Emerson Fisher 480 Installation Instructions

2015-03-30

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Fisherr480 Series Yokeless Piston Actuators

Contents

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

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

Description 1.................................

Specifications 1...............................

Actuator Configurations 4.......................

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

Principle of Operation 6.........................

Pressure Connections 7.........................

Adjustments 7.................................

Actuator Maintenance 8.........................

Disassembly 8................................

Parts Ordering 12...............................

Parts List 12...................................

Figure 1. Fisher 480-15 Piston Actuator

W1867

Introduction

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for Fisher 480 Series yokeless piston

actuators.

Do not install, operate, or maintain 480 Series actuators 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 Process Management sales office before

proceeding.

Description

480 Series actuators (figure 1) are yokeless piston actuators that are used in either throttling or on-off applications

with ball valves, butterfly valves, louvers, dampers, and rheostats. They require pneumatic pressure loading from

double-acting positioners (Fisher 3570) or from on-off loading and unloading devices.

Specifications

Table 1 lists specifications for the 480 Series actuator and table 3 lists specifications for the 3570 actuator.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Table 1. Fisher 480 Series Actuator Specifications

Available Configurations

See the Actuator Configurations section.

Cylinder Pressure

Maximum Allowable:(4) 10.3 bar (150 psig)

Required to Produce a Given Thrust: Seefigure2

Minimum Recommended: Valves with low torque

requirements -- (2.4 bar [35 psig]); all other valves --

(3.4 bar [50 psig])

Maximum Supply Source Consumption

With Positioner and Constant Input Signal: 0.54

normal m3/hr(1) (20 scfh(1)) of air at 6.9 bar (100 psig)

Without Positioner: Depends on cylinder volume and

supply pressure

Travel Information

Maximum Rated Travels, All 480 Series actuators with

Linear Output: See table 2

Travel Stops Available for 480 Series actuators with

105 mm (4.125 inch ) Maximum Rated Travels: See

table 2

Thrust Information

Seefigure2

Torque Output

480, 480-15, and 480-16 (for butterfly valves):

Contact your Emerson Process Management sales

office

Stroking Speeds

See table 2

Operative Ambient Temperature(2)

With Nitrile O-Rings: -46 to 80_C(-50to175_F)

With Fluorocarbon O-Rings (Optional):(3)

-18 to 149_C(0to300_F)

Actuator Size and Piston Size

See table 2

Pressure Connections

Standard is 1/4 NPT. For larger sizes, contact your

Emerson Process Management sales office.

Construction Materials

Actuator:

Part Material

Cylinder and Piston Aluminum

Piston Rod Extension SST, Chrome Plated

Cylinder Seal Bushings Brass

O-Rings Nitrile or Fluorocarbon

Options

J376 Series trip valve system to fail actuator

Jup or Jdown or Jlock in last position

JTopWorxtDXP M21GNEB electrical valve stem

position switch

JMicro-Switch limit switches

1. Normal m3/hr.- normal cubic meters per hour (0_C and 1.01325 bar, absolute); Scfh - standard cubic feet per hour (60_Fand14.7psia).

2. These terms are defined in ANSI/ISA Standard S51.1

3. Without snubber. If this actuator has a snubber, the temperature specification is the same for the nitrile version.

4. The pressure limits in this bulletin and any applicable standard or code limitation for actuator should not be exceeded.

Table 2. Size, Piston, Stroking Speed, and Travel Information

ACTUATOR

SIZE

EFFECTIVE

PISTON AREA

PISTON

DIAMETER

STROKING

SPEED(1)

SINGLE-FLANGE TRAVEL STOPS AVAILABLE

FOR ACTUATORS WITH

105 mm (4.125 INCHES)

MAXIMUM RATED TRAVEL

–16 Versions All Others Except Fisher 487,

487-1(2)

Cm2Inch2mm Inch mm/

sInch/s mm Inch mm Inch mm Inch

30 107 16.5 121 4.75 102 4--- --- 105 4.125 89 3.5

182

258

28.25

55.5

156

216

6.125

8.5

2.05

1.30 206 8.125 105 4.125 89 3.5

1. For actuators with positioners at 6.9 bar (100 psig) supply pressure and all prestroke conditions satisfied. Stroking speeds for actuators without positioners or with snubbers will depend on

the particular construction involved.

2. See 480 series Actuators Specifications for these travels.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Table 3. Fisher 3570 Actuator Specifications

Available Configurations

3570: Valve positioner with two relays and three

pressure gauges for monitoring input signal and

output pressures to the top and underside of the

actuator piston

3570C: Similar to 3570 except that the positioner is

equipped with automotive tire valves instead of

pressure gauges. The valves can be used for clip-on

test pressures gauges. The relay nozzles on these

positioners are locked in place with locknuts to resist

unwanted nozzle movement due to vibration

Input Signal

Standard Ranges: 0.2to1.0bar(3to15psig)or0.4

to 2.0 bar (6 to 30 psig)

Split Ranges: Typically uses one half of standard range

when two control valves are operated by one input

signal from a single controller

Optional Ranges: As required within the limits of the

bellows

Bellows Pressure Rating

Standard Bellows: 3.4 bar (50 psig)

Optional Bellows: 6.2 bar (90 psig)

Supply Pressure

Maximum: 10.3 bar (150 psig)

Minimum: 2.4 bar (35 psig)

Output Signal

Type: Pneumatic pressure as required by the actuator

Action: Field reversible between direct and reverse

(see table 4)

Hysteresis(1,2)

0.15% of total stroke or instrument pressure span

Resolution(1,2)

0.2% of instrument pressure span

Repeatability(1,2)

0.3% of instrument pressure span

Frequency Response(1,2)

Seefigure3

Pressure Connections

Vent: 3/8 NPT

All Others: 1/4 NPT

Pressure Indications

3570C: Tire valves accept standard pressure gauge

chucks

3570: See table below

Type of Indication Number

Used

Standard Gauge Range

bar (psig)

Positioner input signal

gauge 10 to 2.1 (0 to 30) or

0 to 4.1 (0 to 60)

Cylinder supply pressure

gauge 00to11.0(0to160)

Static Air Consumption(3)

0.56 normal m3/hr (20 scfh) with 6.9 bar

(100 psig) supply pressure

Operative Ambient Temperature(1,2)

With Nitrile O-Rings: -34 to 79_C(-30to175_F)

With Fluorocarbon O-Rings (Optional):(3)

-18 to 149_C(0to300_F)

Construction Materials

Actuator:

Part Material

Base, Cover and Beam

Bellows

Bias and Range Spring

Relay Body

Relay Nozzle(s)

Diaphragm

O-Rings

Aluminum, die cast

Brass

Steel, Plated

Zinc, Die Cast

SST

Nitrile or Fluorocarbon

Options

Fisher SS-52 clip-on chuck (with or without gauge) for

3570C positioners

1. These terms are defined in ANSI/ISA Standard S51.1

2. For actuator with positioner only. Does not apply to other constructions or actuator-valve combination.

3. Normal m3/hr.- normal cubic meters per hour (0_C and 1.01325 bar, absolute); Scfh - standard cubic feet per hour (60_F and 14.7 psia).

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Figure 2. Supply Pressure and Thrusts

A5961

NOTE:

THRUSTS IN THOUSANDS OF POUNDS (IN THOUSANDS OF NEWTONS)

FOR ACTUATORS WITH POSITIONERS

MAY BE INCREASED BY 10% FOR ACTUATORS WITHOUT POSITIONERS.

EITHER THIS THRUST, OR THE MAXUMUM ALLOWABLE LOADING FOR THE CONTROL

DEVICE IS THE LIMITING FACTOR FOR USABLE ACTUATOR FORCE.

SIZE 30

ACTUATOR SIZE 40

ACTUATOR

SIZE 60

ACTUATOR

Figure 3. Frequency Response

A5962

1. SIZE 30– 19mm (0.75 INCH) TRAVEL

2. SIZE 40– 38mm (1.5 INCH) TRAVEL

3. SIZE 60– 38mm (1.5 INCH) TRAVEL

Actuator Configurations

480: Yokeless piston actuator with positioner.

481: Yokeless piston actuator without positioner. Other actuators may be obtained without positioner by adding -1 to

thetypenumber.

The above actuators come with standard mounting flange, 105 mm (4.125 inch) maximum rated travel, and threaded

pistonrodconnectionwithsizes30through60formounting on ball valves, louvers, and dampers with brackets.

These actuators may be obtained with the following alternate universal mounting flange constructions:

-15 Added to Type Number: Allows butterfly valve mounting for a standard actuator with 105 mm (4.125 inch)

maximum travel and threaded piston rod connection, and comes in sizes 30 through 60.

-16 Added to Type Number: Provides 206 mm (8.125 inch) maximum travelandthreadedpistonrod connection, and

comes in sizes 40 through 60.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Table 4. Action Under Normal Operating Conditions

ACTUATOR DESCRIPTION DESIRED PISTON MOTION

Down Up

With Positioner Direct-acting Increasing input signal pressure to bellows(1) Decreasing input signal pressure to bellows(1)

Reverse-acting Decreasing input signal pressure to bellows(1) Increasing input signal pressure to bellows(1)

Without positioner Supply pressure loaded on top of piston,

exhausted from bottom

Supply pressure loaded on bottom of piston,

exhausted from top

1. Supply pressure is routed through relays to piston.

Installation

WARNING

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

injury.

Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed

where service conditions could exceed the limits given in table 1 or 3 or on the appropriate nameplates. To avoid such

injury or damage, provide a relief valve for overpressure protection as required by accepted industry or local, state, and

Federal codes and good engineering practices.

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.

Inspect this equipment on arrival to note any damage which may have occurred in transit. If the actuator is attached to

a valve body when received, install the valve in the pipeline with flow in the direction of the arrow on the valve body.

(Some valve types, notably various butterfly valves, can be installed with flow in either direction and are unmarked as

to proper flow direction.)

A three-valve bypass around the main valve is recommended to permit continuous operation during periodic

maintenance or inspection of the main valve.

Figure 4. Operation of Actuator with Positioner

BJ8256-A

A1286

BEAM

FIXED RESTRICTION

RANGE SPRING

BIAS

SPRING

RELAY B

SUPPLY

INSTRUMENT

BELLOWS REVERSED

POSITION

RELAY A

SUPPLY FIXED RESTRICTION

INSTRUMENT PRESSURE

SUPPLY PRESSURE

TOP CYLINDER PRESSURE

BOTTOM CYLINDER PRESSURE

NOZZLE PRESSURE

Instruction Manual

D100291X012

480 Series Actuators

August 2012

When 480 Series actuators are supplied to operate dampers, louvers, or similar equipment, a suitable mounting plate

should be provided, and the piston rod of the actuator connected to the operating arm of the damper, etc., with

appropriate linkage.

Figure 5. Cylinder Diameter and Bolt Center Location, All Actuators (refer to table 5)

BH9452-K

A1290

Table 5. Cylinder Diameter and Bolt Center Location, All Actuators

ACTUATOR SIZE CH, DEGREE OF ARC

mm Inch Standard Flange Universal Mounting Flange

30 171 6.75 045

40 206 8.12 45 45

60 267 10.50 22.5 45

Figure 6. Operation of Actuator with Snubber

32A8303-A

A1287

SNUBBER

POSITIONER

OR SWITCH

-ING DEVICE

SUPPLY PRESSURE

TOP CYLINDER PRESSURE

BOTTOM CYLINDER PRESSURE

UPPERSNUBBERPRESSURE

LOWER SNUBBER PRESSURE

CHECK

VALVES

Principle of Operation

Actuator

These actuators react to a pressure unbalance that is created by loading supply pressure on one side of the piston and

unloading the opposite side. Some type of switching device is required to shift the supply pressure from one side of

Instruction Manual

D100291X012

480 Series Actuators

August 2012

the piston to the other. For most actuators in the 480 Series, this device is a 3570 positioner. However, a separate

loading device must be provided for actuators without positioners.

For actuators with positioners (figure 4), the pneumatic output signal from a controller or instrument is piped to the

positioner bellows. As long as the bellows receives a constant input signal pressure, the beam remains motionless and

allows supply pressure to bleed throughbothrelaynozzlessothataconstantpressure is maintained between the

nozzle and the fixed orifice. The relays are in equilibrium with their inlet and exhaust valves closed.

Assume that a downward piston motion is required and the bellows receives a corresponding change in input signal

pressure. This causes the beam to pivot so that it covers the nozzle on relay A. (Beam movement is accomplished

either by increasing the input signal pressure on a direct-acting positioner to expand the bellows, or by decreasing the

input signal pressure on a reverse-acting positioner to contract the bellows.)

ThenozzlepressureinrelayAincreasesduetotherestriction created by the beam over the nozzle. Through relay

action, the air pressure to the top of the piston is increased. At the same time, relay B reacts to the change in beam

position to decrease the pressure to the underside of the piston. Due to the resulting unbalanced forces acting on the

piston, it moves down, changing the valve plug position.

Piston movement is fed back to the beam by means of a range spring which is connected to the beam and to the

piston rod extension, applying a force to the beam opposite to that caused by the expanding or contracting bellows.

This feedback arrangement prevents overcorrection and ensures a definite position of the piston and valve plug for a

given instrument signal.

If upward piston motion is required, the beam pivots overthenozzleonrelayB.Theresult is relay, piston, and

feedback action opposite that for downward piston motion.

Reversal of positioner action is accomplished simply by removing four screws, inverting the bellows, and installing two

bellowspostsforsupportitthechangeisfromdirecttoreverse action. Bellows posts are stored in the positioner case

and are not used if the change is from reverse to direct.

Actuator with Snubber

As the actuator piston strokes, the snubber piston moves inside an oil-filled cylinder, forcing oil from one side of the

piston to the other through two check valves (see figure 6). Theresistancetoflowcreatedby the settings of the check

valves and the shock absorbing quality of the oil combine to damp out any tendency of the valve plug to jump. The

plug of each check valve is held off its seat by the positioning of the adjusting screws. Thus, with the adjusting screws

backed off all the way, maximum damping will be obtained.

Pressure Connections

480

The 3570 positioner, an integral part of 480 actuator units, is factory-assembled to the actuator. Two connections,

“Supply” and “Instrument”, remain to be made after valve installation. Both are 1/4 NPT holes in the positioner and are

labelled. Minimum supply pressure is 2.4 bar (35 psig), but for optimum performance, supply pressure should be held

as near as possible to the 10.3 bar (150 psig) maximum. Supply pressure air or gas should be clean and dry, as well as

non-corrosive. Use of a Fisher 252 filter is recommended.

The positioner case should always be vented to prevent pressure buildup. If the valve is installed with the actuator

below the pipeline, provide a new vent location in the lowest part of the case by removing the cadmium-plated pipe

plug from the case and screwing it into the standard vent location. This also serves as a drain hole to prevent

accumulation of condensate.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

481

The 481 actuator also requires 1/4 NPT external supply pressure piping. The 481 has only a pressure tap cover on top

of the cylinder. Supply air pressure must be connected to it, and also to the lower cylinder connection located near the

cylinder/cylinder flange joint. An external four-way valve or other switching device must be provided between the

main supply pressure line and these two actuator pressure connections.

Adjustments

All three adjustments on the 480 actuator are on the 3570 positioner. For further information on the positioner, such

as Adjustments, Maintenance, Reversing, and Relay Operation,refer to the Fisher 3570 instruction manual,

D200137X012.

The 481 actuator requires no adjustments.

Actuator Maintenance

WARNING

Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations:

DDo not remove the actuator from the valve while the valve is still pressurized.

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

injury.

DDisconnect any operating lines providing air pressure or a control signal to the actuator. Be sure the actuator cannot

suddenly open or close the valve.

DUse 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.

DUse lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

DThe 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.

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

media.

It is necessary for efficient and proper operation of the actuator that all parts be free from dirt, abrasives, and foreign

material. Upon assembly at the factor, all synthetic rubber O-rings have been coated with water-resistant lithium

grease. It is recommended that this lubricant be used on all O-rings, especially those on moving parts or in contact

with moving parts, whenever the actuator is dismantled.

Disassembly

Refer to figures 7 and 8.

References to “positioner” can be ignored if a 481 actuator is involved.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

1. Bypass the valve body or shut off the pressure in the pipeline.

CAUTION

The adjustable linkage between the actuator and the main valve should not be disconnected when the valve is open with

fluid flowing. (Dampers or louvers should be in safe, stable positions prior to disconnection.)

2. Shut off all pressure to the actuator. Remove all tubing lines (cylinder, instrument, and supply) from the actuator.

3. Remove the positioner cover after loosening the four cover screws on the underside of the positioner base.

4. Disengage the range spring by unscrewing the spring retainer from the piston rod extension.

5. Loosen the two cap screws that hold the positioner to the cylinder. When removing the positioner, do not lose the

small O-ring that is used in the passage from the positioner to the top of the cylinder.

6. Nextremovetheclevisboltfromtheadjustablelinkage.Removethebottomsnapring(key26)andunscrewthe

clevis and the boot locknut from the actuator piston rod.

7. Remove the nuts that hold the cylinder to the mounting flange and lift off the cylinder.

8. Remove the stud bolts (key 123) that hold the cylinder to the cylinder flange. Two slots, 180 degrees apart, are

located at the lower edge of the cylinder. Insert a screwdriver in these slots and pry the cylinder loose. The piston

and piston rod will come out with the cylinder. the piston can then be removed by pulling it out the open end of the

cylinder.

9. Unscrew both seal bushings (keys 7 and 8).

10. Inspect all parts for excessive wear and defects. Replace all worn O-rings. Lubricate as mentioned above.

11. To reassemble, reverse the above procedure.

Note

When reassembling the actuator after the piston rod extension (key 5) has been removed from the piston rod (key 4), clean the

threads of the piston rod thoroughly and apply a thread locking adhesive (medium strength) to the threads. Tighten the piston rod

extension securely to a torque of 203 NSm (150 lbfSft). This torque is approximately equal to the torque that would be developed

by placing a force of 150 pounds on the end of a one-foot wrench, 75 pounds on the end of a two-foot wrench, etc.

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Figure 7. Fisher 480 Piston Actuator - Size 30- 60

40A9540-A

PARTS NOT SHOWN: 27 AND 112

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Figure 8. Fisher 481 Piston Actuator - Size 30- 60

40A9538-A

PARTS NOT SHOWN: 27, 78, 79, AND 112

Instruction Manual

D100291X012

480 Series Actuators

August 2012

Parts Ordering

When corresponding with your Emerson Process Management sales office about this equipment, refer to the serial

number found on the actuator nameplate (key 22). Also, specify the complete 11-character part number from the

following Parts List when ordering replacement parts.

WARNING

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management 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

Part numbers are shown for recommended spares only. For part

numbers not shown, contact your Emerson Process Management sales

office.

Key Description Part Number

1 Cylinder Flange

2Cylinder

3Piston

4PistonRod

5 Piston Rod Extension

7 Upper Seal Bushing

8LowerSealBushing

9* Stem Seal O-ring

Sizes 30, 40, and 60 (2 req'd) 1E73690699

10* Bushing Seal O-ring

Sizes 30, 40, and 60 (2 req'd) 1D34830689

11* Piston Seal O-ring

Size 30 1H86210699

Size 40 1H86220699

Size 60 1H86240699

Key Description Part Number

12* Cylinder Seal O-ring

Size 30 1H86200699

Size 40 1D44480699

Size 60 1H86230699

13 Cylinder Stud

14 Compression Fitting

15 Cylinder Tubing

18 Boot Locknut

22 Nameplate

23 Drive Screw

24* Piston Rod Boot

Sizes 30, 40, and 60 1H93790699

25 Top Boot Snap Ring

26 Bottom Boot Snap Ring

27 Travel stop

30 Piston Nut

31 Positioner

45 Spring Retainer Spacer

78* Cover Seal

481 only 1C85380699

79 Cover Screw

160 Pipe Plug

*Recommended spare parts

Emerson Process Management

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Chatham, Kent ME4 4QZ UK

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot

to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are

governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such

products at any time without notice.

Fisher and TopWorx are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co. Emerson Process

Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective

owners.

Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance

of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.