Emerson Fisher 657 And 667 Installation Instructions

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Fisherr 657 Diaphragm Actuators

Size 80 and 100

Contents

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

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

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

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

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

Actuator Mounting 3...........................

Loading Connection 4......................

Adjustments 4.................................

Travel 4......................................

Spring 5.....................................

Size 80 5.................................

Size 100 5................................

Maintenance 7.................................

Actuator 7...................................

Size 80 Disassembly 7......................

Size 80 Assembly 8.........................

Size 100 Disassembly 10....................

Size 100 Assembly 11.......................

Size 80 Side‐Mounted Handwheel 12.............

Disassembly 12............................

Assembly 13..............................

Size 80 Hydraulic Snubber 13....................

Size 80 Top‐Mounted Handwheel

(Adjustable Up Travel Stop) 13................

Disassembly 14............................

Assembly 14..............................

Size 100 Top‐Mounted Handwheel

(Adjustable Up Travel Stop) 14................

Disassembly 15............................

Figure 1. Sectional view of Fisher 657

Size 100 Actuator

W0366‐1

Assembly 15..............................

Parts Ordering 15...............................

Parts List 16...................................

Introduction

Scope of Manual

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

Fisher 657 actuator in sizes 80 and 100. Refer to separate instruction manuals for information about other equipment

and accessories used with these actuators.

Do not install, operate, or maintain 657 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.

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Table 1. Specifications

SPECIFICATIONS ACTUATOR SIZE

80 100

Nominal Effective Diaphragm Area cm21761 2902

inch2273 450

Yoke Boss Diameters mm 127 127 178

inch 5 5H(1) 7

Acceptable Valve Stem Diameters mm 25.4 or 31.8 31.8 50.8

inch 1 or 1‐1/4 1‐1/4 2

Maximum Allowable Output Thrust

Standard Cast Iron

Construction

All Steel

Construction

N 62942 88075 200170

lb 14150 19800 45000

Maximum Travel mm 76 102

inch 3 4

Maximum Casing Pressure for Actuator Sizing

Standard Cast Iron

Construction

All Steel

Construction

bar 3.4 4.9 6.9

psig 50 70 100

Maximum Diaphragm Casing Pressure(2) bar 4.1 5.5 7.9

psig 60 80 115

Material Temperature Capabilities

_C-40 to 82

_F-40 to 180

Pressure Connections 1/4 NPT internal

Approximate Weights Without Handwheel kg 234 346

lb 515 762

1. Heavy actuator‐to‐bonnet bolting.

2. This maximum casing pressure is not to be used for normal operating pressure.

Figure 2. Schematic Representation of Fisher 657 Actuator

SPRING LIFTS

AIR PUSHES STEM DOWN

AF3833‐A

A0792‐2

Description

The 657 actuator (figure 1) is a direct‐acting, spring‐opposed diaphragm actuator used for automatic operation of

control valves. The actuator positions the valve plug in response to varying pneumatic loading pressure on the

diaphragm. Figure 2 shows the operation of these actuators.

A 657 actuator can be furnished with either a top‐mounted or side‐mounted (size 80 only) handwheel assembly. A

top‐mounted handwheel assembly is normally used as an adjustable‐up travel stop. The size 100 top‐mounted

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handwheel may be used as an auxiliary manual actuator. A side‐mounted handwheel assembly is normally used as an

auxiliary manual actuator.

Specifications

Refer to table 1 for specifications of the 657 actuator. See the actuator nameplate for information about a specific

actuator.

Maximum Pressure Limitations

The casing and diaphragm of 657 actuators are pressure operated. The air pressure provides force to compress the

spring and stroke the actuator. The following explanations describe the maximum pressure limitation for 657

actuators. Refer to the nameplate, warning tag, and table 1 for maximum values.

D Maximum Casing Pressure for Actuator Sizing: This is defined as the maximum pressure that can be applied to

stroke the actuator, overcome unbalance forces, and provide seat load.

D Maximum Diaphragm Casing Pressure: If the maximum diaphragm casing pressure is exceeded, damage to the

diaphragm, casing, or actuator may result. This pressure is not to be used for normal operating pressure.

WARNING

To avoid personal injury or parts damage, do not exceed the Maximum Diaphragm Casing Pressure listed in table 1. The

Maximum Diaphragm Casing Pressure must not produce a force on the actuator stem greater than the maximum allowable

actuator output thrust or the maximum allowable stem load.

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.

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

instruction manual.

When an actuator and valve body are shipped together, the actuator is normally mounted on the valve. Follow the

valve body instructions when installing the control valve in the pipeline. If the actuator is shipped separately or if it is

necessary to mount the actuator on the valve, perform the Actuator Mounting procedures as described below.

For information on mounting valve positioners, refer to the appropriate valve positioner instruction manual.

Actuator Mounting

1. To permit adjustment of the actuator spring, the size 100 actuator must be installed in a vertical position above the

valve body. Mount the actuator on the valve bonnet. Insert the cap screws, and tighten the hex nuts, securing the

actuator to the bonnet.

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2. Screw valve stem locknuts (key 16, figure 4) all the way onto valve stem thread.

3. Connect an air supply to the diaphragm casing.

4. For push‐down‐to‐close valves, be sure the valve plug is on its seat. Apply pressure to ensure that the actuator stem

is fully extended. Reduce actuator loading pressure to retract the stem approximately 3.2 mm (1/8‐inch).

5. For push‐down‐to‐open valves, move valve plug to closed position. On large body sizes, this may require the use of

a pry bar inserted through the body line opening. If the body is installed in a pipeline, the bottom flange (if one is

used) can be removed and the valve plug pushed to the seat from the bottom opening. Pressure the actuator to

move the stem out 3.2 mm (1/8‐inch).

WARNING

To avoid personal injury due to the sudden uncontrolled movement of parts, do not loosen the stem connector cap screws

when the stem connector has spring or loading pressure force applied to it.

CAUTION

Incomplete engagement of both valve stem and 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 the

diameter of that stem.

6. Clamp the actuator and valve plug stems between the two stem connector halves (key 26, figure 4). Insert and

tighten the stem connector cap screws.

7. Thread the stem locknuts against the stem connector.

8. Align the travel indicator scale (key 18, figures 4 and 5) to show valve position.

Loading Connection

1. Connect the loading pressure piping to the connection in the top of the diaphragm casing.

2. Remove the 1/4‐inch bushing (key 33, figure 4 and key 120, figure 5) to increase connection size, if necessary. The

connection can be made with either piping or tubing.

3. Keep the length of tubing or piping as short as possible to avoid transmission lag in the control signal. If an

accessory (such as a volume booster or valve positioner) is used, be sure that the accessory is properly connected to

the actuator. Refer to the positioner instruction manual as necessary.

4. Cycle the actuator several times to check that the valve stem travel is correct and that the travel occurs when the

correct pressure range is applied to the diaphragm.

5. If valve stem travel is incorrect, refer to the Travel procedure in the Adjustments section.

6. If the pressure range is incorrect, refer to the Spring procedure in the Adjustments section.

Adjustments

Travel

Make travel adjustments when the motion observed during actuator travel is different from the travel stamped on the

actuator nameplate. If the Actuator Mounting procedure was followed correctly, this adjustment should not be

necessary.

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When adjusting travel of a reverse‐acting (push‐down‐to‐open) valve, apply a slight pressure on the actuator

diaphragm. This moves the valve plug off the seat, reducing the chance of damaging the valve plug or seat during

adjustments.

1. Back the stem locknuts away from the stem connector, and slightly loosen the stem connector cap screws.

CAUTION

Do not use wrenches or other tools directly on the valve stem. Damage to the stem surface and subsequent damage to the

valve packing may result.

2. Tighten the locknuts together, using a wrench, then screw the valve stem either into the stem connector to

lengthen travel or out of the stem connector to shorten travel.

3. Cycle the actuator to check the travel. If actual travel is not equal to the specified travel, adjust and check travel

until correct. Tighten the stem connector cap screws when correct travel is obtained.

4. Raise the travel indicator disk by threading the stem locknuts against the stem connector.

Spring

Make spring adjustments when the loading pressure range applied to achieve specified travel is not equal to the

pressure range stamped on the actuator nameplate. Refer to the Bench Set pressure range on the nameplate when

the valve contains no pressure and the packing is loosely inserted in the bonnet. Refer to the Max. Allow. Supply on the

nameplate when the valve is controlling the specified pressure drop and the packing is tightened to stop leaks around

the stem.

Monitor loading pressure carefully when making adjustments. Do not exceed the pressure specifications of either the

loading regulator or the actuator casings.

Each actuator spring has a fixed pressure span. Changing the spring compression shifts the span up or down to make

valve travel coincide with the loading pressure range.

Size 80

Remove cover band (key 60, figure 4), insert a rod of approximately 12.7 mm (1/2‐inch) diameter into a hole in the

adjusting screw (key 12, figure 4), and rotate the adjusting screw with the rod. Rotating the screw from left to right

will increase the loading pressure required to start actuator stem travel; opposite rotation will decrease the pressure

required to start travel.

Size 100

CAUTION

The actuator must be in the vertical position when adjusting spring to avoid damage to thrust bearing (key 35, figure 5) and

to properly position spacers required for adjustment.

Remove the shroud plate (key 107, figure 5), and loosen the jam nut (key 115, figure 5).

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Figure 3. Dimension B for Spring Adjustment

LOWER DIAPHRAGM CASING

SPRING SEAT

JAM NUT

ADJUSTING NUT

A0950‐1

B

For small spring forces, adjustments can be made by rotating the adjusting nut (key 114, figure 5). Clockwise rotation

(when viewed from diaphragm casings) of the adjusting nut will increase the loading pressure required to start

actuator stem travel, and counterclockwise rotation will decrease the pressure required to start travel. Tighten the jam

nut when adjustment is complete.

For high spring forces, it is necessary to use spacers between the lower diaphragm casing and the spring seat to isolate

spring force from the adjusting nut.

WARNING

To avoid personal injury from the compressed actuator spring snapping back to its original length, make and use the

spacers by following the instructions in the steps below.

To avoid personal injury, keep hands and tools away from the spring and spring seat as instructed in the following

procedure.

1. It is recommended that three spacers be made of 3‐inch schedule 80 pipe cut to the appropriate length specified in

step 2. If other than the recommended material is to be used, be certain that the spacers are capable of

withstanding the spring force involved. The spacers must be of equal length with ends cut squarely.

2. Measure dimension B as shown in figure 3. Cut length of spacers as follows:

a. If it is desired to decrease spring compression, make the spacers approximately 4.8 mm (3/16‐inch) longer than

dimension B.

b. If it is desired to increase spring compression, make the spacers approximately 4.8 mm (3/16‐inch) shorter than

either dimension B plus the amount of adjustment required or dimension B plus valve travel, whichever is less.

3. Whenever the total amount of adjustment required is greater than valve travel, the adjustment must be made in

two or more steps, and the amount of adjustment taken in each step must be less than valve travel.

4. Pressure the actuator to attain full travel. Cautiously insert the spacers at equal intervals around the spring seat (key

11, figure 5). The spacers must be seated squarely when in use or they may slip out of position. Keeping hands and

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tools away from the spring and spring seat, slowly decrease loading pressure until the spring force holds the spacers

firmly between the spring seat and lower diaphragm casing (key 5, figure 5).

5. Loosen the jam nut. The adjusting nut can now be rotated clockwise (when viewed from the diaphragm casings) to

increase the loading pressure required to start actuator stem travel or counterclockwise to decrease the pressure

required to start travel.

6. Pressure the actuator to move the spring seat away from the spacers, and carefully remove the spacers.

7. If the total adjustment required was greater than valve travel, repeat the procedure. It will be necessary to make

new spacers using the new dimension B and the remaining adjustment required or valve travel, whichever is less.

Tighten the jam nut when adjustment is complete.

Maintenance

WARNING

Avoid personal injury or property damage 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 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.

The maintenance instructions are divided into four sections: actuator (sizes 80 and 100); side‐mounted handwheel

assembly (manual operator); hydraulic snubber; and top‐mounted handwheel assembly (adjustable‐up travel stop).

Actuator

This procedure describes how the actuator can be completely disassembled and assembled. When inspection or

repairs are required, disassemble only those parts necessary to accomplish the job; then, start the assembly at the

appropriate step.

Key numbers refer to figure 4 for size 80 actuators and figure 5 for size 100 actuators.

Size 80 Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric, and remove the tubing or piping from the

top of the diaphragm casing (key 1).

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WARNING

To avoid personal injury from the precompressed spring force thrusting the upper diaphragm casing (key 1) away from the

actuator, relieve spring compression (step 2, below), and carefully remove casing cap screws (key 22) (step 4, below).

2. Remove cover band (key 60). Insert a rod of approximately 12.7 mm (1/2‐inch) diameter into a hole in the adjusting

screw (key 12), and rotate the adjusting screw from right to left until spring compression is relieved. If the actuator

has a handwheel, rotate it counterclockwise, relieving all spring compression.

3. If necessary, the entire actuator may be removed from the valve body by unscrewing two cap screws from stem

connector (key 26) and removing actuator‐to‐bonnet bolting.

4. Unscrew diaphragm casing cap screws and nuts (keys 22 and 23), and lift off upper diaphragm casing (key 1).

5. Remove the molded diaphragm (key 2).

6. For actuators without snubber, remove diaphragm plate and stem (keys 4 and 10) as an assembly. This assembly

can be broken down further, if necessary, by removing the cap screw (key 3).

7. For actuators with snubber (see figure 7), unscrew cap screw (key 3), and remove diaphragm plate (key 4). Remove

stem connector (key 26). Unscrew cap screws (key 85), and remove cylinder assembly (key 74) and attached stem

and upper seat (keys 10 and 90) from actuator.

To disassemble snubber:

a. Unscrew stem from piston/piston rod assembly (key 27).

b. Remove retaining rings, cylinder heads, and piston/piston rod assembly (keys 76, 75, and 27). Replace packing

and O‐rings (keys 103, 104, 77 and 105) as required.

8. Remove actuator spring, upper sleeve, and spring seat (keys 6, 34 and 11).

9. Unscrew cap screws and nuts (keys 62 and 63), and remove spring case (key 29). Cap screws (key 62) on units with

side‐mounted handwheel do not use hex nuts (key 63).

10. For actuators without side‐mounted handwheel, remove adjusting flange (key 36) and attached thrust bearing

and adjusting screw (keys 35 and 12).

11. For actuators with side‐mounted handwheel (see figure 7), unscrew cap screws (key 64), and remove adjusting

flange (key 36) and attached thrust bearing and adjusting screw (keys 35 and 12). Do not lose the key (key 47).

Size 80 Assembly

1. Coat the threads of the adjusting flange (key 36) with anti‐seize lubricant (key 244). Replace the adjusting flange,

adjusting screw, and thrust bearing (keys 36, 12, and 35). Pack bearing with lithium grease lubricant (key 241).

For actuators with side‐mounted handwheel, install the key (key 47) on the adjusting flange (key 36). Coat the

adjusting flange threads with anti‐seize lubricant. Install the adjusting flange so that the key engages the slot in the

lower sleeve. Secure adjusting flange with cap screws (key 64). Adjust set screws (key 40, figure 7) to eliminate free

play in handwheel bearings.

Note

Over‐tightening the set screws will make handwheel operation difficult.

2. Mount the spring case (key 29) to the yoke (key 9) using cap screws and hex nuts (keys 62 and 63).

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3. Position the lower spring seat (key 11), and slide the actuator spring (key 6) squarely onto the spring seat.

4. If the diaphragm plate and actuator stem (keys 4 and 10) were separated, fasten them together using the cap

screw (key 3) and tighten to a torque of 544 NSm (400 lbfSft).

For actuators without a hydraulic snubber, slide upper sleeve (key 34) onto the actuator stem, and then slide upper

sleeve, actuator stem and diaphragm plate into the spring case (key 29) so that the spring (key 6) fits squarely

between the diaphragm plate and the spring seat (key 11).

For actuators with a snubber, thread the actuator stem and upper spring seat (keys 10 and 90) into the piston/piston

rod assembly (key 27). Install the snubber assembly and attached actuator stem into the upper sleeve, spring case

adaptor, and spring case (keys 34, 72, and 29). Secure with cap screws (key 85).

5. Place the diaphragm (key 2) with pattern side facing away from the diaphragm plate (key 4). Align the holes in the

diaphragm and the lower diaphragm casing (key 5).

6. Position the upper diaphragm casing (key 1) on the diaphragm (key 2), and align the holes.

Note

When you replace actuator diaphragms in the field, take care to ensure the diaphragm casing bolts are tightened to the proper

load to prevent leakage, but not crush the material. Perform the following tightening sequence with a manual torque wrench for

size 80 and 100 actuators.

CAUTION

Over‐tightening the diaphragm casing cap screws and nuts can damage the diaphragm. Do not exceed the following

maximum torque values for the appropriate diaphragm material:

EPDM/Meta‐Aramid: 95 NSm (70 lbfSft) Nitrile, Silicone, FKM (fluorocarbon)/Meta‐Aramid: 68 NSm (50 lbfSft)

Table 2. Maximum Torque Values

DIAPHRAGM MATERIAL INITIAL TORQUE

NSm (lbfSft)

FINAL TORQUE

NSm (lbfSft)

EPDM/Meta‐Aramid 41 (30) 82, +/-13 (60, +/-10)

Nitrile, Silicone, FKM/Meta‐Aramid 34 (25) 68 (50)

Note

Do not use lubricant on these bolts and nuts. Fasteners must be clean and dry.

7. Insert the cap screws (key 22) into the diaphragm casing, and tighten the hex nuts (key 23) in the following

manner. The first four hex nuts tightened should be diametrically opposed and 90 degrees apart. Tighten these four

hex nuts to the initial torque value found in table 2 for the diaphragm material being used.

8. Tighten the remaining hex nuts in a clockwise, criss‐cross pattern to the initial torque value found in table 2 for the

diaphragm material being used.

9. Repeat this procedure by tightening four hex nuts, diametrically opposed and 90 degrees apart, to the final torque

value that is specified in table 2 for the diaphragm material being used.

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10. Tighten the remaining hex nuts in a clockwise, criss‐cross pattern to the final torque value that is specified in table

2 for the diaphragm material being used.

11. After the last hex nut is tightened complete another tightening sequence, this time in a circular pattern around

the bolt circle to the final torque value that is specified in table 2 for the diaphragm material being used.

12. Once completed, no more tightening is recommended.

13. Mount the actuator on the valve in accordance with the procedures in the Installation section.

Size 100 Disassembly

Key numbers used in the following procedure are shown in figure 5 except when indicated.

Note

Two construction variations of the size 100 are based on spring length. Group 1 springs have a free length of 845 mm (33‐1/4

inches), and group 2 springs have a free length of 419 mm (16‐1/2 inches).

WARNING

To avoid personal injury from the precompressed spring force thrusting the upper diaphragm casing (key 1) away from the

actuator, relieve spring compression (step 1, below), and carefully remove casing cap screws (key 22) (step 7, below).

1. Remove shroud plate (key 107), loosen jam nut (key 115), and rotate adjusting nut (key 114) until spring

compression is relieved.

Note

To relieve spring compression when high spring forces exist, refer to the Adjusting Actuator Spring section, and follow the

instructions given for size 100 actuators with high spring forces.

2. Remove the pressure tubing or piping from the top of the diaphragm casing.

3. For actuators with top‐mounted handwheel, rotate handwheel (key 51, figure 8) counterclockwise as far as it will

go, unscrew cap screws (key 109, figure 5), and remove handwheel and gear case assembly (key 65, figure 8).

4. For actuators without top‐mounted handwheel, unscrew cap screws (key 109), and remove diaphragm casing

cover (key 123).

5. If necessary, remove the actuator from the valve body by separating the stem connector (key 26) and removing the

actuator‐to‐bonnet bolting. Separate the stem connector by loosening the stem locknuts (key 16) and unscrewing

the four cap screws.

6. Unscrew and remove actuator stem extension (key 116).

7. Unscrew cap screws (key 22), and remove upper diaphragm casing (key 1).

8. Remove backup plate, diaphragm retainer, diaphragm, diaphragm plate, and washer (keys 13, 110, 2, 4, and 117).

9. Unscrew the nuts that attach lower diaphragm casing (key 5) to actuator tie rods (key 21).

10. Remove lower diaphragm casing from tie rods and remove hex jam nut, adjusting nut thrust bearing (used with

group 1 springs only), and spring seat (keys 115, 114, 35, and 11).

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11. Remove seal bushing (key 111) and diaphragm casing cover O‐rings (keys 112 and 113) from upper diaphragm

casing (key 123). Replace with new parts if necessary. Apply lithium grease lubricant to the O‐rings.

12. Remove actuator spring (key 6).

Size 100 Assembly

Note

Units using a group 2 spring require one spring seat (key 11) on each end of the spring (key 6); units using a group 1 spring require

only one spring seat on the diaphragm end of the spring as shown in figure 5.

1. Place the spring and spring seats (keys 6 and 11) inside the spring case.

2. For actuators using a group 1 spring, pack the thrust bearing (key 35) with lithium grease lubricant (key 241). Place

bearing on the spring seat.

3. Screw the hex jam nut and adjusting nut (keys 115 and 114) onto the actuator stem.

4. Install the lower diaphragm casing (key 5) on the actuator tie rods (key 21). Secure with hex nuts.

Note

Before installing diaphragm plate (key 4), rotate adjusting nut (key 114) until the top of the actuator stem is 264 mm (10‐3/8

inches) above the inside surface of the lower casing (key 5).

When installing diaphragm (key 2), be certain that the rubber side of the diaphragm faces away from the spring.

CAUTION

To avoid product damage, smooth the edge of the diaphragm to avoid wrinkling, and be careful that the diaphragm fold

does not get pinched when the upper casing (key 1) is installed.

5. Install washer, diaphragm plate, diaphragm, diaphragm retainer, and backup plate (keys 117, 4, 2, 110 and 13).

6. Apply lithium grease lubricant (key 241) to the thread on the diaphragm end of the actuator stem (key 10).

7. Position the upper diaphragm casing (key 1) on the diaphragm (key 2), and align the holes.

Note

If backup plate (key 13) interferes with installation of upper casing, rotate adjusting nut (key 114) to move the plate.

Note

When you replace actuator diaphragms in the field, take care to ensure the diaphragm casing bolts are tightened to the proper

load to prevent leakage, but not crush the material. Perform the following tightening sequence with a manual torque wrench for

size 80 and 100 actuators.

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CAUTION

Over‐tightening the diaphragm casing cap screws and nuts can damage the diaphragm. Do not exceed 68 NSm (50 lbfSft)

torque.

Note

Do not use lubricant on these bolts and nuts. Fasteners must be clean and dry.

8. Insert the cap screws (key 22), and tighten the hex nuts (key 23) in the following manner. The first four hex nuts

tightened should be diametrically opposed and 90 degrees apart. Tighten these four hex nuts to 34 NSm (25 lbfSft).

9. Tighten the remaining hex nuts in a clockwise, criss‐cross pattern to 34 NSm (25 lbfSft).

10. Repeat this procedure by tightening four hex nuts, diametrically opposed and 90 degrees apart, to a torque of 68

NSm (50 lbfSft).

11. Tighten the remaining hex nuts in a clockwise, criss‐cross pattern to 68 NSm (50 lbfSft).

12. After the last hex nut is tightened to 68 NSm (50 lbfSft), all of the hex nuts should be tightened again to 68 NSm

(50 lbfSft) in a circular pattern around the bolt circle.

13. Once completed, no more tightening is recommended.

14. Install the actuator stem extension (key 116), diaphragm casing cover O‐rings (keys 112 and 113), and seal

bushing (key 111). Install the gear case cover (key 123) or the handwheel assembly (see figure 8).

15. Mount the actuator on the valve, and secure with the actuator‐to‐bonnet bolting. Refer to the Installation section

to connect actuator stem to valve plug stem.

Size 80 Side‐Mounted Handwheel

The side‐mounted handwheel assembly (figure 7) is normally used as a manual operator. The handwheel can be

mounted in either of two positions so that, regardless of valve plug action, counterclockwise rotation always opens

the valve. The assembly is a continuously connected type with an indicator to show neutral position. By rotating

handwheel away from neutral, the handwheel can be used to limit travel in either direction but not both directions at

the same time.

A grease fitting is provided on the gear box for periodic gear lubrication with a general‐purpose grease.

Instructions are given below for complete disassembly and assembly. Perform the disassembly only as far as necessary

to accomplish the required maintenance; then, begin the assembly at the appropriate step.

Key numbers refer to figure 7.

Disassembly

1. Complete steps 1 through 9 of the disassembly portion of the size 80 actuator section.

2. Unscrew cap screws (key 64), and remove adjusting flange (key 36). Do not lose the key (key 47).

3. Unscrew the two screws (key 28), and remove travel stop indicator (key 58) from lower sleeve (key 46).

4. Turn handwheel (key 51) to raise lower sleeve. Continue turning handwheel until lower sleeve is free of worm gear

(key 44). Lift out lower sleeve, bearing and gear retainer, thrust bearings, and worm gear (keys 46, 66, 67, and 44).

5. The worm shaft (key 45) and associated parts can be removed in order to replace or lubricate them. First, remove

the handwheel cap (key 54) and the handwheel (key 51). Do not lose the small ball or spring (keys 55 and 56).

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6. Loosen the two set screws (key 41), and unscrew the two worm retainers (keys 48 and 49). The ball bearings (key

50) will come out with the retainers. Remove the worm shaft (key 45).

Assembly

1. Pack the ball bearings (key 50) with lithium grease lubricant, and insert one ball bearing in the back worm retainer

(key 49) as shown in figure 7 (section C‐C).

2. Thread the back worm retainer and ball bearing (keys 49 and 50) into the gear case. Align the slot in the worm

retainer with the set screw hole in the gear case, insert the set screw (key 41), and tighten it.

3. Coat the worm shaft (key 45) threads with anti‐seize lubricant (key 244), and slide the shaft into the gear case so

that the end of the shaft fits snugly in the back worm retainer.

4. Insert the bearing in the front worm retainer

(key 48), and thread the retainer and ball bearing into the gear case. Align the slot in the retainer with the set screw

hole in the gear case, insert the set screw (key 41), and tighten it.

5. Put the spring and ball (keys 56 and 55) in the handwheel (key 51). Slide the handwheel onto the worm shaft (key

45). Thread the handwheel cap (key 54) onto the worm shaft.

6. Pack the two thrust bearings (key 67) with lithium grease lubricant. Install one thrust bearing; then, install the

worm gear (key 44) followed by the second thrust bearing and the bearing and gear retainer (key 66).

7. The lower sleeve (key 46) has two screw holes in one end. Coat the sleeve threads with lithium grease lubricant,

slide the end of the lower sleeve with the holes into the thrust bearing (key 67), turn the handwheel, and feed the

sleeve through the worm gear. Continue turning the handwheel until the lower sleeve protrudes from the gear

case. Fasten the travel stop indicator (key 58) to the sleeve with the two machine screws (key 28).

8. Install the key (key 47) on the adjusting flange (key 36). Coat the adjusting flange threads with anti‐seize lubricant

(key 244). Install the adjusting flange so that the key engages the slot in the lower sleeve. Secure adjusting flange

with cap screws (key 64).

9. Adjust set screws (key 40) to eliminate free play in the bearings.

Note

Over‐tightening the set screws will make handwheel operation difficult.

10. Install the adjusting screw and thrust bearings (keys 12 and 35). Pack bearings with lithium grease lubricant (key

241), and install as shown in figure 7.

11. Slide the spring case (key 29) into position, and secure with cap screws (key 62).

12. Complete steps 3 through 8 of the size 80 actuator assembly section.

Size 80 Hydraulic Snubber

The size 80 657 is available with a hydraulic snubber, as shown in figure 7, to dampen vertical instability of actuator

stem movement. The snubber is adjusted by rotating the adjusting screws (key 83, figure 7) counterclockwise out of

the reservoir (key 79, figure 7) to increase damping action and clockwise to decrease damping action. The adjusting

screw on the right (the lower of the two adjusting screws in section B‐B of figure 7) regulates downward damping

action, and the screw on the left regulates upward damping action.

Size 80 Top‐Mounted Handwheel (Adjustable Up Travel Stop)

CAUTION

If repeated or daily manual operation is expected, and the actuator is equipped with a casing‐mounted travel stop or

top‐mounted handwheel, the diaphragm could be subject to excessive wear.

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

14

The actuator should be equipped with a side‐mounted handwheel, which is designed for more frequent use as a manual

operator.

A top‐mounted handwheel assembly is normally used as an adjustable‐up travel stop to limit full retraction of the

actuator stem. Turning the handwheel clockwise turns the handwheel stem (key 133, figure 6) into the diaphragm

casing and forces the pressure block assembly (key 179, figure 6) against the diaphragm and diaphragm plate.

Instructions are given below for complete disassembly and assembly. Perform the disassembly only as far as necessary

to accomplish the required maintenance; then, begin the assembly at the appropriate step.

Key numbers refer to figure 4 for actuator parts and figure 6 for handwheel parts.

Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric, and remove the tubing or piping from the

diaphragm casing (key 1).

WARNING

To avoid personal injury from the precompressed spring force thrusting the upper diaphragm casing (key 1) away from the

actuator, relieve spring compression (step 2, below), and carefully remove casing cap screws (key 141) (step 3, below).

2. Remove cover band (key 60). Insert a rod of approximately 12.7 mm (1/2‐inch) diameter into a hole in the adjusting

screw (key 12), and rotate the adjusting screw from right to left until spring compression is relieved. Rotate

handwheel to be sure it is not compressing actuator spring.

3. Unscrew cap screws (key 141), and remove handwheel assembly.

4. Remove hex nut (key 54), and lift off the handwheel.

5. Unscrew support screws (key 182), and remove pressure block, stem, stem collar, and thrust bearing (keys 179,

133, 183, and 175).

6. Unscrew body nut (key 186), and remove gland (key 180). If necessary, remove and replace packing rings (key

181).

Assembly

1. Install new packing rings and gland (keys 181 and 180), and thread the body nut (key 186) onto the body.

2. Lubricate the thrust bearing and stem (keys 175 and 133), with lithium grease lubricant (key 241). Slide stem, stem

collar, thrust bearing, and pressure block (keys 133, 183, 175, and 179) into the body as shown in figure 6 and

install support screws (key 182).

3. Install handwheel and hex nut (keys 51 and 54).

4. Install a new handwheel gasket (key 185).

5. Mount the handwheel assembly on the diaphragm casing, and secure with cap screws (key 141).

6. Reconnect pressure tubing or piping to actuator casing.

Size 100 Top‐Mounted Handwheel (Adjustable Up Travel Stop)

A top‐mounted handwheel assembly is normally used as an adjustable‐up travel stop to limit full retraction of the

actuator stem. Clockwise rotation of the handwheel (key 51) moves the actuator stem (key 10) downward,

compressing the spring (key 6). Spring action returns the stem as the handwheel is turned counterclockwise.

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

15

Instructions are given below for complete disassembly and assembly. Perform the disassembly only as far as necessary

to accomplish the required maintenance; then, begin the assembly at the appropriate step.

Key numbers refer to figure 5 for actuator parts and figure 8 for handwheel parts.

Disassembly

1. Bypass the control valve. Reduce the loading pressure to atmospheric (refer to the Maintenance section), and

remove the tubing or piping from the diaphragm casing.

WARNING

To avoid personal injury from the precompressed spring force thrusting the upper diaphragm casing (key 1) away from the

actuator, relieve spring compression (step 2, below), and carefully remove casing cap screws (key 124) (step 3, below).

2. Rotate handwheel counterclockwise, relieving all spring compression.

3. Unscrew cap screws (key 124), and remove gear case cover (key 123).

4. Loosen the set screws (key 41) in the front and back worm retainers (keys 48 and 49) and handwheel (key 51).

5. Remove retaining ring (key 118), and remove handwheel.

6. Remove front and back worm retainers (keys 48 and 49).

7. Remove worm shaft (key 45).

8. Pull the power screw assembly (key 122). The bearing and gear retainer, thrust bearing, and worm gear (keys 66, 67

and 44) will come out with the power screw.

Assembly

1. Pack the ball bearings (key 50) with lithium grease lubricant (key 241), and insert one ball bearing into the back

worm retainer (key 49).

2. Thread the back worm retainer and ball bearing into the gear case. Align the slot in the worm retainer with the set

screw hole in the gear case, insert set screw (key 41), and tighten.

3. Coat the worm shaft (key 45) threads with lithium grease lubricant, and slide the shaft into the gear case so that the

end of the shaft fits snugly in the back worm retainer.

4. Insert the bearing into the front worm retainer (key 48), and thread the retainer and ball bearing into the gear case.

Align the slot in the retainer with the hole in the gear case, insert the set screw (key 41), and tighten.

5. Slide the handwheel onto the worm shaft (key 45), and install retaining ring (key 118).

6. Pack the two thrust bearings (key 67) with lithium grease lubricant. Install one thrust bearing, then the worm gear

(key 44), followed by the second thrust bearing and the bearing and gear retainer (key 66).

7. Coat the power screw threads (key 122) with lithium grease lubricant. Slide the power screw into the thrust bearing

(key 67), turn the handwheel, and feed the sleeve through the worm gear.

8. Adjust set screws (key 40) to eliminate free play in the bearings.

Note

Over‐tightening the set screws will make handwheel operation difficult.

9. Install gear case cover (key 123), and tighten cap screws (key 124).

Parts Ordering

Each actuator has a serial number stamped on the nameplate. Always refer to this number when corresponding with

your Emerson Process Management sales office regarding replacement parts or technical information. Also, always

refer to the 11‐character part number of each needed part as found in the following parts list.

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

16

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.

Note

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

maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and

end‐user.

Parts List

Note

Part numbers are shown for recommended spares only. For part

numbers not shown, contact your Emerson Process Management sales

office.

657 Sizes 80 & 100

Key Description Part Number

  1  Upper Diaphragm Casing 

  2*  Diaphragm 

   Size 80 

    Nitrile  1R6375X0072

    Silicone  18B2713X132

   Size 100, nitrile & TPES (thermoplastic polyester) 20A2551X012

  3  Cap Screw

  4  Diaphragm Plate 

  5  Lower Diaphragm Casing 

  5  Lower Diaphragm Casing, Yoke, & 

   Tie Rod Ass'y 

  6  Spring  See tables

  8  Cap Screw

  9  Yoke 

 10  Actuator Stem

 11  Spring Seat 

 12  Adjusting Screw

 13  Backup Plate

 14  Travel Indicator

 16  Hex Jam Nut

 17  Machine Screw

 18  Travel Indicator Scale

 19  Nameplate

Key Description Part Number

 20  Drive Screw

 21  Actuator Tie Rod

 22  Cap Screw

 23  Hex Nut

 26  Stem Connector Ass'y 

 28  Cap Screw

 29  Spring Case 

 33  Pipe Bushing

 34  Upper Sleeve

 35  Thrust Bearing

 36  Adjusting Flange

 60  Cover Band Ass'y

 62  Cap Screw

 63  Hex Nut

 88  Tie Rod Washer

 89  Hex Nut

 91  Spring Guide

 92  Cap Screw

106  Washer

107  Shroud Plate

108  Self‐tapping screw

109  Cap Screw

110  Diaphragm Retainer

111*  Seal Bushing, brass 

   Size 100  20A2582X012

112*  O‐Ring, nitrile (2 req'd) Size 100  1H8627X0042

113*  O‐Ring, nitrile Size 100  1R834206992

114  Hex Nut

115  Hex Jam Nut

116  Actuator Stem Extension

117  Washer

118  Retaining Ring

120  Hex Bushing

121  Lifting Pin

123  Diaphragm Casing Cover

128  Vent Ass'y 

241  Lithium grease (not furnished with actuator)  ‐‐‐

244  Anti‐seize lubricant (not furnished with actuator)  ‐‐‐

245*  O‐Ring, nitrile Size 100 only  1C339006992

*Recommended spare parts

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

17

Figure 4. Size 80 Fisher 657 Actuator

APPLY LUB

40A8771‐B

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

18

Figure 5. Size 100 Fisher 657 Actuator

50A2621‐F

APPLY LUB

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

19

Key 6 Size 80 Actuator Spring, steel

SIZE

COMPRESSION

RATE

MAXIMUM

LOAD PART

NUMBER

COLOR

CODE

Lb/in N/mm Lb N

80

335

1000

1650

2100

2600

3100

58.7

175.1

288.9

367.7

455.3

542.8

2480

5630

7900

10,600

10,600

13,800

11,031

25,042

35,139

47,148

47,148

61,382

1J518227082

1H747727082

1H747527082

1H747327082

1H747627082

1H747027082

White

Red

Lt. Blue

Yellow

Lt. Green

White

Key 6 Size 100 Actuator Spring

GROUP

COMPRESSION

RATE MAX LOAD PART

NUMBER

COLOR

CODE

Lb/in N/mm Lb N

1

33‐1/4 Inch (844 mm)

Free Length

1775

2950

4500

6000

310.8

516.5

787.9

1050.6

17,500

25,000

36,000

45,000

77,840

111,200

160,128

200,160

10A2561X012

10A2562X012

10A2563X012

10A2564X012

None

None

None

None

2

16‐1/2 Inch (419 mm)

Free Length

335

1000

1650

2100

2600

3100

58.6

175.1

288.9

367.7

455.2

542.8

2480

5630

7900

10,600

10,600

13,800

11,031

25,042

35,139

47,148

47,148

61,382

1J518227082

1H747727082

1H747527082

1H747327082

1H747627082

1H747027082

Brown

Red

Blue

Yellow

Green

White

Figure 6. Top‐Mounted Handwheel for Size 80 Actuator

APPLY LUB

CV8009‐E

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

20

Size 80 Side‐Mtd Handwheel

Key Description Part Number

  7  Travel Stop

 17  Machine Screw

 28  Machine Screw

 40  Set Screw

 41  Set Screw

 44  Worm Gear

 45  Worm Shaft

 46  Lower Sleeve

 47  Key

 48  Front Worm Retainer

 49  Back Worm Retainer

 50  Ball Bearing

 51  Handwheel

 52  Handgrip

 53  Handgrip Bolt

 54  Handwheel Cap

 55  Ball

 56  Spring

 58  Travel Indicator

 61  Grease Fitting 

 64  Cap Screw

 65  Gear Case

 66  Bearing & Gear Retainer

 67  Thrust Bearing

 68  Cap Screw

 69  Indicator Scale

 70  Stop Indicator Bracket

 71  Machine Screw

243  Pliable sealant (not furnished with actuator)  ‐‐‐

Size 80 Top‐Mtd Handwheel

(Adjustable Up Travel Stop)

 51  Handwheel

 54  Nut

133  Stem

141  Cap Screw

142  Handwheel Body

175  Thrust Bearing 

179  Pressure Block

180  Gland

181*  Packing Ring, TFE‐graphite (2 req'd)  1D7496X0012

182  Support Screw

183  Stem Collar

184  Retaining Ring

185*  Gasket, composition  1J789504022

186  Body Nut

241  Lithium grease (not furnished with actuator) 

246  Spacer

247  Cotter Pin

Size 100 Top‐Mtd Handwheel

(Adjustable Up Travel Stop)

Key Description Part Number

 17  Machine Screw

 40  Set Screw

 41  Set Screw

 44  Worm Gear

 45  Worm Shaft

 48  Front Worm Retainer

 49  Back Worm Retainer

 50  Ball Bearing

 51  Handwheel

 61  Grease Fitting 

 65  Gear Case

 66  Bearing & Gear Retainer

 67  Thrust Bearing

118  Retaining Ring

122  Power Screw Ass'y

123  Gear Case Cover

124  Cap Screw

125  Hex Jam Nut

126  Woodruff Key

127  Slot Cover

Size 80 Hydraulic Snubber

 27  Piston/Piston Rod Ass'y

 63  Hex Nut

 72  Spring Case Adaptor

 73  Cap Screw

 74  Cylinder

 75  Cylinder Head

 76  Retaining Ring

 77*  O‐Ring, nitrile (2 req'd)  1F449206992

 78*  Piston Ring, iron (2 req'd)  1C710321992

 79  Reservoir

 80*  O‐Ring, nitrile  1H624706992

 81  Cap Screw

 82*  O‐Ring, nitrile (2 req'd)  1D687506992

 83  Valve Adj Screw

 84  Jam Nut

 85  Cap Screw

 86  Pipe Plug

 87  Pipe Plug

 90  Upper Spring Seat

 93  Hydraulic Fluid

 94*  O‐Ring, nitrile (2 req'd)  1E591406992

 95  Orifice

 96  Bypass & Check Valve Plug

 97  Spring

 98  E‐Ring

 99  Bushing

100  Flange

101  Packing Sleeve

102  Machine Screw

103*  Packing, nitrile (8 req'd)  1P540806992

104*  Packing, CR (chloroprene) & cotton (4 req'd)  1P540906992

105*  Packing Sleeve O‐Ring, nitrile (2 req'd)  1P541206992

*Recommended spare parts

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

21

Figure 7. Size 80 Fisher 657 Actuator with Side‐Mounted Handwheel and Hydraulic Snubber

APPLY LUB

50A8774‐C

B

B

VIEW A

C

C

VIEW A

SECTION B‐B

SECTION C‐C

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

22

Figure 8. Top‐Mounted Handwheel for Size 100 Actuator

APPLY LUB

50A2622‐F

A

A

SECTION A‐A

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

23

Instruction Manual

D100307X012

657 Size 80 and 100 Actuators

December 2010

24

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 are not

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. 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.

EFisher Controls International LLC 1973, 2010; All Rights Reserved

Fisher is a mark owned by one of the companies in the Emerson Process Management business division 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.