel indicator disk (key 14) or stem connector for the size 87 actuator. Stroke the valve full travel to ensure that

the travel matches the rated travel on the nameplate. If valve travel is not correct, repeat the stem connector

procedure.

Friction Discussion

If you are attempting to adjust the bench set after the actuator is connected to the valve and the packing tightened,

you must take friction into account. Make the spring adjustment so full actuator travel occurs at the bench set values

(a) plus the friction force divided by the effective diaphragm area with increasing diaphragm pressure or (b) minus the

friction force divided by the effective diaphragm area with decreasing diaphragm pressure.

If the stem connector assembly has been installed, the valve friction may be determined by the following procedure:

1. Install a pressure gauge in the actuator loading pressure line that connects to the actuator diaphragm casing.

Note

Steps 2 and 4 require that you read and record the pressure shown on the pressure gauge.

2. Increase the actuator diaphragm pressure and read the diaphragm pressure as the actuator reaches a travel

position in the rated travel of the valve that does not contact a travel stop. Make a reference mark on the travel

indicator scale using tape or some other method at this point.

3. Increase the actuator diaphragm pressure until the actuator is at a travel position greater than the position

referenced in step 2 using the reference point to identify first movement.

4. Decrease the actuator diaphragm pressure and read the diaphragm pressure as the actuator returns to the position

referenced in step 2.

The difference between the two diaphragm pressure readings is the change in the diaphragm pressure required to

overcome the friction forces in the two directions of travel.

5. Calculate the actual friction force:

Friction

Force, = 0.5

pounds

Difference

in pressure

readings, psig



Effective

diaphragm area,

inches2

Refer to table 1 for the effective diaphragm area.

It is difficult to rotate the spring adjustor (key 74, figures 6, 7, 8, 9, and 10) when the full actuator loading pressure is

applied to the actuator. Release the actuator loading pressure before adjusting. Then re-apply loading pressure to

check the adjustment.

Note

For push‐down‐to‐close valves, the valve plug seat is the limit for downward travel and the actuator up‐stop is the limit for upward

(away from the valve) movement. For push‐down‐to‐open valves, the actuator down stop is the limit for downward movement,

and the valve seat is the limit for upward (away from the valve) movement.

Instruction Manual

D100306X012

657 Actuator (30/30i-70/70i and 87)

June 2018

Deadband Measurement

Deadband is caused by packing friction, unbalanced forces, and other factors in the control valve assembly. Deadband

is the range a measured signal can vary without initiating a response from the actuator (see figure 5). Each actuator

spring has a fixed spring rate (force divided by compression). You have verified that the right spring was installed in the

actuator by completing the Spring Verification steps.

Deadband is one factor that affects the control valve assembly operation during automatic loop control. The control

loop tolerance for deadband varies widely depending on the loop response. Some common symptoms of the

deadband being too wide are no movement, a “jump” movement, or oscillating movements of the actuator during

automatic loop control. The following steps are provided to determine the span of deadband. The percent of

deadband is helpful in troubleshooting problems with the process control loop.

1. Start at a pressure near the lower bench set pressure, slowly increase pressure until the valve is approximately at

mid‐travel. Note this pressure reading.

2. Slowly decrease pressure until movement of the valve stem is detected, and note this pressure.

3. The difference between these two pressures is deadband, in psi.

4. Calculate the percent of deadband by:

Deadband, psi

Deadband = —————————————— = nn%

Bench Set Span, psi

NOTE:

 DEADBAND IS CAUSED BY FRICTION.

Figure 5. Typical Valve Response to Deadband

UPPER

BENCH SET

PRESSURE

LOWER

BENCH SET

PRESSURE

CLOSING

VALVE

15 1.0

0.6

0.2

OPENING

VALVE

OPEN

CLOSED MID RANGE

VALVE TRAVEL

DIAPHRAGM PRESSURE, PSIG

DIAPHRAGM PRESSURE, BAR

RANGE OF

DEADBAND 1

UPPER

BENCH SET

PRESSURE

LOWER

BENCH SET

PRESSURE

CLOSING

VALVE

15 1.0

0.6

0.2

OPENING

VALVE

OPEN CLOSED

MID RANGE

VALVE TRAVEL

DIAPHRAGM PRESSURE, PSIG

DIAPHRAGM PRESSURE, BAR

A6763‐2

RANGE OF

DEADBAND 1

DIRECT ACTING VALVE REVERSE ACTING VALVE

BENCH SET BENCH SET

Loading Connection

The loading pressure connections are made at the factory if the valve, actuator, and positioner come as a unit. Keep

the length of tubing or piping as short as possible to avoid transmission lag in the control signal. If a volume booster,

valve positioner or other accessory is used, be sure that it is properly connected to the actuator. Refer to the positioner

instruction manual or other manuals as necessary.

For actuators shipped separately or whenever the actuator pressure connections are installed, use the following steps:

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