Bettis 2000 Series E796 M2CP
User Manual

**Section 1: Introduction

**

1.1: DO

1. Do follow proper storage procedures. Improper storage will void the warranty.

2. DANGER: Do check for proper motor rotation. If the valve goes the wrong direction when the button is pushed, you have no torque or limit protection.
   3-Phase incoming power voltage must have 2 wires reversed.

3. Do read and follow procedures before attempting to energize the actuator.

4. Do cut off electric power before opening the switch compartment.

5. Do install a relief vent in the highest point of the gearbox.

6. Do use valve stem covers of sufficient length.

7. Clean electrical enclosure flange thoroughly and lightly greases before closing.

8. Do secure electrical enclosure bolts (10-12 ft-lb).

9. Do follow an annual maintenance procedure.

10. Do use caution when working on, with, or around valves and actuators.
    You can be dealing with high pressures, forces, voltages, and flammable media.

1.2: DON’T

1. Don’t start up without reading this manual.

2. Don’t stack actuators.

3. Don’t store the actuator on the ground unprotected.

4. Don’t lift the unit by clutch lever or handwheel.

5. Don’t lift a valve assembly by the electrical actuator.

6. Don’t operate electrically without first checking proper phase rotation, torque, and position limit switch adjustments (follow instructions on pages 2, 4, and 5).

7. Don’t plug the actuator motor by starting and stopping repeatedly to move a too stiff valve. Check for the cause.

8. Don’t jumper torque switches except as recommended by Wiring Diagram or Valve Manufacturer.

9. Don’t use oversize thermal motor overloads to eliminate the tripping problems.
   Find the cause and correct it.

10. Don’t use a cheater to force the handwheel. You can damage gearing and shafts.
    Find the cause and correct it.

11. Don’t operate the handwheel shaft at more than 250 RPM.

12. Don’t torque the seat valve, sluice gate, or damper unless the valve manufacturer recommends.

1.3: Lubrication
Bettis Actuators are factory filled with a high-quality lubricant carefully selected to ensure actuator performance under specified operating conditions. Refer to Bettis JOB SPEC SHEET to identify the lubricant provided. Normal operation may not require lubricant replacement.

1.4; Maintenance
At least once a year a check should be made on your Bettis actuator.
a. Disconnect all electrical power to the actuator.
b. Open electrical enclosure. Inspect and tighten all electrical connections.
c. Visually inspect for any electrical or mechanical damage.
Replace worn or damaged components.
d. Check lubrication consistency and level. Fill or replace if required.

1.5; Pressure Relief
During the operation of the electric actuator, the gear temperature increase in combination with variations of outdoor temperature will cause a small pressure build-up within the actuator gearbox. Bettis furnishes Pressure Relief Vent Fitting Part No. 83385. Placement on the Actuator can be determined only after field location and position of valve have been determined. Select the highest 1/2 NPT vent location on the actuator gearbox; remove the 1/2 NPT plug and replace it with 83385. The possible locations of the vent are shown on Bettis Outline Drawing.

1.6: Short Term Storage
(Stored at Job Site less than one year from shipment)

1. The actuator should be stored with the motor shaft in the horizontal position and the electrical enclosure in either the horizontal or vertical position.
2. Actuators should be stored indoors free from job site dirt, mud, moisture, and temperature changes.
3. If indoor storage is not possible, the actuator must be stored off the ground above possible water or snow level. Remove M2CP and store with other electrical and electronic equipment in a protected warehouse. If M2CP is not removed, the Space heater MUST be energized to protect electrical controls.
4. Bettis supplies NPT plugs in each conduit entry. Do not remove until electrical hook-up. The customer conduit should be routed to enter the electrical enclosure at 1-1/2 (1.50) NPT located at the lowest point, so condensation does not drain into the enclosure and damage parts.
5. Cover units loosely with a plastic sheet. This serves as partial protection from the rain.

1.7: Long-Term Storage
(Stored more than one year from shipment)

1. Store indoors or M2CP should be removed and stored in a protected area.
   Follow procedures for short-term storage.

WARNING
Failure to store actuator properly ill void warranty of electrical and electronic components.

Section 2: M2CP Electrical Hook Up

Remove PWR and TBM covers to expose terminals for custom wiring. Bettis Modular Control Package (M2CP) is available and configured in many combinations of electrical and electronic parts. Refer to WIRING DIAGRAM and Bettis JOB SPEC SHEET for components provided by Bettis. Connect control wires to TBM and Power (motor) Voltage to PWR terminals. If an optional M2CP mounted circuit breaker was specified, connect power voltage leads to the circuit breaker.
Bettis terminal blocks are furnished with wire binding screw connectors with rising captive plates, allowing field connection by several methods:

1. strip and connect bare wire
2. strip and install wire ferrule
3. strip and install crimp-on insulated or non-insulated ring tongue or similar terminal

Circuit Breaker accepts:

1. bare wire strip, or
2. wire ferrule

2.1: Electrical Hook Up
Step 1. Move valve to mid-position by handwheel. This will allow sufficient time to stop the actuator in case of improper hook-up or reversed incoming power voltage phases.
Step 2. Identify a means of removing power from the actuator during check out.
Be sure no erroneous remote control signal can be received causing the actuator to energize.
Step 3. Energize Open control to check the operation of contactors and pushbuttons.
Open controls must move the valve in the Open direction. If the valve Closes, the actuator must be stopped and the power input must be rewired.
CAUTION
If voltage is improperly phased, Torque and Position Limit Switches are not in the circuit to protect the valve.
Step 4. Seal all field conduit entries in accordance with National Electric Code.

Section 3: Assembly to Valves

3.1: Threaded Valve Stem
3.1.1: Locknut Lockpin Installation

1. With the actuator in place on the valve, ensure proper flange mating and valve actuator orientation.
2. Use a number 30 (.1285) drill bit to drill a hole 3/4 inch deep into the Drive Sleeve assembly threads for the Locknut Lockpin (56) using groove in Stem Nut Locknut as a drill guide.
3. Install Locknut Lockpin (56) into the drilled hole to prevent Stem Nut Locknut from working loose and turning.

NOTE:
Install Locknut Lockpin (56) into the drilled hole to prevent Stem Nut Locknut from working loose and turning. When installing, the Locknut Lockpin – it should extend 1/4 inch above the Drive Sleeve assembly to allow for future removal.

3.1.2: Stem Nut Installation (Multi-turn)

1. Unscrew Locknut (55) holding Bronze Stem Nut (54) and remove the Stem Nut and Key (52).
2. Lubricate Stem and run Stem Nut down Stem to check acme thread fit, then remove Stem Nut and set aside.
3. Lower actuator over Stem onto valve flange. The screws thru the valve flange into the actuator must engage a minimum of one full screw diameter deep into the bottom base and be tightened to a preload. See assembly drawing for screw size and torque to tighten properly.

3.2: Mounting Screws
If Bettis supplied adaptation, the mounting screws are included. If adaptation to the valve was the responsibility of others, the mounting screws are not furnished by Bettis. Screws thru adapter MUST engage a minimum of one screw diameter deep into Bettis actuator base.

1. Screw Stem Nut on Stem until it enters Drive Sleeve. Line (52) Key and (54) Drive Sleeve keyway and insert (52) Key.

2. Turn the handwheel in the Open direction, pulling the Stem Nut into Drive Sleeve until it bottoms out (the valve will begin to open).
   **** CAUTION
   Locknut must be tight against stem nut.

3. Lower Locknut (55) over Valve Stem and screw into place firmly against the top of Stem Nut. Tap Locknut ears using brass drift until tight.

3.2.1: Thrust Spool (Model 4000 and 5000)

1. Locate Thrust Mounting bolts.
2. Remove eight mounting bolts and separate the Spool from the actuator.
3. Position Spool over Valve Stem. Thread Spool onto Valve Stem until it meets valve plate.
4. Bolt and secure the Spool onto the valve.
5. Position actuator above Spool. Lower actuator onto Spool while manually rotating the unit until ears on Stem Nut and ears on main Drive Sleeve mesh.
6. Grease flange face before securing unit to Spool.
7. Re-install thrust plate mounting bolts. Tighten to proper torque.

NOTE:
Reverse procedure if Stem Nut needs to be replaced. The actuator does not need to be returned to the factory for this procedure.

3.2.2: Spline Bushing (Quarter-Turn)
Bettis removable Spline Bushing allows easy adaptation to valve shaft diameter and Key. The actuator may be rotated with respect to the valve shaft for unexpected or awkward
field installations.

1. Move valve to full Open or Close.
2. Place Spline Bushing on valve shaft with Key and tighten set screw.
3. Using the handwheel on the actuator, move the gear position indicator arrow to full Open or Close (the position in Step 1).
4. Position actuator so Spline Bore is correctly aligned with the Spline Bushing on stem shaft.
5. Move the actuator onto the shaft until the flange faces properly mate. Secure with screws thru the adapter flange into the base of the actuator.

3.3: Quarter-Turn Valve
3.3.1: Stop Setting Procedure
Built-in mechanical stops are provided to prevent handwheel operation beyond total valve travel (90 ± 6°). End of travel stops is independently adjusted, locked in place, and sealed.

Loosen both Locknuts (46) and back out two Stopbolts (86) to allow the valve to close and open fully. Ensure Electrical Travel Limit Switches have been adjusted (see the appropriate section of this manual), proceed as follows:

1. Run actuator electrically to full Close.
2. Screw Close (86) Stopbolt in until it seats, then back off 1/2 turn. Install (48) Washer and tighten (46) Locknut.
3. Run actuator electrically to full Open.
4. Screw Open (86) Stopbolt in until it seats, then back off 1/2 turn. Install (48) Washer and tighten (46) Locknut.

Bettis Modular Control Package (MCP) is available and configured in thousands of possible combinations of electrical and electronic parts. Refer to WIRING DIAGRAM and Bettis JOB SPEC SHEET provided by Bettis with each actuator.
Back out two Stopbolts (1) to allow the valve to close and open fully. Set Travel Limit Switches (see page 4).

1. Run actuator electrically to full Close.
2. Screw Close (1) Stopbolt in until it seats, then back off 1/2 turn. Tighten (2) Lockscrew.
3. Run actuator electrically to full Open.
4. Screw Open (1) Stopbolt in until it seats; back off 1/2 turn. Tighten Locknut.
5. Install (3) and (4) Seal Washer and Screw.

CAUTION
Do not set actuator position Limit Switches to drive into mechanical stops.
Damage can occur if the unit is repeatedly stalled into end stops.

Section 4: Limit Switch Setting Instructions

4.1: Before Making Limit Switch Setting

1. Move valve to mid-position (use handwheel).
2. Phase the power (motor) voltage and make sure that the open contactor moves the valve Open and the closed contactor moves the valve Closed.

4.2: To Set Open Limit Switch (LSO)

1. Open valve during handwheel operation note rotation direction of a screwdriver (Figure 6) in LSO Adjusting Shaft. After the valve is fully Open, Close its three handwheel turns to allow for coasting when the motor is actuated.

2. Disengage spring-loaded gear: Push Disengage Shaft in (Figure 7a) down, then rotate 90° so the shaft is captured down. This will disengage limited switch gears from the spring-loaded drive gear. NOTE:
   Many turns may be required to set limit switches; it may be convenient to use a reversible variable speed drill to rotate the adjusting shafts instead of a screwdriver.

3. Line up LSO indicator: If the switch rotor arrow does not line with round holes (within ± 15°) on the plate as shown in Figure 8a, rotate the screwdriver in the same direction noted in Step 1 until the switch just rotates. If arrows line up as shown in Figure 8b, rotate the screwdriver in the opposite direction until the switch just rotates.

4. Re-engage the spring-loaded drive gear by rotating the disengage shaft in Figure 8a. Spring loaded disengage shaft will rise.
   NOTE:
   To ensure limit switch gears have re-engaged properly with spring-loaded drive gear, firmly “jiggle” (rotate) all adjusting shafts with a screwdriver back and forth. The proper engagement has been made if all shafts (LSC, LSO, LSA, and LSB) will not turn with a screwdriver.

4.3: Set (LSC) Close Limit Switch

1. Close the valve, using the handwheel. During handwheel operation note the rotation direction of the screwdriver in the LSC adjusting shaft. After the valve is fully Closed, Open its three handwheel turns to allow for the coast.
2. Repeat steps 2 through 5 of LSO setting instructions with a screwdriver in the LSC cavity.
   NOTE:
   “Jiggle” adjusting shafts.

4.4: To Set Intermediate Switch (LSA or LSB), If Included
Open Valve to the desired position, then repeats steps 2 thru 5 of LSO.
NOTE:
“Jiggle” adjusting shafts.

4.5: Torque Seated Valves
If the valve is a torque seated valve, and the geared limit contacts are used for indication only, the LSC switch should be set several handwheels turns ahead of the torque switch contact action. This gives proper valve position Lamp indication in spite of minor position variations which might occur due to torque seating.

4.6: Torque Switch Calibration

To set Close Torque Switch (TSC)
a. Close valve using the handwheel. Set valve to the desired torque. Observe the rotating dial for a number that corresponds to desired Close Torque.
b. Insert a screwdriver in the TSC slot. Press down to disengage and turn the arrow to the setting determined in the above point “a”. Release at this point and it will then re-engage and remain set.
c. Back the valve away from the Close position and reseat by the handwheel to verify the torque trip point is at the desired setting. The trip point of the switch is a distinctive click as it breaks contact.

DANGER
Reverse power voltage phasing removes torque switch protection from reversing contractor coil circuits. Valve damage could occur. If phasing has not been checked, do so before proceeding. Back valve away from Close position with handwheel and test torque electrically, using Close controls. Readjust as required.

4.7: To set Open Torque Switch (TSO)
Follow the procedure for TSC at the TSO dial.

4.8 Torque Switch Rotation Limit
Adjustment rotation may be limited, Remove the dial to expose anti-rotation pins.
Remove pins from position 10 and insert them into the desired hole.

Section 5: Multi-turn Actuators

Multi-turn top-mounted and side-mount bevel gear actuators require the use of Gear
Reduction Assembly part no. 84055-0000 for Mechanical Dial Position Indication MDPI and 1-turn Pot. N-number replaces -0000 to complete part no. For 1-turn Pot only without Dial Indication part no. is 84117-0000. Refer to Bettis JOB SPEC SHEET for MDPI furnished. MDPI Mechanical Dial Position Indication is a gear reduction assembly to convert multi-turn valve stem nut turns to 270 degrees (.75 turn) for viewing position indication arrow thru the glass window on the actuator electric switch compartment cover. The point of rotation reference has been designated as N-number. N is the total number of electric actuator 12-tooth gear limit spring-load pinion rotations for full valve stroke.

5.1: Calibration
MDPI and POT Drive are calibrated after LSC and LSO are properly set (see page 4). Move valve to Close position. Manually rotate the MDPI arrow to indicate Close. Calibration is now complete. Open the valve to check that the MDPI arrow goes to Open, indicating that N is correct for full valve travel. The potentiometer, if included, has been calibrated. Mechanical dial travel is 270°. Approximately 5% of total Pot resistance is left on each end for total valve travel.

5.2 Quarter-Turn Model P, Q, R, and M
Top-mount P, Q, and R, and several models of M/MG’s side-mount do not require MDPI gear reduction assembly for 1-turn Pot. If a multi-turn Pot is required, Bettis JOB SPEC SHEET will list 84131-0000 or the correct assembly.
Spec Sheet will list:

1. Pot clutch gear,
2. Pot input gear, and
3. potentiometer.

Section 6: M2CP Wiring Diagram Symbols

6.1 Description
Refer to Bettis JOB SPEC SHEET and Bettis WIRING DIAGRAM for components furnished.

| The potentiometer slider is geared to Valve Position and “in-step” at all times.
---|---
| Outputs: 120, 12, and 18 V AC.
| Actuated by position limit switches.
| LSC shows open. LSO shown made.
| N.C. Double Break Contacts Open when an overload occurs. N.O. contacts make.
|
| Momentary N.C. Contact
| Momentary N.O. contacts connect control voltage to reversing contactor 8 coils.
Seal-in contacts C and O (14,13) on the contactor allow travel without continued holding down of the pushbutton.
| Factory wired by Bettis.
|
| Heater in Switch. Compartment is standard
|
| Showing Open and Close coils, Mechanical Interlock, and Electrical Interlock Contacts O (21, 22) and C (21, 22)
| To prevent (TSO) contact tripping when the valve has been jammed closed – LSC contact allows valve to open slightly. Contact then open, ensuring torque protection for remaining travel.
|
|
|
|
|
|

Section 7: Troubleshooting

Table 1.

necessary
Open in Control Circuit| Refer to the appropriate wiring diagram and check for continuity
Insulation Resistance Breakdown in Motor| Perform Meg ger Test
No Power available to Actuator| Tripped Circuit Breaker| Reset Circuit Breaker
Handwheel Hard to Turn| Valve Stem improperly Lubricated| Lubricate with Grease
Actuator Lubrication has broken down| Clean out old grease and replace it with the recommended lubricant
Valve packing gland too tight| Loosen packing gland nuts as necessary
Drive Sleeve Bearing Failure| Replace Bearing
Jammed Valve| Refer to Valve Maintenance
Valve only opens or closes partially with motor| Torque Switch Setting too low| Check Setting and Reset if necessary
Limit Switch Improperly Set| Check Switch Actuation and recalibrate if necessary
Torque switch is
properly set, but actuator Torque’s out in mid-travel, open or closed direction| Damaged or bent valve stem| Refer to Valve Maintenance
Valve packing too tight| Refer to Valve Maintenance
Jammed Valve (obstruction in line)| Refer to Valve Maintenance
The handwheel will not operate the valve| Handwheel shaft bearing assembly malfunction| Repair or replace as necessary
Sheared gear key or Stripped Gearing| Replace as necessary
PS Shifter Position or Malfunction| Replace Gear(s)
Broken Handwheel Shaft| Repair or replace as necessary
Broken Valve Stem or Stripped Stem Not| Repair or replace as necessary
Handwheel Skipping| Handwheel operating at high speed| (D2e5cor lamps them and heel speed
Motor runs ut will operate the valve not| Motor Bearing Assembly Malfunction| Repair or replace as necessary
Sheared gear key (fastener pin)| Replace
Stripped Gearing| Replace
Broken Valve Stem or Stripped Stem Not| Repair or replace as necessary
PS shifter position or malfunction| Replace PS Assembly
Moisture in Electrical Enclosure| Leakage through Conduit Entry| Install an approved Seal-off or re-route conduit to enter
Enclosure from the bottom of the enclosure
Electrical Enclosure is not properly sealed| Inspect and replace 0-ring if necessary
Space Heater Inoperable| Check Circuit continuity for Heater
Gear (Oil) in Electrical Enclosures| Pressure Relief Fitting not installed| Install Pressure Relief Fitting
Bad Seal on TX or GIL Assembly| Replace Stat-O-Seals or 0-Rings
Rotate Actuator Mounting

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