Emerson Bettis G2XXX M11 series Operating instructions

Service Instructions
124843E Rev. C
August 2015
G01 through G10 Double-Acting Pneumatic
Actuators with M11 Hydraulic Override

I
Service Instructions
124843E Rev. C
Table of Contents
August 2015
Table of Contents
Table of Contents
Section 1: Introduction
1.1 General Service Information ...................................................................... 1
1.2 Definitions ................................................................................................. 2
1.3 General Safety Information ........................................................................ 2
1.4 Bettis Reference Materials .......................................................................... 2
1.5 Service Support Items ............................................................................... 3
1.6 Lubrication and Fluid Requirements............................................................ 3
1.7 General Tool Information ............................................................................ 3
1.8 Actuator Storage......................................................................................... 4
1.9 Actuator Installation ................................................................................... 4
1.10 Actuator Start-Up........................................................................................ 4
1.11 Actuator Operation..................................................................................... 5
Section 2: Actuator Disassembly
2.1 General Disassembly .................................................................................... 6
2.2 Pneumatic Power Module Disassembly ......................................................... 6
2.3 Drive Module Disassembly ............................................................................ 9
2.4 M11 Hydraulic Override Cylinder Disassembly............................................. 11
Section 3: Actuator Reassembly
3.1 General Reassembly .................................................................................... 13
3.2 Drive Module Reassembly ........................................................................... 13
3.3 Pneumatic Power Module Reassembly ........................................................ 18
3.4 G2 and G3 Early Model Pneumatic Power Module Reassembly..................... 21
3.5 M11 Hydraulic Override Cylinder Reassembly.............................................. 23
3.6 Actuator Testing ......................................................................................... 25
Section 4: Field Conversions
4.1 Construction Reversal (Exchange Module Locations) ................................ 27
Section 5: Module Removal and Installation
5.1 Pneumatic Power Module Removal ............................................................. 28
5.2 Pneumatic Power Module Installation ......................................................... 28
5.3 M11 Hydraulic Overrides Cylinder Removal ................................................. 29
5.4 M11 Hydraulic Override Cylinder Installation............................................... 30
5.5 Powr Swivl Module Removal........................................................................ 31
5.6 Powr Swivl Module Installation.................................................................... 31

II
Service Instructions
124843E Rev. C
Table of Contents
August 2015
Table of Contents
Section 6: Actuator Support Information
6.1 M11 Hydraulic Override System Fluid Volume........................................... 33
6.2 Module Weights by Item Number and Actuator Housing Size................... 33
6.3 G01 Tool Style and Wrench Size................................................................ 34
6.4 G2 Tool Style and Wrench Size.................................................................. 35
6.5 G3 Tool Style and Wrench Size.................................................................. 35
6.6 G4 Tool Style and Wrench Size.................................................................. 36
6.7 G5 Tool Style and Wrench Size.................................................................. 36
6.8 G7 Tool Style and Wrench Size.................................................................. 37
6.9 G8 Tool Style and Wrench Size.................................................................. 37
6.10 G10 Tool Style and Wrench Size ................................................................ 38
Section 7: Troubleshooting
7.1 Fault Insertion........................................................................................... 39
7.2 Operational Test ....................................................................................... 40
Section 8: Removal and Decommissioning
8.1 Removal and Decommissioning................................................................ 41
Section 9: Document Revision ��������������������������������������������42
Appendix A: List of Tables ���������������������������������������������������43
Appendix B: List of Drawings ���������������������������������������������44

Service Instructions
124843E Rev. C August 2015
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™ G01XXX-M11, G2XXX M11, G3XXX M11, G4XXX M11,
G5XXX M11, G7XXX M11, G8XXX M11, and G10XXX M11 Double-Acting G-Series
Actuators with one Pneumatic Power Module and one M11 or M11 S Hydraulic
Override Module.
1.1.2 Normal recommended service interval for this actuator series is five 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 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.
1.1.8 Actuator module weights are listed in Section 6 Table 6.2.
1.1.9 When removing seals from seal grooves, use a commercial seal removing tool
or a small screwdriver with sharp corners rounded off.
1.1.10 Use a non-hardening thread sealant on all pipe threads.
CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS
Apply the thread sealant per the manufacturer’s instructions.
1.1.11 Bettis recommends that disassembly of the actuator components should be
done in a clean area on a workbench.

Service Instructions
124843E Rev. C
August 2015
2
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 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
instructions contained within this Service Instruction are strictly adhered to and executed
by well trained, equipped, prepared and competent personnel.
WARNING: READ WARNING MESSAGES CAREFULLY
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 PLANT SAFETY PROCEDURES
This 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.

Service Instructions
124843E Rev. C August 2015
3
Section 1: Introduction
Introduction
1�4 Bettis Reference Materials
1.4.1 Assembly Drawing for G01-M11 through G10-M11 Double-Acting with one Pneumatic
Power Module and one Hydraulic Override Module use part number 115680.
1.4.2 M11 Manual Hydraulic Override System operating instructions part number
126858 with M11 Assembly Drawing part number 126567.
1.4.3 M11-S Manual Hydraulic Override System operating instructions part number
121962 with M11-S Assembly Drawing part number 121090.
NOTE:
If you require a specific assembly drawing (IE: GXX-M3 OR HYD) please contact Emerson
Actuation Technologies Bettis by phone or email at [email protected]
1�5 Service Support Items
1.5.1 Bettis module service kits.
1.5.2 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 installed.
Table 1� G-Series Actuator Models
Actuator Model Bettis Part Number Actuator Model Bettis Part Number
G01 None required G5/G7 117369
G2 123616 G8/G10 117368
G3/G4 117370
1.5.3 Commercial leak testing solution.
1.5.4 Non-hardening thread sealant.
1�6 Lubrication and Fluid Requirements
NOTE:
Lubricants and hydraulic fluids other than those listed in step 1.6.1 and 1.6.2 should not
be used without prior written approval of Bettis Product Engineering.
1.6.1 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 or
cans and they are marked ESL-4, 5 and 10 lubricant.
1.6.2 FLUID REQUIREMENTS: M11 Manual Hydraulic Override System - All temperature
service (-20°F to +350°F)/(-28.9°C to 176.6°C) use Dexron II or Shell Tellus
T-32 Automatic Transmission Fluid. Low temperature service (-50°F to 150°F)/
(-45.5°C to 65.6°C) use Univis J13 or HVI 13 Hydraulic Fluid.

Service Instructions
124843E Rev. C
August 2015
4
Section 1: Introduction
Introduction
1�7 General Tool Information
1.7.1 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 6.3 through 6.10.
1�8 Actuator Storage
For 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 period.
1�9 Actuator Installation
1.9.1 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 the guess work out of the installation.
1.9.2 Actuators that 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 onto the valve. Refer to
the valve manufacturer's recommendations for specific 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 specifications for
total rotation.
1.9.3 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, and seals.
1�10 Actuator Start-Up
1.10.1 Prestart-up checks
1. Inspect to ensure the unit has been mounted onto valve properly. Gear
flange mounting bolts, stem key, setscrew(s) are installed and secured.

Service Instructions
124843E Rev. C August 2015
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Section 1: Introduction
Introduction
2. No tubing damaged or accessories dislodged during the shipping or
the installation.
3. Indicated position confirms valve position.
4. All switching valves in normal operating position as per
SCHEMATIC / INSTRUCTIONS
1.10.2 Check Connections
1. Pneumatic / hydraulic components connected as per schematic enclosed
or in service manual supplied.
2. Pneumatic supply connected to the identified ports.
3. Electrical connection terminals are secured.
4. Wiring as per enclosed diagram or service manual supplied.
1.10.3 When actuator is first placed 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 to exercise the seals so as to achieve a service ready
condition.
1.10.4 The actuator speed of operation is determined by a number of factors includes:
1. Power supply line length
2. Power supply line size
3. Power supply line pressure
4. Control valve and fitting orifice size
5. Torque requirements of the valve
6. Size of the actuator
7. Setting of speed controls
8. Hydraulic manual override (where available)
1.10.5 Due to the interaction of these variables, it is difficult to specify a "normal"
operating time. Faster operating time 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
1.10.6 Slower operating time may be obtained by using flow control valves to meter
the exhaust. Excessive exhaust flow metering may cause erratic operation.
1�11 Actuator Operation
1.11.1 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.
1.11.2 Manual Operation: All pressure must be vented or equalized on both sides of
the pneumatic piston prior to manual operation.

Service Instructions
124843E Rev. C
August 2015
6
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.
2.1.1 Section 2 - Actuator Disassembly is written to either completely disassemble
the entire actuator or can be used to disassemble individual modules as needed
(pneumatic power module or drive module, M11 override module or hydraulic
override cylinder).
2.1.2 The pneumatic power module and the hydraulic override cylinder can be
disassembled while still attached to the drive module or they can be removed
from the drive module and disassembled separate to the actuator (refer to
Section 5 - Module Removal And Installation).
NOTE:
Use a means of capturing the hydraulic fluid that will be lost during the removal or disassembly
of the hydraulic override power module. Use a bucket, tub, and large container, etc.
2.1.3 To ensure correct reassembly; that is, with pneumatic power module or M11
hydraulic cylinder assembly on same end of drive module as was, mark or tag
right (or left) and mark mating surfaces.
2�2 Pneumatic Power Module Disassembly
NOTE:
Review Section 2 steps 2.1.1 through 2.1.3 General Disassembly before proceeding with
pneumatic power module disassembly.
WARNING: DISCONNECT OPERATING PRESSURE
If not already removed disconnect all operating pressure from actuator power cylinders.
2.2.1 Mark and record location of the ports on outer end cap (3-80) and inner end cap (3-
10).
2.2.2 Refer to assembly drawing sheet 1 Detail "E". Remove two socket cap screws (3-
130), with lockwasher (3-140), from outer end cap (3-80).
2.2.3 Remove two tie bar hex nuts (3-90) from outboard side of outer end cap (3-80).