Masoneilan Manual

Instruction Manual EF35002 08/10

Putting You In Control

®

35002 Camflex II Series Rugged, All-Purpose Rotary Control Valves

Table of Contents

Page

SAFETY INFORMATION ......................................................................................................1 ABOUT THIS MANUAL ....................... ................ ............... ............... ................ ............... ....1 WARRANTY ..........................................................................................................................1 1. INTRODUCTION ...............................................................................................................2 2. GENERAL ..........................................................................................................................2 3. PRINCIPLE OF OPERATION ...........................................................................................2 4. UNPACKING .....................................................................................................................3 5. INSTALLATION .................................................................................................................3 6. AIR SUPPLY PIPING ........................................................................................................4 7. PLACING IN SERVICE .....................................................................................................4 8. DISASSEMBLY .................................................................................................................4 8.1 ACTUATOR REMOVAL FROM BODY S/A ..............................................................4 8.2 ACTUATOR COMPLETE DISASSEMBLY ...............................................................5 8.3 VALVE BODY .........................................................................................................5 9. MAINTENANCE ................................................................................................................7

10.

11. 12. 13. 14.

9.1 SPRING DIAPHRAGM REPLACEMENT..................................................................7 9.2 BODY S/A INTERNAL PARTS ................................................................................8 9.3 YOKE ASSEMBLY ..................................................................................................9 REASSEMBLY PROCEDURES ......................................................................................9 10.1 SPRING DIAPHRAGM ACTUATOR ......................................................................9 10.2 SPRING DIAPHRAGM ACTUATOR ON BODY S/A ..............................................9 10.3 HANDWHEEL REASSEMBLY .............................................................................10 10.4 LIMIT STOP REASSEMBLY ................................................................................10 10.5 VALVE BODY REASSEMBLY .............................................................................10 10.6 SEAT RING ALIGNMENT ....................................................................................11 10.7 DVD PLATE REASSEMBLY ................................................................................12 ACTUATOR STEM ADJUSTMENT .............. ................ ............... ................ ........... ......12 CHANGING BODY POSITION .....................................................................................13 CHANGING ACTUATOR ACTION ...............................................................................14 MANUAL ACTUATOR OPTION ...................................................................................15 14.1 DISASSEMBLY PROCEDURE ............................................................................15 14.2 MAINTENANCE ..................................................................................................15 14.3 REASSEMBLY PROCEDURE .............................................................................15

Copyright Masoneilan® is a registered trademark of Dresser, Inc. All information contained herein is believed to be accurate at the time of publication and is subject to change without notice. Copyright 2010 by Dresser, Inc. All rights reserved.

Safety Information

About this Manu al

Important - Please Read Before Installation Masoneilan 35000 Series control valve instructions contain DANGER, WARNING, and CAUTIONlabels, where necessary, to alert you to safety related or other important information. Read the instructions carefullybefore installing and maintaining your control valve. DANGER and WARNING hazards are related to personal injury. CAUTION hazards involve equipment or property damage. Operation of damaged equipment can, under certain operational conditions, result in degraded process system performance that can lead to injury or death. Total compliance with all DANGER, WARNING, and CAUTIONnotices is required for safe operation.

• The information in this manual is subject to change without prior notice. • The informationcontained inthis manual,in whole or part, shall not be transcribed or copied without Masoneilan’s written permission. • Please report any errors or questions about the information in this manual to your local supplier. • These instructions arewrittenspecifically forthe 35000 Series control valve, and do not apply for other valves outside of this product line.

Warranty Items sold by Dresser®, Inc. are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment provided said items are used according to Dresser recommended usages. Dresser, Inc. reserves the right to discontinue manufacture of any product or change product materials, design or specifications without notice.

This is the safety alert symbol. It alerts you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Note: Prior to installation

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

When used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage. Note: Indicates

important facts and conditions.

Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves ®

1

• The valve must be installed, put into service and maintained by qualified and competent professionals who have undergone suitable training. • All surrounding pipe lines must be thoroughly flushed to ensure all entrained debris has been removed from the system. • Under certain operating conditions, theuse of damaged equipment could cause a degradation of the perfor mance of the system which may lead to personal injury or death. • Changes to specifications, structure, and components used may not lead to the revision of this manual unless such changes affect the function and performance of the product.

1. Introduction

3. Principle of Operation

The following instructions are designed to assist maintenance personnel in performing most of the maintenance required on the Camflex® II valve and if followed carefully willreduce maintenance time.

The concept of the Camflex® II valve is based on an eccentrically rotating spherical plug contained in a free flow body design. The plug seating surface is joined by flexible arms to a hub which slides onto a rotating shaft. The plug is free to center itself along the axis of the shaft. A positive seal between plug and seat is achieved by elastic deformation of theplug arms. The chamfered seat ring is fixed in the valve body by a threaded retainer.

Masoneilan has highly skilled Service Engineers available for start-up, maintenance and repair of our valves and component parts. In addition, regularly scheduled training programs are conducted to train customer service and instrumentation personnel in the operation, maintenance and application of our control valves and instruments. Arrangements for these services can be made through your Masoneilan Representative or District Office. When performing maintenance use only Masoneilan replacement parts. Parts are obtainable through your local Masoneilan Representative or District Office. When ordering parts always include MODEL and SERIAL NUMBER of the unit being repaired.

2. General These installation and maintenance instructions apply to 1" through 12" sizes (DN 25 through 300 sizes), all available ratings, and pneumatic actuators. The model number, size and rating of the valve are shown on the serial plate. Refer to Figure 1 to identify the valve model.

The plug and shaft are rotated through an angle of 50° by a lever linked to a powerful spring-opposed rolling diaphragm actuator. The solid disk-type handwheel and locking hex nut, optional, are mounted on the yoke, opposite the actuator and may be used to manually operate the valve or as a limit stop. A threaded hole in the opposite side of the yoke is plugged but can be equipped with an optional cap screw and locknut, which may be inserted as a limit stop in the other direction, or in combination with the handwheel to lock the valve in aselected position. ® The handwheel on Camflex II is designed to be used for emergency action only.

35002 Series Body Numbering System Actuator Assembly Digits

1st

A c t u at o rT yp e 20 Manual Actuator 35 Spring-opposed rolling-diaphragm 70 Double acting cylinder

2nd

Body Series 35 Valve

Body Assembly Digits

1st

2nd

3

5

3rd

Seat Design

Ac t u a t o rM o un t in g 1 Parallel to pipeline, valve closes on stem extension 2 Parallel to pipeline, valve opens on stem extension 3 Perpendicular to pipeline, valve closes on stem extension 4 Perpendicular to pipeline, valve opens on stem extension 5 Parallel to pipeline, valve closes on stem extension 6 Parallel to pipeline, valve opens on stem extension 7 Perpendicular to pipeline, valve closes on stem extension 8 Perpendicular to pipeline, valve

(1) optional, Camflex with separable bonnet.

Figure 1

®

5th

SB

2

opens on stem extension

Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves

4th

2

1 2 3 4 5

Metal Soft seat Metal seat Lo-dB Soft seat Lo-dB Ceramic TRIM

Design Series

Design

2

SB(1)

Seat Ring

Plug

Fluid Flow

Shaft Guide Bushing Handwheel Flexible Arms Guide Bushing

Lever Actuator

Air

Figure 2

The actuator is generally mounted with air-loading to counter the 4. Unpacking dynamic torque on the plug. In Figure 2 the flow direction tends Care must be exercised when unpacking the valve to prevent to open the plug and the actuator is oriented to close it with increasing air pressure. The actuator spring force assists plug off- damage to the accessories and component parts. Should balance forces to open the valve on air failure. If the valve is to any problems arise, contact the Masoneilan Representative or close on air failure, the body would beturned around in the line so District Office. that flow tends to close theplug and the actuator position would Note: For ease of shipment and to prevent damage, valves be reversed.

equipped with the spring diaphragm actuator are shipped

The Camflex® II valve has a modified linear flow characteristic, with the handwheel unassembled. Refer to Section 10.3 for which is the same in either flow direction. It can be easily handwheel assembly procedures. transformed to an equal percentage when equipping the valve with a positioner series, 8000 series, SVI (Smart Valve Interface) or FVP [4700 (Fieldbus Valve Positioner)]. Reduced TRIM factors 0.4 and 0.6 are available on all sizes. The flow capacity of a 0.4 factor is 40% of the nominal capacity of the valve and it is 60% for the 0.6 factor. Factors 0.1 and 0.2 are available on the 1" (DN 25) valve.

5. Installation

The Camflex® II valve has been assembled at the factory in accordance with specific instructions concerning flow direction and actuator mode. The valve must be installed so that the controlled substance will flow through the valve in the direction indicated by the flow arrow (25), which is located on the upper ® The ability of the Camflex II valve to handle a wide range of part of the valve bonnet. The valve actuator should be installed process fluid temperatures is due to the long integrally cast so the actuator is above the centerline of the shaft. To install the bonnet. This affords ample radiation surface to normalize the valve in the line, proceed as follows: packing temperature. Therefore, with self-lubricating TFE Aramid fiber packing, the valve handles temperatures from -200°C to + 400°C (-320°F to +750°F). When insulating the valve, do not insulate the valve bonnet (see Figure 3).

CAUTION

Any change in flow direction or actuator mode must be accomplished as outlined in Sections 7 and 10 of this instruction manual. Failure to follow these could result in personal injury and equipment malfunction. A. Check the model number on the serial plate (56) against the numbering System described in Figure 1 to determine the

valve mode. B. Clean piping and valve of all foreign material such as welding chips, scale, oil, grease or dirt. Gasket surfaces should be thoroughly cleaned to ensure leak proof connections. Figure 3 Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves ®

3

C. To allow for in-line inspection, maintenance or removal of the valve without service interruption, provide a manually operated stop valve on each side of the Camflex ® II valve with a manually operated throttling valve mounted in the by-pass line.

7. Placing in Service

Note: If a flanged Camflex® II is being installed and the distance between flanges is established by ANSI or DIN, spool pieces (spacers) are inserted between the line flange and the valve body flange. Gaskets and valve bolting are then installed and torqued using standard flange and line bolting criteria.

With the valve properly installed in the line and all air or electrical service connected, it is recommended that the valve be run through one cycle to ensure proper functioning. Proceed as follows: A. Back off the hand wheel (53) so that it will not interfere with the operation of the valve and tighten the handwheel lock (52). Note: If the valve is equipped with the optional limit stop (77), it should also be backed off to prevent interference with the operation of the valve.

D. For flangeless valves, refer to Figure 23 and determine the B. Apply correct air pressure to the ac tuator. correct size and quantity of bolts to be used for the valve and flange rating. Note: Valve should function smoothly and with maximum

pressure, the valve indicator (6) should show full open or

E. If the valve is to be installed in a horizontal position, install the lower flange bolting to provide a cradle, which will help support the valve while installing the remaining bolts.

C. Relieve air pressure and return valve to normal mode.

F. Place the valve in the line.

D. Gradually open process lines to place the valve in service.

G. Select and install correct gaskets.

E. Check for leaks. Repair as required.

wound gaskets, suitable for service conditions are recommended.

full close depending on valve mode.

Note: Spiral

H. Insert remaining flange bolting ensuring that the bolts align with the special bosses on the body, which assure the valve is centered in the line and also prevent rotation. Note: For

certain flange standards, through bolting is not possible because of the valve body neck or bonnet. To accommodate flange bolting, guide arms with threaded holes or slots are provided on the valve body to receive flange bolts (refer to Figure 22). I. Tighten flange bolts evenly and firmly.

F. If desired, the handwheel may beused as a limit stop. Set in desired position and lock. G. If the optional limit stop (77) is used, set and tighten locknut.

8.1 Actuator Removal From Body S/A (Refer to Figure 16 and Figure 17)

CAUTION Note: If the valve is equipped with manual handwheel, it may now be placed in service.

6. Air Supply Piping Air is supplied to the actuator through the 1/4" NPT tapped connection in the diaphragm case. Refer to Figure 14 to determine the correct supply pressure and tubing size, then connect air supply piping.

Maintenance required on the internal components of the valve or re-orientation of the actuator and body, requires that the actuator and yoke be removed from the valve. On the size 6, 7 and 9 actuators, for ease of handling and reassembly, it is recommended that the spring barrel be removed from the yoke and then the yoke separated from the valve body.

CAUTION Prior to performing maintenance on the valve, isolate the valve, vent the process pressure and shut off supply and signal air lines to the actuator.

CAUTION Do not exceed maximum air pressure indicated. Personal injury and equipment malfunction could result.

When the valve is equipped with regulators or other accessories supplied by Masoneilan, only connections to those accessories are required since the piping to the actuator is connected at the factory. Some valves equipped with electrical accessories will require appropriate wiring. Refer to manufacturer’s instructions for correct wiring information. Note:

®

Always ensure process pressure, air pressure and electrical service are off and the valve is isolated and relieved of pressure before performing maintenance on the valve.

8. Disassembly

If the valve is to be insulated, do not insulate thevalve bonnet.


CAUTION

4

Note: If the valve will be reassembled in the same orientation, it is recommended that the body to yoke orientation and the actuator to yoke orientation be marked in relation to each other. This will simplify reassembly.

A. If required, remove the valve from the line. B. Remove rear cover (29) and front cover (32) by removing the two cover screws (30). C. Remove bottom cover (11) and spring barrel boss cover (58).

D. Remove indicator (88) by removing the two screws (89).

8.2 Actuator Complete Disassembly

E. Loosen handwheel lock (52) and turn handwheel (53) soit does not interfere with the movement of theever l (34).

The spring diaphragm actuator used on the Camflex® II valve was designed basically as a low cost non-replaceable item and therefore disassembly isnot recommended. However, in some instances and for emergency purposes, disassembly may be required. Proceed as follows.

On valves supplied with the optional limit stop, (Figure 17) loosen nut (78) and back off the limit stop screw (77) so it will not interfere with the movement of the lever (34). Note:

F. Connect an air line to the actuator supply port and using a manual loading panel or regulated air supply, apply enough air pressure to the actuator so the lever will move to an intermediate position.

CAUTION

A. If the actuator is not removed from the body proceed to the paragraph 9.1 A. to 9.1 L. B. Loosen locknut (46) then remove the clevis (35) and the locknut (46). C. Loosen and remove capscrew (41) and remove diaphragm case (42) and diaphragm (40). D. Using a deep socket, loosen and remove locknut (45) and washer (44).

Do not exceed pressure listed in Figure 14 for actuator used. Do not use handwheel to move the lever.

E. Remove piston (43) and spring (39) and inspect all components.

Note: If the valve is to be reassembled using the same orientation, it is recommended that the yoke (33) and lever (34) alignment, in the closed position, be marked to simplify reassembly and alignment of the lever and shaft to ensure proper valve functioning. See Figure 17.

F. Proceed to section 10.2 for reassembly.

G. Remove clevis pin clips (5). H. Remove clevis pin (7). I. Relieve air pressure from actuator enabling clevis (35) to disengage from lever (34). Note: If

the valve is equipped with a positioner, refer to the appropriate positioner instruction for procedures on cam or lever removal. Then proceed to step K.

8.3 Valve Body (Refer to Figures 4 and 16) Maintenance to the internal components required on the Camflex ® II Valve can normally be easily determined since the seat ring and plug can be seen once the valve is removed from the line. Although it may be determined that the seat ring does not need replacement, it must be noted that the new plug and seat ring must be lapped, thus requiring the disassembly of the body. It is recommended that both seat ring and plug be replaced if one or the other is damaged due to service. After the actuator has been removed from the body, disassemble the valve using the following procedure:

J. Remove shaft cover (9) by removing cover screw (10).

CAUTION

CAUTION

Depending on the size and weight of the actuator. It is recommended that proper lift and support procedures be utilized when removing the spring barrel or yoke. K. Ensure spring barrel is properly supported.

Prior to performing maintenance on the valve, isolate the valve and vent the process pressure. A. For 35000 SB (Separable Bonnet) versions, remove bonnet nuts (104) and lift off bonnet (102) complete with packing (17) and packing follower (15) from the body as an assembly. Proceed to step D.

L. Loosen and remove cap screws (36) and lockwashers (37), then remove spring barrel (38).

B. Remove packing follower (15).

M. Loosen lever capscrew (49).

C. Remove safety pin (16).

N. Loosen the stud nuts (94) and disengage the packing flange.

CAUTION

O. Loosen the stud nuts (27) to separate the actuator from the body S/A.

With body secure, grasp lever and yoke and separate. Yoke, lever and packing flange are removed at the same time. The yoke may have to be struck with Note:

a soft face mallet to break it loose.

The purpose of the safety pin is to prevent the shaft from being pushed out if the yoke is removed while the valve is still pressurized. The internal components of the valve cannot be removed without first removing the safety pin. D. Pull on the shaft (19) to remove it. Note:Difficulty is sometimes encountered when removing the shaft from the plug mainly due to an excessive accumulation of deposits between the plug splines and the shaft. Application of heat to the plug shaft bore while using one of the following methods will facilitate removal.


5

CAUTION

CAUTION

When using heating devices, ensure that proper safety practices are observed. Such items as the flammability and toxicity of the controlled substance must be considered and proper precautions taken.

Do not pry the bushing usingthe seat for leverage.If the bushing cannot be easily removed, proceed to section 8.3.1 and remove the seat ring retainer and seat ring then remove the bushing. Place a piece of soft stock (brass, etc.) between the inner seat shoulder and prying device to prevent damage to the seat sealing area of the body.

If the shaft is not removed easily, replace the lever (34) on the splined end of the shaft (19), tighten the lever capscrew (49) and using a mallet, tap the lever (34) as close to the shaft as possible and remove the shaft (19).

8.3.1 Seat Ring Removal (Refer to Figure 16)

If the shaft cannot be removed by tapping the tightened lever, Figure 20 illustrates an alternative method of removal. Using a pipe nipple of suitable size and length and reversing the packing flange and stud nuts as shown,

The following procedures outline the recommended method for removing the seat ring retainer (3) with the use of retainer wrenches. Masoneilan manufactures and has available, for a nominal price, seat ring retainer wrenches for the Camflex® II, 1" through 4" (DN 25

the shaft may be acked j out of the body.For larger valves, the use of an additional washer and nipple to assist in holding the tightened lever is recommended. The lever should be tightened at a point where the hub on the lever is flush with the end of the spline.

through 100) sizes. It is highly recommended that wrenches be purchased or fabricated to facilitate removal and reassembly of the seat ring (2) since SPECIFIC TORQUES MUST BE ACHIEVED to obtain tight shutoff and ensure proper functioning of the valve.

Note:

E. The components which should come out with the shaft (19) are: the packing (17), packing box ring (23 or 100), spacer tube (20) and upper guide bushing (21).

Figure 5 shows the recommended materials, thickness and method of construction along with specific dimensions to facilitate construction.

Note: The

spacer tube (20) and upper guide bushing (21) may remain in the body. They should be removed. The spacer tube (20) can only be removed by pulling it out the bonnet end of the body. The upper guide bushing (21) may be pushed through the body after removing the plug or pulled through the bonnet end of the body. On valves designed for use on slurry or viscous service, the upper guide bushing has an inner “O” ring (92) and an outer “O” ring (93) and the lower guide bushing has inner “O” ring (95) and outer “O” ring (96) (Refer to Figure 4). 93

21

22

3/16" STEEL PLATE WELDED KEY STOCK B

WELDED HEX NUT C

A

96 A

A = O.D. Seat Ring Retainer B = Width of slot in Retainer C = I.D. of Seat Ring Retainer

92

Figure 5

95

A. Secure the valve body in avise or appropriate holding device with the seat ring facing up. Figure 4 - Optional “O” ring arrangement

CAUTION

F. Remove the plug (4) through the end of the body opposite the seat ring.

Care must be taken to avoid damage to the gasket face on the valve body.

G. Remove the lower guide bushing (22). Note: A groove is provided in the bushing for prying out the bushing using a screwdriver. If the bushing will be pried out it should be pried from two sides to prevent jamming the bushing during removal. If the bushing does not come out easily, fill the bushing with grease, insert the shaft (19) into the valve insuring that the machined portion of the shaft starts into the lower guide bushing. Using a soft faced mallet, strike the end of the shaft lightly until the bushing is pushed out partially. Remove the shaft and complete removal of the bushing by prying out using the groove provided.


B. Place retainer wrench so it engages retainerlugs. C. Engage the retainer wrench with animpact wrench or suitable wrench and loosen, then remove retainer (3) by turning counterclockwise. D. Lift out seat ring. Note: In an emergency, drifts may be usedto remove the seat ring retainer. However, two drifts should be used and placed in the slots 180° apart and struck simultaneously.

6

8.3.2 DVD Removal (Refer to Figure 16) ® In case of Camflex with the DVD option, model number 35x3x or 35x4x, the DVD is installed in the body, it is recommended to use the DVD wrenches to remove this device (105). Masoneilan manufactures and has available, ® for a nominal price, DVD wrenches for the Camflex II, 1" through 12" sizes (DN 25 through 300 sizes). lt is highly recommended that wrenches be purchased or fabricated to facilitate removal and reassembly of the DVD (105) since SPECIFIC TORQUES MUST BE ACHIEVED to ensure proper clamping of this DVD plate.

Figure 6 shows the recommended thickness and method of construction along with specific dimensions to facilitate construction.

Care must be taken to avoid damage to the gasket face on the valve body. B. Place DVD plate wrench so it engages reta iner lugs. C. Engage the retainer wrench with animpact wrench or suitable wrench and loosen, then remove DVD (105) by turning counter-clockwise.

9. Maintenance 9.1 Diaphragm Replacement (Refer to Figures 16 and 17) The recommended maintenance to be performed on the Camflex® II Spring Diaphragm Actuator is limited to the replacement of the diaphragm (40). Removal of the actuator from the valve is not required. To replace the diaphragm, proceed as follows:

H T

Ød

CAUTION

A

The valve must be isolated and free from any service pressure. All electrical or air pressure to component parts must be off. Pressure to actuator must be relieved.

ØD

Valve Size

CAUTION

Handwheel (53) and limit stop (77) must be backed off to allow free travel of the lever (34).

A d D H T inches inches inches inches inches (mm) (mm) (mm) (mm) (mm)

A. Bypass the valve, shut off stop valves and isolate valve in compliance with CAUTION note listed above.

1" (DN 25)

1.063 (27)

0.142 (3.6)

1.236 (31.4)

0.079 (2)

0.4 (10)

B. Shut off and disconnect air supply tubing to the actuator .

11⁄2"

1.496

0.157

1.772

0.118

0.5

C. Remove the four capscrews (41) from diaphragm case

(DN 40) 2" (DN 50)

(38) 1.929 (49)

(4) 0.157 (4)

(45) 2.205 (56)

(3) 0.118 (3)

(12) 0.7 (18)

(42) and remove diaphragm case. D. Remove diaphragm (40).

3" (DN 80)

2.913 (74)

0.177 (4.5)

3.248 (82.5)

0.157 (4)

0.8 (20)

4" 3.858 (DN 100) (98)

0.197 (5)

4.213 (107)

0.275 (7)

0.8 (20)

6" 5.905 (DN 150) (150)

0.236 (6)

6.260 (159)

0.354 (9)

1.0 (25)

8" 7.913 (DN 200) (201)

0.236 (6)

8.268 (210)

0.394 (10)

1.0 (25)

10" 9.843 (DN 250) (250)

0.236 (6)

10.315 (262)

0.394 (10)

1.2 (30)

12" 11.732 (DN 300) (298)

0.276 (7)

12.204 (310)

0.472 (12)

1.2 (30)

Note: Diaphragm

is glued to the top ofthe piston (43).

E. Remove tape or glue from the top of the piston and clean thoroughly. F. Clean diaphragm case (42) and spring barrel (38) at the area that engages the diaphragm bead in preparation for reassembly. Note: To

hold the diaphragm in place on the piston, an adhesive disc (adhesive both sides) or rubber cement is used. If rubber cement is used, it should be applied to both the piston and the diaphragm or in accordance with the manufacturer’s directions for the adhesive used. For recommended adhesives see Figure 15. G. Apply adhesive tape or cement to the top of the ip ston.

Figure 6 A. Secure the valve body ina vise or appropriate holding device with the plug side facing up (refer to Figure 16).

H. The inscription “Piston Side” is located on the diaphragm (40). If used, apply cement to this side of the diaphragm. I. Center and adhere diaphragm(40) to the top of the piston (43) (see Figure 7, Step A). J. Roll the diaphragm (40) inside the spring barrel (38) until the bead on the diaphragm is located in the spring barrel groove (see Figure 7, Step B).


7

Figure 7

9.2.1 Hard Seat Lapping

CAUTION Ensure that the capscrew holes in the diaphragm case and spring barrel are aligned to prevent twisting of the diaphragm in aligning the holes. The diaphragm case (42) is normally assembled with the air inlet port placed on the bottom side of the actuator. Depending on the desired location, it can be placed in any desired position around the spring barrel which allows the capscrew holes to line up. However, the drain hole in the spring barrel must always be facing down to allow for draining of any moisture which may enter the spring barrel cylinder (38). If the valve is equipped with the optional purge line, that line is inserted into the drain hole.

Lapping is the process of working the valve sealing parts against each other with an abrasive, to produce a close fit. To perform the lapping operation, proceed as follows. A. Clean the seat ring sealing surface in the valve body and the seat ring shoulder. B. Apply a small amount of fine grinding compound to the seat ring shoulder.

K. Place the bead of the diaphragm (40) over the diaphragm case lip (42) and carefully slide the diaphragm case (42) down over the piston (43) until itseats on spring barrel (38). (see Figure 7, Step C). L. Ensure that the diaphragm case (42) is evenly seated on the spring barrel (38), insert the four capscrews (41) and tighten evenly. M. Connect air supply line to diaphragm case (42).

Figure 8

N. Turn on air supply and check for leaks. O. If necessary, reposition handwheel (53) and limit stop (77), (optional) to desired location and place valve back in service.

9.2 Body S/A Internal Parts ® During a maintenance of Camflex II valve it is necessary to inspect all the internal parts to determine if they are worn, corroded and damaged, especially the following seating area:

C. Insert the seat ring into the body and lap lightly by rotating the seat ring in the body, ensuring that the entire seat ring sealing surface in the valve body is lapped. Do not rotate in one place. Note: Figure 8 illustrates a simple tool which may be fabricated to facilitate this lapping operation on smaller valves.

– body and seat ring contact area.

D. Remove seat ring and clean thoroughly.

– the seating surface of the plug and seat ring.

E. Place seat ring on a flat surface with the seating area facing up.

– the guide surface of the shaft and the guide bushing.

F. Apply a small amount of fine grinding compound to the seat ring seating surface.

All parts which are damaged must be replaced by srcinal Masoneilan spare parts.


8

G. Lap the plug lightly against the seat ring while turning and oscillating the plug inall directions. H. Clean seat ring, plug and valve body thoroughly in preparation for reassembly.

Note: Depending on the actuator position, ensure that the body studs (short studs) when placed through the yoke holes will be positioned in the front of the yoke opening for ease of accessibility.

9.2.2 Soft Seat

C. Ensure that grommet (12) and shaft bearing (8) are in the yoke. Turn shaft so the plug is in the closed position.

Do not lap the soft seat ringto the plug; however, the seat ring must be lapped to the valve body. The procedure for lapping the seat ring to the body is the same as stated in items A through D of Section 9.2.1 on Hard Seats.

D. Slide the valve shaft partly into the lower yoke opening, allowing enough room to place packing flange (14) over the shaft (19). Note: Packing

flange (14) is placed on the shaft (19) with the concave side toward the valve packing (17).

9.3 Yoke Assembly (Refer to Figures 16 and 17) Maintenance required on the yoke (33) is limited to replacement of the grommet (12) and the shaft bearing (8). To replace either, the actuator must be separated from the body. (Depending on the type of actuator used, refer to appropriate section). Insert the grommet into the yoke with the recessed part of the grommet towards the shaft bearing. The shaft bearing (8) is slip fit into the yoke and is removed by pushing it out towards the grommet.

E. Ensure slots in packing flange (14) line up with packing flange studs (13). F. With packing flange on the shaft, continue sliding the valve shaft toward the yoke (33) and through the grommet (12) in the yoke (33). G. Place the lever (34) in the yoke and in line with the shaft so the boss on one side of the lever shaft hole is toward the shaft bearing (8) and engage the shaft to the lever splines.

CAUTION

Note: Shaft

Ensure the bearing seat in the yoke is clean. The bearing should slide in easily. Do not use excessive force to push bearing in.

10. Reassembly Procedures

must engage lever so the indicator dot on the clevis pin, when placed in the lever hole, shows the valve closed. Temporarily place clevis pin into lever (34) and check indicator dot alignment. Dot should just start touching the closed indicator line on the front cover (32) (Refer to Figure 18). If the orientation is not changed, align lever and mark on yoke then check alignment. (Refer to Figure 17).

10.1 Spring Diaphragm Actuator When the actuator has been disassembled using Section 8.2 to reassemble the actuator, proceed as follows: A. Replace spring (39) in piston(43).

CAUTION Do not use air pressure to check alignment, since during normal operation and with full air pressure, the Indicator may overshoot the closed Indicator mark on the cover. This is acceptable.

B. Replace washer (44) and locknut (45). Note: Locknut (45) must be threaded the full length of the threads.

C. To reassemble the diaphragm and upper diaphragm case, refer to Section 9.1, steps E. through L.

H. Slide shaft completely through lever to engage shaft bearing (8). Yoke should now be fully seated on the valve bonnet flange.

D. Replace locknut (46) and clevis (35).

I. Replace and tighten body stud nuts (27).

E. Determine correct orientation and replace actuator on yoke and replace lockwashers (37), capscrews (36) and tighten firmly.

J. Replace packing flange stud nuts (94) and finger tighten only. K. Slide the lever (34) on the shaft (19) toward the valve and tighten lever capscrew (49).

F. Refer to Section 11. for actuator stem adjustment.

10.2 Spring Diaphragm Actuator on Body S/A (Refer to Figures 16 and 17)

L. Pull the lever and shaft toward the bearing (8) in the yoke.

After completing the required maintenance or changing valve, actuator and yoke assembly, reassemble using the following procedure: A. Determine correct valve to actuator orientation. B. If required, reposition body studs (28) and packing flange studs (13).


9

10.4 Limit Stop Reassembly Two different types of assembly for the limit stop in function of the actuator size: see Figure 9.

10.5 Valve Body Reassembly (Refer to Figure 16) Prior to reassembly, the valve body should be thoroughly cleaned and the seat ring and plug may be lapped as indicated in Section 9.2. Upon completion of the above, proceed as follows: LIMIT STOP STD CAMFLEX 6" and 7"

CAUTION Lubricants and sealers are required during reassembly. Figure 15 identifies recommended products for certain service conditions. Ensure that any lubricant used is compatible with service conditions.

LIMIT STOP STD CAMFLEX 4.5"

A. Apply a small amount of thread lubricant to the seat ring retainer threads and install seat ring retainer (3) and hand tighten only.

.

Figure 9

CAUTION

CAUTION

Do not tighten the seat ring retainer to torque specification at this time. B. Place valve body (1) on flat surface so that the seat is down.

This is required to ensure the shaft (19) is shouldered on the shaft bearing (8) and to ensure free operation of the valve. M. Loosen lever capscrew (49) and slide lever (34) so it will shoulder against the shaft bearing (8) and tighten capscrew (49). Note:

if the actuator has been removed proceed to step N. If itcylinder has not,(38) proceed to Section 11, Actuator Stem Adjustment.

C. Coat lower guide bushing (22) with recommended lubricant and insert into the body.

Groove in the guide bushing (22) must be towards the body center. Refer to Figure 10 for correct assembly sequence. If the shaft (19) is the srcinal design it may have a circular grove, if so, install the retaining ring (18). Note:

N. Determine the desired actuator action and replace actuator cylinder (38) on the yoke (33) and secure in place with four capscrews (36) and lockwashers (37). O. Proceed to Section 11, Actuator Stem Adjustment.

10.3 Handwheel Reassembly A. Place the valve so the position cover (11) is up. B. Remove Truac ring (50) and handwheel washer (51) from the handwheel powerscrew. C. Insert handwheel powerscrew with lock (52) in place into the appropriate hole in the yoke and screw in clockwise. D. Replace the washer (51) and Truac ring (50) E. Back off handwheel lightly against washer and lock in the off position with lock (52). F. Replace bottom cover (11) by snapping in place.

use the handwheel, loosen the lock (52) and turn. The handwheel can be used as a limit stop on the valve by locking it in any position.

®

D. Coat the upper guide bushing (21) spacer tube (20) and the shaft splines (plug side) with recommended lubricant. E. Insert the spacer tube (20) over the lubricated part of the shaft.

CAUTION

Note: To


Figure 10

When a recessed groove exists in the spacer tube (20), this spacer tube (20) must be placed on the shaft (19) so that the shaft shoulder or retaining ring fits into the recessed groove on one end of the spacer tube (20).

10

F. Place upper guide bushing (21) on the shaft (19).

S. Install packing (17) insuring that the skive cut of each piece of packing is offset approximately 120° from that of the adjacent piece of packing.

G. Place plug (4) in body so it rests on the seat. H. Insert the shaft sub-assembly into the body (1) and engage plug (4) and lower guide bushing (22). Note: The shaft (19) should be inserted into the plug so that when the plug is seated, the slot at the outer end of the shaft is perpendicular to the flow through the valve.

Sizes 1" through 3" (DN 25 through 80) use 7 pieces of packing; sizes 4" through 12" (DN 100 through 300) use 6 pieces of packing. Note:

T. Install packing follower (15) rounded, bevel side out. U. Proceed to Section 10.6 on seat ring alignment.

In case of 35000 SB, separable bonnet version, follow the operations described from N to U.

10.6 Seat Ring Alignment

I. Install the packing box ring (23), bevel side out, over the shaft Aligning the seat ring (2) and plug (4) is required whenever (19) and into the valve bonnet being sure that the hole in the the seat ring or plug have been replaced or disassembled. ring is aligned with the threaded port in the bonnet. Proceed as follows: J. Apply a suitable lubricant to the threads of the safety pin

A. Place valve on flat surface with retainer (3) and seat ring (2)

(16) and screw into the body neck and tighten.

facing up. Note: The casting marks (=) indicate the seat ring end of the body.

CAUTION

B. Remove the retainer ring (3) and the seat ring (2).

The Safety Pin is a safety device which must not be replaced by a plug. Use only genuine Masoneilan supplied safety pins. Pin must engage hole in packing box ring (23). Test by manually pulling on the shaft to verify engagement.

C. Apply a thin coat of sealant to the seat ring shoulder that engages the body and replace seat ring (2). D. Apply a small amount of thread lubricant to the seat ring retainer threads and install seat ring retainer (3) and hand tighten only.

K. Install packing (17) insuring that the skive cut of each piece of packing is offset approximately 120° from that of the adjacent piece of packing.

1" thru 3" (DN 25 through 80) use 7 pieces of packing; sizes 4" thru 12" (DN 100 through 300) use 6 pieces of packing.

CAUTION

Note: Sizes

Do not tighten the seat ring retainer to torque specification at this time.

L. Install packing follower (15) rounded, bevel side out.

E. Replace lever (34) on valve shaft (19) and tighten lever capscrew (49).

M. Proceed to Section 10.6 on seat ring alignment.

F. Using the lever (34) manually close theplug with sufficient force to allow seat ring and plug to align.

N through U apply to separable bonnet design only: N. If necessary, install the studs (103) in the bonnet (102).

G. Using the seat ring wrench, tighten seat ring retainer to the minimum torque value specified in Figure 12.

O. Install the stop ring (100). P. Place the gasket (101) in the groove of the bonnet. The old gasket (101) must not be re-used. Q. Place the bonnet with the studs on the body and screw the nuts (104). R. Tighten the nuts (104) according the table of Figure 11.

Va l v e S i z e

Tor q u e l b . f t

To rq u e m .N

1" (DN 25) 11⁄2" (DN 40)

22

30

2" (DN 50) 3" (DN 80)

55

75

4" (DN 100)

55

75

6" (DN 150)

107

145

Figure 11 Note: It is important to tighten the nuts step by step, during the tightening the bonnet flange must keep the shaft axis aligned.


11

Note: In some cases, for the valves from 3" to 12" (DN 80 to 300) with metal seat, the alignment can be improved by placing a piece of paper 0.10mm (0.004") thick and approximately 6mm (1/4") wide at a point where the leading edge and the trailing edge of the plug contacts the seat ring and close the plug. With a slight pressure on the lever, the paper strips should both be clamped in place. For the valve 8" to 12" (DN 200 to 300), the piece of paper shall be 0.20mm (0.008") thick and 12mm (1/4") wide.

C. If applicable, back off optional limit stop (77) so it will not interfere with the operation of the lever (34).

Minimum Torque

Valve Size

l b .f t

m .N

1" (DN 25)

60

81

11⁄2" (DN 40)

95

130

2" (DN 50)

100

135

3" (DN 80)

290

395

4" (DN 100)

363

490

6" (DN 150)

825

1120

8" (DN 200)

975

1320

10" (DN 250)

1350

1830

12" (DN 300)

2250

3050

D. Apply air pressure to the actuator and move lever (34) to an intermediate position.

CAUTION Do not exceed pressure listed in Figure 14 for the actuator used. Do not use handwheel (53) to move lever (34). E. Remove adjustable indicator (88) by removing the two screws (89). F. Remove clevis pin clip (5), remove clevis pin (7).

Figure 12

G. Relieve air pressure to the actuator to allowthe clevis (35) and lever (34) to separate.

H. Proceed to section on body to actuator assembly.

10.7 DVD Plate Reassembly

Note: If

Using the same method and tooling as described in 8.3.2, tighten the Lo-dB plate at the indicated torque given in the table of Figure 13.

Tightening Torque

Valve Size 1" (DN 25)

l b .f t 100

11⁄2" (DN 40)

81

110

2" (DN 50)

100

135

3" (DN 80)

220

295

4" (DN 100)

363

490

6" (DN 150)

780

1050 1320

8" (DN 200)

975

10" (DN 250)

1320

1830

12" (DN 300)

2250

3050

H. Insert clevis pin (7) back in lever (34). I. Manually push the lever (34) so the valve is in the closed position. J. Temporarily replace front cover (32) and check the location of the clevis pin (7) in relation to the closed position indicator mark on front cover (32).

m.N

74

the unit is air-to-open, separate clevis (35) and lever (34) then loosen clevis locknut (46) andremove clevis.

CAUTION The relationship must be as shown in Figure 18. If it is not, the yoke must be separated from the body and the lever (34) repositioned on the shaft. Refer to appropriate section. Failure to comply could result in the valve short stroking or over stroking and could damage the valve.

Figure 13

Note: If

the unit is air-to-open, replace clevis locknut (46) and clevis (35).

11. Actuator Stem Adjustment (Refer to Figures 16 and 17)

K. Proceed to one of the following sections for final adjustment. Air-to-Open, Section (K-1), Air-to-Close Section (K-2). K-1. Air-to-Open

After completing step A through J of Section 11, proceed as follows:

CAUTION

A. Scribe a line on the clevis (35) in line with the inside of the yoke.

The following procedures must be adhered to in order to ensure correct valve operation. Failure to do so could result in valve damage and equipment malfunction.

B. Connect a regulated air supply directly to the actuator and gradually apply 8 psig (.55 barg) for size 9 actuators and 7 psig (.48 barg) for the others.

Correct actuator stem adjustment is imperative for proper valve functioning. With the actuator assembled to the valve in the desired location and orientation proceed as follows:

C. The clevis should move approximately 1/4".

If any of the following steps were completed during maintenance or reorientation of actuator to valve, proceed to the next step.

D. With the lever and valve plug in the fully CLOSED position, the holes in the clevis (35) and lever (34) should be inline.

Note:

A. Remove front cover (32) and rear cover (29) by removing the two-cover screws (30). B. Back off handwheel (53) so it does not interfere with the operation of the lever (34).


12

Note: If holes are in line proceed to Step J. If not in line, continue to next step.

E. Move lever (34) to full open position. F. Gradually apply sufficient air pressure to extend clevis locknut (46) to an accessible position.

F. Loosen clevis locknut (46).

CAUTION

G. Screw clevis (35) in or out so that when the air pressure corresponding to the closed position mentioned in C above is applied, clevis holes and lever will be inline.

Do not exceed pressure listed in Figure 14 for the actuator used.

H. Insert clevis pin (7) so indicator dot is visible through front cover (32) and secure with clevis pin clips (5).

G. Loosen clevis locknut (46). H. Reduce air pressure to actuator to 7 psig.

J. Insert clevis pin (7) so indicator dot is visible through front cover (32) and secure with clevis pinclips (5). Note:

On the size 6 and 7 actuators, without the adjustable indicator (88), the clevis pin (7) must be installed so it protrudes toward the front cover (32). If the indicator dot is damaged, paint may be applied to the end of the clevis pin (7) facing the front cover (32) to make it more visible. Note:

I. Screw clevis (35) in or out on actuator stem so that the holes in the clevis (35) and lever (34) are aligned with the lever and plug in the fully closed position.

On the size 6 and 7 actuators, without the

adjustable (88), thethe clevis (7)(32). must be installed so indicator it protrudes toward frontpin cover If the indicator dot is damaged, paint may be applied to the end facing the front cover (32) to make it more visible. K. Gradually apply sufficient air pressure to extend clevis locknut (46) to an accessible position and tighten firmly.

I. Tighten clevis locknut (46). J. Relieve air pressure to actuator. K. If used, replace adjustable indicator (88) to lever (34) with screws (89). Note: If required, adjust indicator (88) to front cover (32) indicator marks with the valve in the closed position.

L. Replace front cover (32) and rear cover (29) and secure in place with cover screws (30).

CAUTION

M. Replace spring barrel boss cover (58) and bottom cover (11) (Snap fit).

Do not exceed pressure listed in Figure 14 for the actuator used.

Note: Prior

to placing the valve in service, operate the valve actuator through one complete cycle to ensure proper functioning.

L. Relieve air pressure. M. If used, replace adjustable indicator (88) to lever (34) with screws (89).

If required, adjust indicator to front cover indicator marks.

N. If desired, set handwheel (53) or optional limit stop (77) to desired position.

Note:

12. Changing Body Position

N. Replace front cover (32) and rear cover (29) and secure in place with cover screws (30). O. Replace spring barrel boss cover (58) and bottom cover (11) (Snap fit). Note: Prior to placing the valve in service, operate the valve actuator through one complete cycle to ensure proper functioning.

P. If desired, set handwheel (53) or optional limit stop (77) to desired position. K-1. Air-to-Close

After completing step A through J of Section 11, proceed as follows: A. Manually push lever (34) to the fullCLOSED position.

CAUTION Before any change in flow direction or actuator mode is made, the valve and actuator must be resized using current process conditions. Any change in the flow direction or actuator mode must be accomplished as outlined in this instruction, otherwise equipment malfunction could result. Changing service requirements or service conditions may require ® a change in flow direction through the Camflex II valve. Figure 19 illustrates the various positions and flow directions in which the valve may be placed to accommodate requirements.

CAUTION

B. Connect a regulated air supply to the actuator.

C. Gradually apply the final air pressure corresponding to the Changing the body position and flow direction could also require closed position. See value on the serial plate. relocating the actuator. Ensure that the actuator location and action are in accordance with the recommended positions and D. the Withholes the lever and(35) valve the should CLOSED in the(34) clevis andplug leverin(34) be position, in line. modes illustrated in Figure 19. Illustrations are shown looking at the body through the bonnet with the actuator in front of the Note: If holes are in line proceed to Step H, if not in line, valve. The plug shaft is always rotated in a clockwise direction continue to the next step. by the actuator to open the valve. E. Release air pressure so clevis (35) will separate from lever (34). Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves ®

13

G. Remove Truarc ring (50) and washer (51) from handwheel powerscrew assembly. A. Refer to Figure 19 and determine which is the desired valve position, flow direction and which actuator position is required. H. Unscrew and remove handwheel powerscrew assembly from yoke (33). B. Proceed to the appropriate section of this instruction for the I. Remove handwheel thread plug (48). required disassembly and assembly procedures.

To change body position proceed as follows:

If the actuator is equipped with the optional limit stop (77), in place of the handwheel thread plug, it must be removed. Note:

13. Changing Actuator Action

CAUTION

CAUTION

Before any change in flow direction or actuator mode is made, the valve and actuator must be resized using current process conditions. Any change in the flow direction or actuator mode must be accomplished as outlined in this instruction, otherwise equipment malfunction could result.

Depending on the size and weight of the actuator, it is recommended that proper lift and support procedures be

utilized when removing the spring barrel or yoke. J. Ensure spring barrel isproperly supported. A. Remove front cover (32) and rear cover (29) by removing the K. Loosen and remove capscrews (36) and lockwashers (37) two cover screws (30). then remove spring barrel (38). B. Remove spring barrel boss cover (58) (Snap fit). C. Remove bottom cover (11) (Snap fit).

CAUTION

D. Using a manual loading panel, apply sufficient air pressure to the actuator to move the lever (34) to an intermediate position.

If the orientation of the actuator to valve requires that the yoke be rotated about the valve, it is recommended that Section 12 on changing yoke position be accomplished before proceeding.

CAUTION Do not exceed pressure listed in Figure 14 for actuator used. Do not use handwheel to move lever. E. Remove clevis pin clips (5)and remove clevis pin (7). F. Position lever so it does not contact handwheel power-scre w assembly.

Valve Size

Maximum Air Supply

Actuator Size Diameter

Austenitic Stainless Steel Shaft

A 564 Gr 630 Shaft

i n c h e(sm m )

kP a

Recommended Tubing

Psi

kP a

Psi

mm

1"(DN25)

4 1⁄2 (114)

138

20

138

20

4x6

i n ch e s 1

11⁄2"(DN40)

4 1⁄2 (114)

172

25

172

25

4x6

1

2"(DN50)

4 1⁄2 (114)

207

30

207

30

4x6

1

⁄4" ⁄4" ⁄4"

3" (DN 80)

(152) 6

207

30

207

30

4x6

1

4" (DN 100)

(152) 6

310

45

310

45

4x6

1

6" (DN 150)

(177) 7

448

65

310

45

4x6

1

8" (DN 200)

(177) 7

517

75

379

55

4x6

1

10" (DN 250)

(177) 7

517

75

448

65

4x6

1

12" (DN 300)

(177) 7

517

75

517

75

4x6

1

6" (DN 150)

(228) 9

344

50

276

40

4x6

1

8" (DN 200)

(228) 9

344

50

276

40

4x6

1

10" (DN 250)

(228) 9

448

65

310

45

4x6

1

12" (DN 300)

(228) 9

517

75

379

55

4x6

1

Figure 14


14

⁄4" ⁄4" ⁄4" ⁄4" ⁄4" ⁄4" ⁄4" ⁄4" ⁄4" ⁄4"

S e r v i ce

S ealant

L u b r i ca n t

D i a p h r a g mGl u e

Condensate and Steam

Silver Seal T-J, Turbo 50 or HYLOMAR SQ 32

Molykote G or GRAPHENE 702

3M High Track adhesive transfer tape (or equal)

Cryogenic -20°F to -320°F (-29°C to -196°C)

Crown N. 9008 Teflon Spray or RODORSIL CAF 730

Crown N. 9008 Teflon Spray or GRAPHENE 702

3M Pressure sensitive tape, double coated (or equal)

Oxygen

Drilube type 822 or BONNAFLON S/9

Drilube type 822 or OXIGNENOEX FF250

Eastman 910 Cement (or equal)

All Others*

John Crane Plastic lead N.2 HYLOMAR SQ 32

Molykote G or GRAPHENE 702

Goodyear Plibond Cement (or equal)

* Except Food Services.

Figure 15

L. With the yoke assembled to the valve in the required orientati on, 14. Manual Actuator Option place spring barrel (38) on desired yoke location and secure with capscrews (36) and lockwashers (37), and tighten firmly. The manual type actuator is designed to close the valve by rotating the handwheel in a clockwise direction. Anti-rotation M. Screw in handwheel powerscrew assembly into the of the handwheel is obtained through a detente device located powerscrew hole of the yoke which is on the opposite side between handwheel (53) and retainer (87). of the spring diaphragm actuator. Note: Handwheel action is always the same as air action and opposes the spring.

N. Replace handwheel washer (51) and Truarc ring (50) and back off handwheel so the powerscrew will not interfere with the operation of the lever. O. Replace handwheel thread plug (48).

If the valve is equipped with the optional limit stop (77) instead of the thread plug, it must now be installed, but ensure it is backed off as not to interfere with the operation Note:

of the lever at this time. P. Proceed to Section 11, on Actuator Stem Adjustment.

14.1 Disassembly Procedure The disassembly procedure for manual actuator is similar to the procedure for spring diaphragm actuator see Section 8.1.

14.2 Maintenance Routine maintenance of the manual actuator requires that a suitable lubricant be periodically applied to the handwheel powerscrew. Bearings may require replacement due to service conditions or corrosion. The replacement of the handwheel detent mechanism should be required.

14.3 Reassembly Procedure There is no specific adjustment for the reassembly of manual actuator. For details see Figure 21.


15

Parts Reference Ref .

Qty.

P a r tN a m e

R ef.

1

1

Body

2

1

SeatRing

3

1

Retainer

4

1

5

2

ClevisPinClip

32

6

1

IndicatorDot

33

7

1

Clevis Pin

34

8

1

Bearing

9

1

ShaftCover

Plug

Q t y.

28 29

2 1

30

BodyStud RearCover

2

CoverScrew

2

ScrewRetainer

31

35

P a r tN a m e

1

FrontCover

1

Yoke

1

Lever

R ef.

56

Qt y.

1

57

SerialPlate

2

58

PlateScrew

1

60

BossCover

•

61

Counter-Flange

•

64

Gasket

•

67

Stud

•

1

Clevis

68

36

4

CapScrew

77

4

LockWasher

78

Stud

•

Nut

1

TravelStop

10

1

CoverScrew

37

11

1

BottomCover

38

12

1

Grommet

13

2

PackingFlangeStud

14

1

Packing Flange

41

4

Cap Screw

91

1

15

1

Packing Follower

42

1

Diaphragm Case

92

1

16

1

SafetyPin Packing

39 40

43

1

Nut

1

SpringBarrel

88

1

1

Spring

89

2

Diaphragm

90

1

1

1

Inner O-Ring OuterO-Ring

19

1

20

1

Spacer

21

1

UpperGuide

49

1

22

1

LowerGuide

50

1

23

1

PackingBoxRing

51

HandwheelWasher

103

4

BonnetStud

24

1

WarningPlate

52

1

HandwheelLock

104

4

BonnetNut

25

1

FlowArrow

53

1

HandwheelShaft

105

1

Lo-dBPlate

26

2

PlateScrew

54

1

HandwheelPlate

4

AdaptorScrew

27

2

Nut

46 48

55

LockNut

1

LockNut

•

2

1

Nut InnerO-Ring OuterO-Ring

100

1

101

1

BodyGasket

102

1

Bonnet

Plate Screw

**Quantity varies by size and bonnet type. Confirm required quantity from valve serial records.

®

96

1

ThreadPlug

* Applies to srcinal design only.


95

LeverCapScrew TruarcRing

1

2

Outer O-Ring

1

1

94

InnerO-Ring

**

Shaft

LockWasher

1

IndicatorScrew

17

45

1

93

AdjustableIndicator

18*

ShaftRetainingRing

44

Piston-Stem

P a r tN a m e

17

106 107

StopRing

1

Adaptor

ACCEPTABLE

NOT ACCEPTABLE

Figure 18

AIR TO OPEN FLOW TENDING TO CLOSE CLOSE ON AIR FAILURE

4

2

8

6

DIRECTION OF FLOW

AIR TO CLOSE FLOW TENDING TO OPEN OPEN ON AIR FAILURE 3

7

1

5

DIRECTION OF FLOW

The body is shown behind the actuator.

Figure 19

PACKING FLANGE REVERSED LEVER ARM

PACKING STUD NUT STEM

PIPE

BOLT FLAT WASHER BONNET

PIPE

Figure 20

Figure 21 Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves ®

18

Flanged Bodies Long Stud (T) (64) Short Stud (G) (67)

Long Stud (T) (64) Short Stud (G) (67)

Nuts

Long Stud (T) (64) Short Stud (G) (67)

Nuts

Nuts

Valve Rating Qty.

Length inches (mm)

Di a .

Qt y.

Length D ia . inches (mm)

Qt y .

1" (DN 25)

3.00 (76.2)

300 (50) 600 (100) PN 10 PN 16 PN 25

EN DIN

(M14)

8T

8G

3.00 (76.2)

8T

(71.0)

Qt y.

3.50 (88.9)

M12

8

8G

3.50 (88.9)

16

8T

(84.0)

8T

(M14)

8T

5 ⁄ 8"

(M16)

1 ⁄ 2"

2.75 (70.0) 16

M16

Qt y.

3.25 (82.5)

16

16

3 ⁄ 4"

(M20)


2" (DN 50)

11 ⁄2" (DN 40)

1 ⁄ 2"

2.50 (63.5)

150 (20) ANSI EN (ISO PN)

Qt y .

8

16

5 ⁄ 8"

16T

3.50 (88.9)

8T + 8G

4.25 (108.0) 3.75 (95.2)

8T

(84.0)

32

(M16)

24

M16

16

PN 40

( 3"

ANSI EN (ISO PN)

8T

3.50 (88.9)

300 (50)

16T

4.25 (108.0)

600 (100)

12T + 4G

5.00 (127.0) 4.25 (108.0)

PN PN PN PN

EN DIN

8D 0N )

150 (20)

10 16 25 40

300 (50) 600 (100) PN 10 PN 16 PN 25 PN40

EN DIN

3 ⁄ 4"

(M20)

( 4"

16T

3.50 (88.9)

16T

4.50 (114.3)

28

12T + 4G

5.75 (146.0) 5.00 (127.0)

(M16)

(84.0) M16

D2N 00)

7 ⁄ 8"

24T

5.50 ( 140.0)

20T +

7.50 (190.5)

11⁄ 8"

4G 16T

6.75 (171.5)

(M30)

(102.0)

M20

24T

(123.0) (137.0)

M24 M27

(M24)

7 ⁄ 8"

1 ( 0"

32 48

24T

M20

28

6.75 (171.5) 6.00 (152.4)

3 ⁄ 4"

(M20) 1" (M27)

15T + 1G

6.25 (158.8)

24T

(106.0) (115.0) (133.0) (151.0)

7 ⁄ 8"

(M24) 1" (M27)

48 64

M20

48

1 ⁄ 2"

: 1 ⁄ 2" 13 UNC 2A/2B

5 ⁄ 8"

: 5 ⁄ 8" 11 UNC 2A/2B

3 ⁄ 4"

: 3 ⁄ 4" 10 UNC 2A/2B

7 ⁄ 8"

: 7 ⁄ 8" 9 UNC 2A/2B

11 ⁄ 4" : 11 ⁄ 4" 8 UNC 2A/2B Figure 22

19

M24

(155.0) (120.0)

M30

31

24T

4.75 (120.6)

32T

6.75 (171.5)

24T

(106.0) (115.0) (133.0) (151.0)

7 ⁄ 8"

(M24)

48

11 ⁄ 8 " (M30)

64

M20 M24 M27 M30

48

N/A M20 M24 M27 M30

11 ⁄ 8" : 11 ⁄ 8" 8 UNC 2A/2B 67

44

1 2" (DN 300)

N/A

32

32 48

32 (119.0)

32

1" : 1" 8 UNC 2A/2B

®

20T + 4G

D2N 50)

32T

64


4.75 (120.6)

(102.0)

M24

4.50 (114.3)

44

48

4.00 (101.6)

24T

M16

(102.0) (123.0)

3 ⁄ 4"

(M20) (M24)

16T 32

16T

N/A

(M20)

3 ⁄ 4"

32 16T

4.25 ( 108.0)

6" (DN 150)

5 ⁄ 8"

32

(92.0)

16T

D 10 N0)

16

(84.0)

( 8" 150 (20)

(M16)

16T

PN 63/64

ANSI EN (ISO PN)

5 ⁄ 8"

Flangeless Bodies

Valve Rating

Long Stud (T) (64) Short Bolt (G) (67) Cap Screws (V) (68)

Nuts

Length inches (mm)

Qt y.

Qty.

D ia .

Long Stud (T) (64) Short Bolt (G) (67) Cap Screws (V) (68) Qt y .

1" (DN 25)

EN

150 (20) 300 (50) 400 600 (100) PN 10 PN 16 PN 25 PN 40

DIN

PN 63/64

ANSI (ISO PN)

7.50 (190) 4T

7.75 (195)

7.50 (190)

8.10 (205)

( 3"

ANSI (ISO PN)

4T

10.25 (260)

400

12.0 (305) 4.50 (115)

8

18

7T 2G

PN PN PN PN

10 16 25 40

7T 2G

10.25 (260)

(8" 150 (20)

ANSI (ISO PN)

6T 4V

300 (50) 400

10T 4V

600 (100) PN 10

6T 4V

PN 16 EN DIN

PN 25 PN 40 PN 63/64

10T 4V

5⁄ 8"

(M16)

3 ⁄ 4"

16.25 (410) 3.5 (89)

7 ⁄ 8"

17.0 (430) 4.0 (102)

1"

18.125 (460) 4.25 (108)

11 ⁄ 8 "

14.25 (360) 3.0 (76)

7T 2G

D2N 00)

13.75 (350) 3.0 (73)

13.75 (350) 3.0 (76)

18 *A

3 ⁄ 4"

12

20

12T 8V

12

(M20) 7 ⁄ 8"

15.75 (400) 3.25 (82)

(M24) 1" (M27)

17.0 (430) 3.75 (93)

11 ⁄ 4 " (M33)

20

8T 8V

9.0(230)

7T 2G

9.0 (230) 3.75 (95)

5 ⁄ 8"

9.0 (230)

Qt y .

8 5 ⁄ 8"

18

5 ⁄ 8"

(M16)

4T

8 9.50 (240)

3 ⁄ 4"

(M20)

10 (250)

3 ⁄ 4"

(M20) 7⁄ 8"

(M24)

6" (DN 150)

D 10 N0 ) 5 ⁄ 8"

12.0 (305) 4.50 (115)

3 ⁄ 4"

7T 2G

8

14.25 (360) 5.50 (140)

7⁄ 8"

11.50 (290) 3.75 (65)

(M16)

12.0 (305) 4.50 (115)

Length Di a . inches (mm)

4T

(M16)

11.50 (290) 3.75 (95)

1 ( 0"

8T 8V

8

8

( 4"

8D 0N )

600 (100)

EN DIN

3 ⁄ 4"

9.0 (230)

(M16)

3 ⁄ 4"

8.75 (220)

4T

5 ⁄ 8"

5 ⁄ 8"

Qt y.

Nuts

2" (DN 50)

1 ⁄ 2"

7.50 (190)

300 (50)

7T 2G

4T

1 ⁄ 2"

8

PN 100

150 (20)

8

(M12)

4T

Qt y.

11 ⁄2" (DN 40)

7.50 (190)

1 ⁄ 2" 5 ⁄ 8"


Long Stud (T) (64) Short Bolt (G) (67) Cap Screws (V) (68)

Nuts

5 ⁄ 8" 3 ⁄ 4"

(M20)

11T 2G

13.75 (350) 4.50 (115)

*B 26

16.25 (410) 5.50 (140)

18 *B

7T 2G

D2N 50 )

14.0 (350) 4.50 (115) 14.25 (360) 5.50 (140)

*C

1"

16.0 (400) 6.0 (150) 18 *D

18 *B 26

3 ⁄ 4"

26 3 ⁄ 4"

(M20) 7⁄ 8"

(M24)

7 ⁄ 8"

19.0 (480) 3.75 (95)

1"

20.50 (520) 4.25 (108)

11 ⁄ 8"

20.50 (520) 4.75 (120)

11 ⁄ 4"

16T 8V

22.50 (570) 4.75 (120)

3 ⁄ 4"

–

–

8T 8V

18.50 (470) 3.0 (76)

(M24)

19.0 (480) 3.25 (82)

1" (M27)

20.50 (520) 3.75 (95)

11⁄ 8" (M30)

21.25 (540) 4.0 (100)

11 ⁄ 4 " (M33)

(M20)

16.50 (420) 3.0 (76)

(M24)

17.0 (430) 3.25 (82)

1" (M27)

18.125 (460) 3.75 (95)

11⁄ 8" (M30)

20.0 (510) 3.75 (93)

11 ⁄ 4" (M33)

16

24

7 ⁄ 8"

8T 8V 12T 8V

16

*Use one washer (66) for each short stud as shown on the left figure:

12T 8V

18.50 (470)

7 ⁄ 8"

20.50 (520) 3.75 (95)

1"

22.50 (570) 4.25 (108)

16

24 11 ⁄ 4 " 32 –

– 7 ⁄ 8"

1 ⁄ 2"

: 1 ⁄ 2" 13 UNC 2A/2B

5 ⁄ 8"

: 5 ⁄ 8" 11 UNC 2A/2B

3 ⁄ 4"

: 3 ⁄ 4" 10 UNC 2A/2B

A: M16N (18x32x3)mm B: M20N (22x40x3)mm C: M22N (24x45x3)mm D: L16N (18x40x3)mm Figure 23 Instructions EF35002 - 08/10 Camflex II 35002 Series Control Valves ®

20

18 *C

1 2" (DN 300)

16.50 (420) 3.0 (76)

16.50 (420) 3.0 (76)

18 *B

7 ⁄ 8"

: 7 ⁄ 8" 9 UNC 2A/2B 1" : 1" 8 UNC 2A/2B 11 ⁄ 8" : 11 ⁄ 8" 8 UNC 2A/2B 11 ⁄ 4" : 11 ⁄ 4" 8 UNC 2A/2B

16

24

Notes


21

DIRECT SALES OFFICE LOCATIONS BELGIUM Phone: +32-2-344-0970 Fax: +32-2-344-1123

ITALY Phone: Fax:

+39-081-7892-111 +39-081-7892-208

BRAZIL Phone: Fax:

+55-11-2146-3600 +55-11-2146-3610

JAPAN Chiba Phone: Fax:

+81-43-297-9222 +81-43-299-1115

CANADA Ontario Phone: Fax:

+905-335-3529 +905-336-7628

KOREA Phone: Fax:

+82-2-2274-0748 +82-2-2274-0794

CHINA Phone: Fax:

+86-10-8486-4515 +86-10-8486-5305

GERMANY Viersen Phone: +49-2162-8170-0 Fax: +49-2162-8170-280 INDIA Mumbai Phone: Fax: New Delhi Phone: Fax:

+91-22-8354790 +91-22-8354791

Phone: Fax: MEXICO Phone: Fax:

UNITED STATES Massachusetts Phone: +1-508-586-4600 Fax: +1-508-427-8971

SINGAPORE Phone: +65-6861-6100 Fax: +65-6861-7172

Corpus Christi, Texas Phone: +1-361-881-8182 Fax: +1-361-881-8246 Dresser Direct Deer Park, Texas Phone: +1-281-884-1000 Fax: +1-281-884-1010 Dresser Flow Technologies Houston, Texas Phone: +1-281-671-1640

SOUTH AFRICA Phone: +27-11-452-1550 Fax: +27-11-452-6542

+60-3-2161-0322 +60-3-2163-6312

SOUTH & CENTRAL AMERICA AND THE CARIBBEAN Phone: +55-12-2134-1201 Fax: +55-12-2134-1238

+52-5-310-9863 +52-5-310-5584

SPAIN Phone: Fax:

MALAYSIA

FRANCE Courbevoie Phone: +33-1-4904-9000 Fax: +33-1-4904-9010

SAUDI ARABIA Phone: +966-3-341-0278 Fax: +966-3-341-7624

+34-93-652-6430 +34-93-652-6444

THE NETHERLANDS Phone: +31-15-3808666 Fax: +31-18-1641438

UNITED ARAB EMIRATES Phone: +971-4-8139-200 Fax: +971-4-8838-038

RUSSIA Veliky Novgorod Phone: +7-8162-55-7898 Fax: +7-8162-55-7921 Moscow Phone: +7 495-585-1276 Fax: +7 495-585-1279

UNITED KINGDOM Wooburn Green Phone: +44-1628-536300 Fax: +44-1628-536319

Fax: California Phone: Fax:

+1-281-671-1735 +1-562-941-7610 +1-562-941-7810

+91-11-2-6164175 +91-11-5-1659635

About Dresser, Inc.

About Dresser Masoneilan

Dresser Inc. is a global leader in providing highlyengineered infrastructure products for the global energy industry. Leading brand names within the Dresser portfolio include Dresser Wayne® retail fueling systems, Waukesha® ® natural gas-fired engines, Masoneilan control valves, Consolidated® pressure relief valves, and ROOTS® blowers and rotary gas meters. The company has manufacturing and customer service facilities strategically located worldwide and a sales presence in more than 150 countries. www.dresser.com

Dresser Masoneilan, headquartered in Houston, Texas, has been the leading global partner in process control valves and solutions for more than 100 years. A business segment of Dresser, Inc., the company delivers customized products, services and diagnostic solutions for oil and gas, process and power generation applications. www.dresser.com

Dresser Masoneilan Dresser, Inc., Flow Technologies 10343 Sam Houston Park Drive Houston, Texas 77064 U.S.A T. +1-281-671-1640 F. +1-281-671-1735 E. [email protected]

© 2010 Dresser, Inc. All rights reserved.

EF35002 08/10

www.dresser.com


210 0 0 Series Control Valves Complete Line of Rugged, Top Guided, Globe Valves with Lo-dB® / Anti-Cavitation Capabilities

Instruction Manual EH21000 09/10

Table of Contents ........................................................................................ Page IMPORTANT: SAFETY WARNING .......................................................................................1 1. INTRODUCTION ...............................................................................................................2 2. GENERAL ........................................................................................................................2 3. UNPACKING ....................................................................................................................2 4. INSTALLATION ................................................................................................................2 5. AIR PIPING .......................................................................................................................3 6. BODY DISASSEMBLY ....................................................................................................3 6.1 THREADED TRIM ................................................................................................3 6.2 QUICK-CHANGE TRIM ........................................................................................3 7. MAINTENANCE/REPAIR .................................................................................................3 7.1 THREADED SEAT RING REMOVAL ....................................................................3 7.2 BUSHING REMOVAL ............................................................................................4 7.3 LAPPING SEATS ..................................................................................................4 7.3.1 THREADED TRIM ...................................................................................4 7.3.2 QUICK-CHANGE TRIM ...........................................................................4 7.4 Lo-dB PLUG ..........................................................................................................5 7.5 PLUG STEM PINNING..........................................................................................5 7.6 PACKING BOX ......................................................................................................6 7.6.1 KEVLAR/PTFE PACK. RING (STANDARD) .............................................6 7.6.2 EXPANDED GRAPHITE P. RING (OPTION) ...........................................6 7.6.3 LE PACKING (LOW EMISSION) (OPTION) ............................................7 7.7 SOFT SEAT PLUG ................................................................................................8 8. VALVE BODY REASSEMBLY .........................................................................................8 8.1 THREADED TRIM ................................................................................................8 8.2 QUICK-CHANGE TRIM ........................................................................................9 8.3 HIGH PRESSURE & ANGLE DESIGN ................................................................9 9. ACTUATORS....................................................................................................................9 9.1 TYPES 87/88 ACTUATORS ..................................................................................9 10.BELLOWS SEAL ASSEMBLY .......................................................................................9 10.1 BELLOWS VALVE DISASSEMBLY ...................................................................14 10.1.1 THREADED TRIM ................................................................................14 10.1.2 QUICK-CHANGE TRIM .......................................................................14 10.2 REPAIR .............................................................................................................15 10.2.1 PLUG / STEM BELLOWS / BONNET EXTENSION S/A ....................15 10.3 PLUG AND SEAT RING SEATING SURFACES ...............................................16 10.4 BONNET REASSEMBLY ..................................................................................16 10.5 VALVE BODY REASSEMBLY ...........................................................................16 10.6 ACTUATOR TO BODY S/A AND PLUG STEM ADJUSTMENT ........................16


About this Manual

Safety Information

• The information in this manual is subject to change without prior notice.

Important - Please Read Before Installation

• The information contained in this manual, in whole or part, shall not be transcribed or copied without Masoneilan’s written permission.

Masoneilan model 21000 Series Control Valves instructions contain DANGER, WARNING, and CAUTIONlabels, where necessary, to alert you to safety related or other important information. Read the instructions carefully before installing and maintaining your control valve. DANGERand WARNING hazards are related to personal injury. CAUTIONhazards involve equipment or property damage. Operation of damaged equipment can, under certain operational conditions, result in degraded process system performance that can lead to injury or death. Total compliance with all DANGER, WARNING, and CAUTIONnotices is required for safe operation.

• Please report any errorsor questions about the information in this manual to your local supplier. • These instructions are written specifically for the 21000 Series Control Valves, and do not apply for other valves outside of this product line.

Warranty Items sold by Dresser ® are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment provided said items are used according to Dresser recommended usages. Dresser, Inc. reserves the right to discontinue manufacture of any product or change product materials, design or specifications without notice.


This instruction manual applies to the Masoneilan21000 Series Control Valves. The control valves MUST BE: • Installed, put into service and maintained by qualified and competent professionals who have undergone suitable training.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in seriousinjury.

• Under certain operating conditions, the use of damaged equipment could cause a degradation of the performance of the system which may lead to personal injury or death. • Changes to specifications, structure, and components used may not lead to the revision of this manual unless such changes affect the function and performance of the product. • All surrounding pipe linesmust be thoroughly flushed to ensure all entrained debris has been removed from the system.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

When used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage. Note: Indicates important facts and conditions.

Instructions EH21000 - 09/10 21000 Series Control Valves

1

1st

2nd

Actuator Type 87 Spring Diaphragm Air to Close 88 Spring Diaphragm Air to Open

1st

Body Series 21

2nd

3rd

4th

Flow Characteristics

Plug Type

0. Undefined 1. Linear 2. Equal Percentage 3. Modified Percent

0. 1. 6. 7.

Undefined Contoured Soft Seat Single Stage Lo-dB®/ Cavitation Containment 8. Double Stage Cavitation Containment 9. Double Stage Lo-dB®

5th

6th

Seat Type 0. Undefined 4. Quick Change 5. Threaded

Optional Configuration A Angle Body BS Bellows Seal EB Extension Bonnet C Cryogenic Extension Bonnet

Figure 1 - Numbering System

1. lntroduction

The 21800 Series double stage anti-cavitation valve is derived from the 21700 single stage anti-cavitation valve through a The following instructions should be thoroughly reviewed modification to the cage and plug. Substitution of the standard and understood prior to installing, operating or performing cage with an anti-cavitation cage permits the pressure drop to maintenance on this equipment. Throughout the text,be split bet ween the t wo stages efficiently. safety and/or caution notes will appear and must be The 21900 Seriesdouble stage Lo-dB® valve is also derived strictly adhered to, otherwise, serious injury or equipment from the 21700 single stage Lo-dBvalve through a modification malfunction could result. to the cage and plug. Substitution of the standard cage, with a Masoneilan has a highly skilled After Sales Department Lo-dB cage permits the pressure drop to be split between the available for start-up, maintenance and repair of our valves two stages efficiently. and component parts. In the 21800/21900 Series designs, enlargement of the plug head Arrangements for this service can be made through your local up to the cage diameter permitsimultaneous s throt tling of the plug Masoneilan Representative or After Sales Department. When Cv and the cage Cv. It also provides optimum allocation of the performing maintenance use only Masoneilan replacement parts. pressure drop between thewo t stages along the entire plugtravel. Parts are obtainable through your local Masoneilan Representativ e or Spare Parts Department.When ordering parts, always Recommended spare parts required for maintenance are listed in the Parts Reference table on page 14. The model number, include Model and Serial Number of the unit being repaired. size, rating and serial number of the valve are shown on the identification tag located on the actuator. Refer to Figure 1 for 2. General the 21000 series numbering system. These installation and maintenance instructions apply to all sizes and ratings of the Masoneilan 21000 Series control 3. Unpacking valves regardless of the type of trim used. Care must be exercised when unpacking the valve to prevent 21000 Series single ported top guided control valves are damage to the accessories and component parts. Should any designed with built in versatility making them well-suited to problems arise, contact the local Masoneilan Representative handle a wide variety of process applications. or After Sales Department. Standard construction offers a contoured plug (21100 Series) with a threaded seat ring or a quick change seat ring. The heavy top 4. lnstallation plug guiding provides maximum support to ensure plug stability. 4.1 Before installing the valve in the line, clean piping and valve of all foreign material such as welding chips, A series of reduced area tr im is available to provide wide flow scale, oil, grease or dirt. Gasket surfaces should be range capabilities in all valve sizes. thoroughly cleaned to ensure leak-proof joints. Tight Shutoff Class IV leakage is standard. Optional constructions 4.2 To allow for in-line inspection, maintenance orremoval of (one of which is the21600 Series soft seat plug) meet IEC 534-4 the valve without service interruption, provide amanually and ANSI/FCI 70.2 Class V and Vl requirements. operated stop valve on each side of the 21000 Series ® An optional Low Emission LE Packing is available to assure valve with a manually operated throttling valve mounted compliance with the fugitive emission containment requirements. in the by-pass line (See Figure 2). Replacing the conventional plug with the single stage Lo-dB design (21700 Series)provides excellent noise attenuation or anti-cavitation performance. Instructions EH21000 - 09/10 21000 Series Control Valves

4.3The valve must be installed so that the controlled substance will flow through the valve in the direction indicated by the flow arrow located on the body.

2

• •

With contoured plug (21100/21600) or Lo-dB plug (21700/21900)

G. Bonnet (8), plug (16), bushing (12) and seat ring (14) may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate Section of this instruction manual.

:flow-to-open

On anti-cavitation design (21700/21800) :flow-to-close

4.4For heat-insulated installation, do not insulate the valve bonnet. Take necessary protective measures relate to personal safety.

6.2 Quick-Change Trim (Figure 13 or 15) After removing the actuator, disassemble the body using the following procedure:

5. Air Piping The actuators are designed to accept1/4" NPT air supply piping. Use 1/4" OD tubing (4 x 6 mm) or equivalent for all air lines. If the supplyair line exceeds 25 feet in length(7 meters) or if the valve is equipped with volume boosters, then3/8" tubing (6 x 8 mm) is preferred. AII connections must be free of leaks.

A. If there is a leak detection connection on the lateral NPT port of the bonnet, disconnect this piping as well. B. Remove body stud nuts (10). C. Remove bonnet (8), and plug stem (1) and plug (16) sub-assembly together as one unit. D. Since the cage (13), seatng ri (14) and seat ring gasket (15) are held in place by the bonnet, they may now be removed.

CAUTION

Note: Spiral wound gaskets (11 & 15) are standard in the 21000 Series design and it is imperative that new gaskets be installed each time the valve is disassembled.

Do not exceed supply pressure indicated on serial plate located on the yoke of the actuator.

E. Remove packing flange stud nuts (3), packing flange (4) and packing follower (5).

6. Body Disassembly

F. Remove plug (16) and plug stem (1) sub-assembly from the bonnet (8).

Access to the internal components of the body should be accomplished with the actuator removed. To remove the actuator from the body, refer to the actuator instruction No. ER8788 for a type 87/88 multispring actuator.

CAUTION

CAUTION

Care must be taken to avoid damage to the plug and plug guide.

Prior to performing maintenance on the valve, isolate the valve and vent the process pressure. Shut off the supply air line and the pneumatic or electric signal line.

6.1 Threaded Trim (Figure 12 or 14)

H. All components may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate Section of this instruction manual.

After removing the actuator, disassemble the body using the following procedure : A. If there is a leak detector connection on the lateral NPT port of the bonnet, disconnect this piping as well.

7. Maintenance & Repair

B. Remove body stud nuts (10).

The purpose of this section is to provide recommended maintenance and repair procedures. These procedures assume the availability of standard shop tools and equipment.

C. Remove bonnet (8), and plug stem (1) and plug (16) sub-assembly together as one unit.

7.1 Threaded Seat Ring Removal (Figure 12 or 14)

Note: Spiral wound body gaskets (11) are standard in the 21000 Series design and it is imperative that a new gasket be installed each time the valve is disassembled.

Threaded seat rings (14) are installed tightly by the manufacturer, and after years of service they may be difficult to remove.

D. Remove packing flange stud nuts (3), packing flange (4) and packing follower (5).

To facilitate removal, seat ring wrenches can be fabricated to engage the seat ring lugs and adapted to a standard wrench. If the seat ring is exceptionally resistant to removal, the application of heat or penetrating oil should be helpful.

E. Remove plug (16) and plug stem (1) sub-assembly from the bonnet (8).

CAUTION

CAUTION

Care must be taken to avoid damage to the plug and plug guide.

When using heating devices, ensure that proper safety practices are observed. Flammability and toxicity of the process fluid must be considered and proper precautions taken.

F. Remove old packing (6) [and optional lantern ring (7) if a leak detection connection has been installed]. Refer to Figure 5. Instructions EH21000 - 09/10 21000 Series Control Valves

G. Remove old packing (6) [and optional lantern ring (7) if a leak detection connection has been installed]. Refer to Figure 5.

3

7.2 Bushing Removal The bushing (12) is press fit into the bonnet and does not normally require replacement. If necessary, it may be pulled or machined out. When machining the bushing out, care must be taken to maintain proper dimensions and tolerances in the bonnet. These will be furnished upon request.

7.3 Lapping Seats

CAUTION Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily for guiding purposes only.

Lapping is the process of working the valve plug against the seat ring with an abrasive to produce a close fit. If valve leakage is excessive, lapping becomes necessary. The plug and seat ring seating surfaces should be free of large scratches or other defects, and the contact surfaces of the seats should be as narrow as possible. This may require dressing both parts in a lathe. The seating surface angle of the plug is 28 degrees and the seat ring is 30 degrees

7. lnsert two or three pieces of packing (6) into the packing box to assist in guiding the stem and plug during lapping. 8. Screw a drilled and tapp ed rod with a T -handle onto the plug stem and secure with a locknut (see Figure 4). Note: As an alternative, drill a hole through a flat steel plate and fasten to the plug stem using two locknuts.

(relative to the centerline axis). A good grade of fine grinding compound is required for the lapping operation.

9. Apply slight pressure on the stem, and rotate the stem in short oscillating strokes (around 8 to 10 times). Repeat this step as necessary.

The compound should be mixed with a small quantity of lubricant such as graphite. This will slow the cutting rate and prevent tearing of the seating surfaces. The amount of lapping required depends on the materials, condition of seating surfaces, and accuracy of machining. lf a short period of lapping does not visibly improve seating, there is usually no advantage in continuing as excessive lapping may result in rough seats. The only remedy is replacement or re-machining of one or both parts. When lapping new plugs and seat rings, begin with a medium fine (240 grit) and finish with a finer grade (600 grit).

Note: The plug should be lifted and turned 90° each time before repeating Step (9). This intermittent lifting is required to keep the plug and seat ring concentric during lapping.

CAUTION

Note: Lapping should produce a line contact area, not the entire surface, due to the difference in seat angles.

Avoid over-lapping as this can cause damage to the seating surface rather than improve leakage performance.

CAUTION

10.After completion of the lapping operation, remove bonnet and plug. The seating area of the seat ring and the plug must be cleaned of all lapping compound in preparationfor reassembly.Do not remove seat ring.

Before lapping, the plug and stem sub-assembly must be concentric. (See pinning operation, section 7.5).

7.3.2 Quick-Change Trim (Figure 13 or 15)

7.3.1 Threaded Trim (Figure 12 or 14)

1. CIean body gasket surface areas.

1. CIean body gasket surface areas. 2. When seat has been removed, ensure that the sealing surface in the body bridge and the threads are thoroughly cleaned. Note: A sealant compatible with the process should be applied sparingly to the seat ring threads and sealing shoulder.

2. Install a new seat ring gasket (15) and insert seat ring (14) in the body. Note: Gasket (15) is temporarily placed to hold the seat ring during lapping. It is imperative to use a new gasket or a test part having the same geometrical characteristics in order to ensure the correct position of the seat ring during lapping.

3. lnstall and tighten seat ring using fabricated wrench used for removal.

This gasket (or similar part) can be kept after lapping for future use.

CAUTION

The gasket used for lapping must not be reused for the body reassembly. 3. Apply lapping compound at several spots equally

Do not over-tighten. Do not strike seat ring lugs directly. This could distort the seat ring resulting in seat leakage.

spaced around the seating area of the seat ring. 4. Insert the cage (13) into the body.

4. Apply lapping compound on the plug at several spots equally spaced around the seating area.

5. lnsert the stem and plug sub-assembly carefully into the body until it is seated.

5. lnsert the stem and plug sub-assembly carefully into the body until it is seated. Instructions EH21000 - 09/10 21000 Series Control Valves

6. Place bonnet (8) on the body and fasten the bonnet to the body using four body stud nuts (10) spaced equally apart. Apply slight pressure and tighten evenly.

6. PIace bonnet (8) on the body.

4

A. Reference Marking on the Plug Stem

CAUTION

Measure the depth of the pilot recess in the plug (Dimension X in Figure 9), and make a reference markon the plug stem at the same distance from the thread.

Ensure that the seat ring (14), cage (13) and bonnet (8) are properly aligned.

Note: While pinning is being performed, care must be taken not to damage the seatingsurface or plug guide. Always use a soft metal or plastic vice jaws with cylindrical features to hold the plug guide area (see Figure 9).

7. Fasten the bonnet to the body using four body stud nuts (10) spaced equally apar t. Apply slight pressure and tighten evenly.

B. Screwing Stem to Plug

CAUTION Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily for guiding purposes only. 8. Insert two or three pieces of packing into the packing box to assist in guiding the stem and plug during lapping. 9. Screw a drilledand tapped rod with a T-handle onto the plug stem and secure with a locknut (see Figure 4). Note: As an alternative, drill a hole through a flat steel plate and fasten to the plug stem using two locknuts. 10.Apply slight pressure on the stem, and rotate the stem in short oscillating strokes (around 8 to 10 times). Repeat this step as necessary.

Hold the plug (with vise jaw assembly) in a vise.

•

Lock two nuts against each other on the end of the new plug stem, and screw the stem solidly into the plug using a wrench on the upper nut.

When properly assembled,the referencemark (see SectionA above) should be flush with the end of the plug guide.

C. Drilling the New Parts • If the plug is already fully drilled (typical for 440 C hardened stainless steel material or solid stellite), then drill the stem to the same diameter (Diameter Cin Figure 9) as the plug shank hole. •

If the plug guide area has a center mark, PIace the plug guide on a V-block and use a suitable drill size to either:

Note: The plug should be lifted and turned 90° each time before repeating Step (10). This intermittent lifting is required to keep the plug and seat ring concentric during lapping.

— Match the hole size in the plug, or — Match Diameter C (see Figure 9) Drill through the plug-stem assembly.

11.After completion of the lapping operation, remove bonnet and internal parts. The seating area of the seat ring and the plug must be cleaned of all lapping compound in preparation for reassembly.

•

If the plug guide area does not have any hole or any center mark,

— Measure Dimension D based on the plugguide diameter

7.4 Lo-dB® PIug (Figure 8, 14 or 15) The procedures used for performing maintenance on a valve equipped with Lo-dB plugs (21700/21800/21900 Series) are the same as those used for Threaded or Quick Change Trim.

CAUTION

and stem diameter (see Figure 9). — PIace the plug guide on a V-block, and make a center mark on the plug guide area using a center punch. — Drill through the plug-stem assembly using a suitable size drill bit. In all cases after drilling: Remove any burrs from the plug guide hole by making a slight chamfer.

Maintenance of the plug should be limited to cleaning of the ports and the procedures defined under Sections 7.3 (Lapping) and 7.5 (Pinning) as required.

7.5 PIug Stem Pinning Plug stem pinning inthe field may be required of r the following: — Replacing existing plug and stem, or — Replacing existing stem only

Replacing Plug and Stem

D. Pinning the Plug-Stem Assembly 1. Select the correct size pin based on the plug guide diameter and stem diameter (see Figure 9). Apply a small amount of grease on the pin and hand assemble it into the hole in the plug. 2. Press fit the pin into the hole using a hammer. Complete the pinning operation by taking care to ensure that the pin is recessed by the same amount at both sides (see Figure 9). 3. After the plug has been pinned, it should be placed in a

If it is necessary to replace the plug, then the plug stem must be replaced at the same time. The srcinal pin hole in an existing stem will not provide the necessary fit, and might seriously impair the strength of the assembly.


•

lathe to ensure it is concentric with the stem. If the assembly is not running true, then the stem should be placed in a collet with the plug guide against it and the plug should be adjusted. Alignment of plug stem can be performed by means of a soft faced mallet.

5

Replacing Existing Stem Only

C. By means of a hooked instrument, remove packing (6) ensuring not to damage the sealing surfaces of the packing box or plug stem.

A. Removing Existing Pin and Stem 1. Place the plug guide on a V-block and use a drift punch to drive out the old pin.

Note: On valves equipped with an optional lubricator connection, the lantern ring (7) must also be removed to gain access to lower packing rings.

Note: If it is necessary to drill out the pin, use a drill bit slightly smaller than the pin diameter.

D. Replace packing rings (6).

2. Hold the plug guide in a vise (see note on opposite side of page). 3. Lock one nut against another at the end of the plug stem. Using a wrench onthe lower nut, unscrew the stem from the plug. The stem is removed by turning it counter-clockwise.

B. Screwing Stem to Plug

Note: Assemble and compress rings one at a time into packing box. The skive cut of each packing ring must be placed about 120 degrees apart. Note: On valves equipped with an optional lubricator connection, refer to Figure 10 for correct amount of rings to place under the lantern ring (7).

Refer to step B of the previous section on “REPLACING

E. Replace packing follower (5) and packing flange (4).

PLUG AND STEM”.

F. Replace and tighten packing stud nuts (3).

C. Drilling the New Stem

CAUTION

PIace the plug guide on a V-block and use a suitable size drill bit to drill the stem (use the hole in the plug as a guide). Note: If the hole in the plug guide has been slightly damaged while removing the old pin, choose a drill bit and a pin with a slightly larger diameter than the normal pin.

Do not overtighten. G. Place valve back in service and only tighten packing as necessary to stop external leakage.

D. Pinning Select the correct size pin based on the plug guide diameter and pin hole diameter. Proceed as described in part D of the previous section, taking care not to damage the plug guide area.

Note: In an emergency, string packing may be used as a temporary repair only. It must be replaced with the correct packing as soon as possible. 7.6.2 Flexible Graphite Rings (Optional - See Figure 6)

7.6 Packing Box (Figures 12 to 15)

Note: Flexible graphite packing rings replacement may require disconnecting the plug stem from the actuator stem and removal of the actuator if rings are not skive cut.

Packing box maintenance is one of the principle actionitems of routine servicing. Tightness of the packing is maintained

A. Remove actuator from the body S/A.Refer to actuator instruction No. ER8788 for a type 87/88 actuator.

by packing compression. Compression is achieved by evenly tightening the packing flange nuts (3) against the packing flange (4). Care must be taken not to over tighten as this could prevent smooth operation of the valve. If all compression is used up and the valve leaks, then new packing is required.

B. Loosen and remove packing flange nuts (3).

Ensure plug stem alignment following the pinning operation.

CAUTION

D. By means of a hooked instrument, remove packing (6) ensuring not to damage the sealing surfaces of the packing box or plug stem. Note: On valves equipped with an optional lubricator connection, the lantern ring (7) must also be removed to gain access to lower packing rings.

Valve must be isolated and the pressure vented before performing packing box maintenance.

E. Replace new packing set (6); first assemble a backup ring (Graphite Filament Yarn braided ring), then the flexible graphite rings (smooth rings), and finally another braided back-up ring (refer to Figure 6).

Proceed as follows : 7.6.1 Braided PTFE with Carbon or Aramid Core (Standard) (Figures 12 to 15)

Note: Assemble and compress rings one at a time into packing box.

Note: The Braided PTFE/Carbon or Aramid packing rings have a skive cut allowing packing replacement without disconnecting the plug stem from the actuator connector or actuator stem.

Note: On valves equipped with an optional lubricator connection, refer to Figure 10 for correct arrangement according to valve size.

A. Loosen and remove packing flange nuts (3).

F. Assemble packing o f llower (5) andpacking flange (4).

B. Lift the packing flange (4) and packing follower (5) up the valve stem.

G. Assemble and tighten packing stud nuts (3).

Note: They may be taped in place to keep them out of the way before proceeding. Instructions EH21000 - 09/10 21000 Series Control Valves

C. Remove packing flange (4) and packing follower (5) from the plug stem.

6

The packing box may be bored or honed oversizeby up to 0.015" (0.38 mm) above the nominal diameter to improve the finish. For instance, a nominal 0.875 " (22.22 mm) packing box may be bored or honed up to 0.890" (22.60 mm) and the LE Packing will still seal properly.

CAUTION Do not overtighten. H. Proceed to appropriate instructions for actuator and valve assembly adjustment.

Packing box must be finished to the bottom of the bore.

I. Place valve back in service and only tighten packing as necessary to stop external leakage.

7.6.3.1.3 Packing

7.6.3 LE ® Packing (Optional - See Figure 7) The Masoneilan LE (Low Emissions) Packing is a high performance packing system capable of containing fugitive emissions well below the specifications of the most severe recommendations. It is also available in a firesafe configuration. The packing isprovided as a set of five pieces. It consists of two adapter rings and three V-rings. An alternating pattern of Perfluoroelastomer (PFE) and long carbon fiber filled Teflon (PTFE) V-rings are used. Applied properly, this packing exhibits very little cold flow (or creep). Consequently, it can effectively prevent fugitive emissions leaks from a control valve. The LE Packing system can directly replace conventional packing, requiring no modification to the control valve or actuator. A spring loaded, two-piece follower assembly is used to maintain a constant load on the packing, and is necessary for thermal cycling applications. As the definition of thermal cycling can vary, and processes are potentially subject to unpredicted thermal gradients, LE Packing is only available with the spring loaded follower. Installation should be performed as detailed in the following paragraphs.

Inspect packing rings. Do not use packing if any nicks or scratches on packing are observed. Check packing and ensure that it is in the proper arrangement (see Figure below). PFE material can be identified by the gloss black molded finish. PTFE material has a dull black machined finish. PTFE - female adapter PFE - V-Ring PTFE - V-Ring PFE - V-Ring PTFE - male adapter

7.6.3.1.4 Spring Loaded Follower The spring loaded follower consists of an upper and lower follower and eight (8) disc springs (see Figure below). The springs are installed inside the lower follower and positioned alternately. The assembly is held together by tape, which must be removed before installation. Scribe Mark

7.6.3.1 Preparation

Upper Follower

Disc Springs

7.6.3.1.1 Stem

Lower Follower

Inspect stem for any nicks or scratches on the surface finish. Reject the stem for any of these reasons as they may damage packing.

7.6.3.2 Packing Installation

Note: A properly etched part number on the stem in the packing area will have no adverse effect on the performance of the packing.

a. The packing must be lubricated with Krytox ® fluorinated grease prior to installation (Krytox GPL206 or equivalent).

Stem finish should be 3-7 AARH (Ra 0,1/0,2).

b. Packing should be lubricated as a set (not individually ) to minimize getting lubricant between the rings.

7.6.3 .1.2 Packing Box Note: Bonnets that have a lube hole or leak detection port are unacceptable for use with the packing arrangement shown in Figure 7.

c. Packing should be lubricated with a generous application to the O.D. and I.D. of the packing set. Note: All exposed surfaces of the packing set must be covered with the lubricant.

CAUTION

d. PFE/PTFE is to be installed as a set. Carefully slide the packing set down the stem. Do not cock or force the packing on the threads.

Packing box should be clean and free of burrs, rust, and any foreign matter.Parts can be cleaned with denatured alcohol.

If the packing set separates while on the stem, do not remove. Continue installing the remaining pieces to put the set back together.

Note: Packing box finish should be 125 AARH (Ra 3,2) or better.


e. Gently press the packing into the packing box. Do not tap the packing down into the box.

7

f. The spring loadedfollower isinstalled on op t of the packing. This follower is installed as an assembly held together by tape. This tape should be removed after assembly . Proper assembly of the packing box will leave the top of the Lower Follower 0.25 - 0.50 inches (6 to 13 mm) above the bonnet. A groove is scribed into the O.D. of the upper follower. The packing flange is tightened evenly until the top of the Lower Follower aligns with the scribe mark (groove) in the Upper Follower. Note: This is the optimum loading for this packing. Further tightening will shorten life of the packing. Thread locking compound can be used on packing nuts. g. The packing should be checked for leakage. h. Packing load should be checked after the valve has cycled approximately 500 times. Adjust if necessary. No further adjustment should be required for the life of thepacking.

7.7 Soft Seat Plug (Figure 3)

For 3/4"- 2" valves : a. Place new insert on shank and insert retainer as shown in Figure 3. b. lnstall plug tip intoshank sub-assembly.Hand tighten and ensure plug tip seats evenly against insert. For 3" - 8" valves: a. Apply a light coat of lubricant tothe O-ring and install on insert retainer.

CAUTION Ensure any lubricant used is compatible with service conditions. b. Install new insert on insert retainer and assemble as shown in Figure 3. c. Install plug tip into insert retainer sub-assembly insuring the plug tip seats evenly on the insert. F. Carefully place the plug sub-assembly into a soft jaw vise, holding the plug by the flats provided on the upper end of the shank.

The soft seat plug used in the 21000 Series valve has a replaceable insert. To remove and replace the insert, proceed as follows.

CAUTION

CAUTION The shank OD is the plug guide. Extreme care must be taken to prevent scoring or marring this surface. Failure to do so could result in damage to the guide bushing and destruction of the plug. Two flats are provided for holding.

When using a vise to hold the plug, extreme care must be taken not to damage the plug shank. G. Using the appropriate tool used during disassembly, firmly tighten the plug tip.

A. Loosen set screw until the head of the set screw is flush with the OD of the shank.

CAUTION

Note: On 3/4"- 2" size valves, the plug tip has a machined slot into which a bar can be inserted for removal. On 3"- 6" size valves, the plug tip has two machined holes into which a tool (fabricated with appropriate size pins) can be inserted for removal.

The plug tip must be tightened, allowed to set for approximately 4 hours, re-tightened, allowed to setanother 4 hours, then tightened one more time. The purpose of this tightening sequence is to allow the insert material to “cold flow” into place on theplug sub-assembly.

B. Carefully place plug sub-assembly into a soft jaw vise, holding the plug by the flats provided on the upper end of the shank.

H. Following the above tightening sequence, securely tighten the set screw down into the plug. Plug is ready for assembly into the valve.

CAUTION

8. Valve Body Reassembly After completion of the required maintenance, the valve should be reassembled using the following procedures:

When using a vise to hold the plug, extreme care must be taken not to damage the plug shank.

Note: If any of the following steps were completed during maintenance, then proceed to the next step.

C. Using the appropriate tool, unscrew plug tip (counterclockwise) from the shank sub - assembly.

8.1 Threaded Trim (Figure 12 or 14)

D. Remove insert O-ring (for valve sizes 3"- 8" only) and insert retainer. Discard existing insert and O-ring.

A. CIean all gasket mating surfaces.

E. Thoroughly clean all remaining metallic components and install new insert and O-ring as follows (according to valve size):

B. Apply a small amount of sealant to the seat ring threads and sealing shoulder. Install seat ring into valve body. Note: A sealant compatible with the process should be applied sparingly. C. lnstall and tighten seat ring using wrench used for removal.


8

E. Install body gasket (11).

CAUTION

F. Assemble bonnet (8) and body stud nuts (10) and tighten. Bonnet must be positioned so the packing flange studs are at 90° to the flow center line.

Do not over-tighten. Do not strike seat ring lugs directly. This could distort the seat ring resulting in unwarranted seat leakage.

CAUTION

D. Carefully install plug and stem assembly. Note: Valve should be lapped before final assembly. See Section 7.3. E. Install body gasket (11). Note: Spiral wound body gaskets (11) are standard in the 21000 Series design. It is imperative that a new gasket be installed each time the valve is disassembled.

Care must be taken to ensure that the cage, seat, and bonnet are properly aligned in the body. Cage should be installed with parts at lower end, near seat r ing. Tighten nuts (10) until metal to metal contact is obtained with proper bolt torque. Refer to Figure 11 for proper bolt torque and tightening sequence specifications. G.lnsert packing (6)

F. Assemble bonnet (8) and body stud nuts (10). Bonnet must be positioned so the packing flange studs are at 90° to the flow center line.

[and lantern ring (7) on valve

equipped with an optional lubricator or leak detection connection]. Refer to Section 7.6 for proper packing assembly procedure for standard or optional designs. H. Install packing follower (5) and packing flange (4).

CAUTION

I. Install packing flange stud nuts (3).

Tighten nuts (10) until metal to metal contact is obtained with proper bolt torque. Refer to Figure 1 for proper bolt torque and tightening sequence specifications.

CAUTION

G. lnsert packing (6)[and lantern ring (7) on valve equipped with an optional lubricator connection]. Refer to Section 7.6 for proper packing assembly procedure for standard or optional designs. H. Install packing follower (5)and packing flange (4).

Do not overtighten (See Section “7.6. Packing Box”). J. If a leak detection connection was installed, connect it on the lateral NPT port in the bonnet. If not, ensure that the 1/4" NPT plug remained in place (Figure 5). K.For actuator assembly and plug stem adjustment, proceed to the actuator instruction No. ER8788 for a type 87/88 multispring actuator.

I. lnstall packing flange stud nuts (3).

8.3 High Pressure & Angle Design (Figures 16 & 17)

CAUTION

Standardtrim is used within these optionalbody configurations. Refer to the applicable sections within this instructions manual.

Do not overtighten (See Section “7.6. Packing Box”).

9. Actuators

J. If a leak detection connection was installed, connect it on the lateral NPT por t in the bonnet. If not, ensure that the 1/4" NPT plug remained in place (Figure 5).

9.1 Types 87/88 Actuators Refer to Instruction No. ER 8788 for removal, maintenance, assembly and adjustment.

K.For actuator assembly and plug stem adjustment, proceed to the actuator instruction No. ER8788 for a type 87/88 actuator.

10.Bellows Seal Assembly

8.2 Quick-Change Trim (Figure 13 or 15) A. CIean all gasket mating surfaces.

CAUTION

B. Install seat ring gasket (15) and seat ring (14). Note: Spiral wound gaskets (11 & 15) are standard in the 21000 Series design. It is imperative that a new gasket be installed each time the valve is disassembled.

SINCE THIS IS A SEALING BELLOWS, THE PLUG STEM SHOULD NEVER BE TURNED UNDER ANY CIRCUMSTANCES.

C. Install cage (13). D. Carefully install plug and stem assembly. Note: Valve should be lapped before final assembly. See Section 7.3. Note: For 2" valves with Cv 30 Lo-dB / Anti-Cavitation trim only, steps C and D must be reversed such that the plug and stem assembly is installed prior to the cage. Instructions EH21000 - 09/10 21000 Series Control Valves

9

There is a built-in anti-rotation feature, consisting of a double flat surface machined on the plug stem that slides into a rectangular slot machined in the upper bushing (30) of the bellows (see Figure 19 - Section a). IT IS IMPORTANT TO DISCONNECT THE ACTUATOR FROM THE VALVE BEFORE CHANGING THE ACTUATOR ROTATIONAL POSITION.

T-Handle Figure 2 - Typical Installation Lock Nut

Shank

Skirt & Insert Retainer

Flats

Flats Set Screw

Set Screw

Insert Retainer Insert

Plug Tip 3 /4" -

2 " V al ve Si ze s

Plug Tip O-ring

3" - 8 " V al ve Siz es

Figure 4 - Seat Lapping Device

Figure 3 - Soft Seat Plugs (Optional)

Braided Back-up Rings

Flexible Graphite Rings

Figure 6 - Flexible GraphiteRings Arrangement(Optional)

Figure 5 - Lubricator Connection(Optional)

Figure 7 LE® (Low Emission) Packing Arrangement (Optional)


10

Figure 8 Lo-dB (Type 21900) and Anti-cavitation (Type 21800) Double Stage Trim (Optional)

D

Cylindrical machining diameter of the jaws = plug guide diameter “A”

C Dia.

X

X

B

A

Reference Mark

=

=

Plug Guide Plug Stem Dia. “A” Dia. “B” in.

mm

Pin Hole Dia. “C”

in.

mm

in.

.87

22.22

1/2 12.70 .138

3.50

1.50 38.10

1/2 12.70 .138

2.38 60.32

3/4 19.05 .197

2.75 69.85

3/4 19.05 .197

“D”

mm

in.

mm

“X” in.

mm

1.25 32

.50

13

3.50

1.25 32

.50

13

5.00

1.88 47.5

.75

19

5.00

1.88 47.5

.75

19

Soft metal or plastic vise jaws

Figure 9 - Plug Stem Pinning

Packing box with Kevlar/PTFE packing rings

Packing box with Flexible Graphite packing rings and Back-up rings

Quantity of Packing Rings (6)

Valve Size

Braided Back-up Rings

in.

mm

3/4 to 4

20 to 100

6

6

150 to 200

7

7

Total

Total Flexible Graphite Rings

Lantern Ring (7)

6 to 8

Lantern Ring (7)

Figure 10 - Packing Ring Arrangements with Optional Lubricator Connection


11

Assembly Torque Requirements Valve Size inch

mm

Qty. 150 300 &

.75 &1

20 & 25

4

4

600

8

66

125 25

1/2"-13NC-2A

169

5

45 5

89

5

407

30

40

2500

8

7/8"-9NC-2A

100

136

300

407

30

50

2500

8

1-1/8"-7NC-2A

160

217

640

868

60

3

80

600

8

900&1500

100

8

600

6

150

8

200

5/8"-11NC-2A

45

61 125

5/8"-11NC-2A 12

150 600 -

230

10

1125

132

20 75

179 560

81 14

312

830

169

27 102

10

14

759

45

61

542

2100

2847

115

156

45

61

132

179

10

14

125

1-1/4"-8NC-2A

179

41

400

1"-8NC-2A

12

108 305

1-1/2"-8NC-2A

12

600

80

132

225

1"-8NC-2A

8

150 & 300

61

1-1/8"-8NC-2A

8

900&1500

45

3/4"-10NC-2A

8

150 300 & 4

5/8"-11NC-2A

7 41

2

6

61 7

1.5

150 300 &

7 61

759

300

N.m 7

45

89 66

136

5 89

560

34

100

Lbs.Ft

759

66

25

7/8"-9NC-2A

66 560

34

Pre-Load

N.m 89

34 169

1"-8NC-2A

8

Lbs.Ft

34

125

1/2"-13NC-2A

Maximum

N.m

25

1"-8NC-2A

8

900 & 1500

25

1/2"-13NC-2A

4

2500 40 & 50

Lbs.Ft

1/2"-13NC-2A

600 900 1500 &

Minimum

Size(inch)

4

150 300 & 1.5 &2

Torque Requirements

Bolting Requirements

ANSI Class

169

235

560

319

759

1200

1627

45 100

61 136

Notes: 1. Do not exceed Maximum Torque values listed. 2. Tighten in increments until required torque levels are reached. 3. Reject assembly if metal-to-metal contact is not achieved after reaching Maximum Torque. 4. Torque requirements shown are for standard B7 studs and 2H nuts.

Bellows Bonnet Assembly Torque Requirements Torque Requirements Bolting Requirements Qty.

Minimum

Size(inch)

Lbs.Ft

Maximum

N.m

Lbs.Ft

Increments

N.m

Lbs.Ft

Pre-Load

N.m

Lbs.Ft

N.m

8

1/2"-13NC-2A

20

27

30

41

5

7

5

7

8

5/8"-11NC-2A

25

34

55

75

10

14

5

7

Notes: 1. Do not exceed Maximum Torque values listed. 2. Tighten in increments noted until required torque levels are reached. 3. Torque requirements shown are for standard B7 studs and 2H nuts.

1

1

1 8

6 3

4

4 4

3

5 6

2

12

5

2

7 2

1

5

8

9

10

7

3 4

3

6

2

11

Figure 11 - Bolting Torques and Tightening Sequence


12

Figure 13 Figure 12 Threaded Seat Ring - Contoured Plug - Full Capacity Quick Change Trim - Contoured Plug - Full Capacity

Figure 14 Threaded Seat Ring - Lo-dB Plug

Figure 15 Quick Change Trim - Lo-dB Plug

PARTS REFERENCE Ref. 1 2 3 4 5

Part Name

Ref.

Plug Stem Packing Flange Stud Packing Flange Stud Nut Packing Flange Packing Follower

6 Packing 7 Lantern Ring (optional) 8 Bonnet Recommended spare parts

Part Name

9 Body Stud 10 Body Stud Nut 11 Body Gasket 12 Plug Guide Bushing (Incl. w/ref. 8) 13 Cage * 14 15 16

Seat Ring Seat Ring Gasket * Plug

* Only on Quick Change Trim


13

Ref.

Part Name

17 Plug Pin 18 Body 19 Drive Nut

Figure 17 - Angle Body Design 3/4" to 6" Valve Sizes ANSI Class 150 to 600 3/4" to 2" Valve Sizes ANSI Class 900 to 2500

Figure 16 - 21000 Series 3/4" to 2" Valve Sizes ANSI Class 900 to 2500

10.1 Bellows Valve Disassembly (Figure 19)

•

Note: Spiral wound gaskets are standard in the 21000 BS Series design. IT IS RECOMMENDED THAT NEW GASKETS ARE INSTALLED EACH TIME THE VALVE IS DISASSEMBLED.

CAUTION

10.1.1 T hreaded Trim After removing the actuator, disassemble the body S/A using the following procedure: •

Remove stem bellows S/A (30) by the top of the bonnet extension (29). If necessary, disengage the upper bushing of assembly (30) using a screwdriver in the groove provided for this purpose.

Be careful not to damage the seating surfaces of the bellows bushing.

Disconnect the leak-off circuit from the bonnet (if this option is included). Remove nuts (27) and bonnet studs (26) from the bonnet (25).

•

Remove the bonnet and spacer gaskets (28) and the body gasket (11).

•

Bonnet extension (29), plug (16), guide bushings and seat ring (14) may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate section of these instructions.

•

Remove packing flange stud nuts (3), packing flange (4) and packing follower (5). Remove bonnet (25).

•

Remove existing packing (6).

•

Remove body stud nuts (10).

•

Remove bonnet extension (29), stem bellows S/A

10.1.2 Quick-Change Trim

(30) and plug (16) at the same time. Remove the plug pin (17), then remove the plug (16) from the plug stem (30). (See section 10.2.1.1 for unpinning the plug stem).

Removal of the quick-change trim is accomplished using the same procedures as removal of the threaded trim.

•


14

However, after the bonnet extension (29) has been removed from the body, remove the cage (13), the seat ring (14) and the seat ring gasket (15).

10.2 Repair

10.2.1.3 Plug Stem Pinning

The purpose of this section is to provide recommended maintenance and repair procedures. These procedures assume the availability of standard shop tools and equipment.

Replacing Plug and Stem/Bellows S/A

10.2.1 Plug/Stem Bellows/Bonnet Extension S/A Plug stem pinning in the field may be required for: •

Replacing existing plug and stem-bellows S/A

•

Replacing stem-bellows S/A only

A. Screw Stem into Plug – Lock two nuts against each other on the end of the plug stem and use a flat spanner on the upper nut to prevent rotation of the stem-bellows S/A. Screw the plug onto the lower part of the stem while inserting the plug shank into the guide bushing (12) in the bonnet extension (29).

If the plug needs replacing, the stem-bellows subassembly should be replaced at the same time.

– Pull and hold the plug (16) out of the bonnet extension (29) to allow access to the plug pin 17). (

The srcinal pin hole in a stem which is being reused sometimes prevents a satisfactory result being obtained and can also weaken the plug-stem assembly.

B. D rilling the New Parts •

(typical for 440C hardened stainless steel material or solid stellite), then drill the stem to the same diameter (Diameter C in Figure18) as the Plug Shank Hole.

If the stem-bellows sub-assembly is being replaced, the new assembly can be fitted on an existing plug as long as it is in good condition and the removal of the pin has not deformed the hole or damaged it in any other way. •

Note: Always use soft metal vise jaws to hold the plug guide surface. Failure to take this precaution could result in damage to the plug guide surface during pinning (see Figure 18).

– Match the hole size in the plug, or – Match Diameter C (see Figure 18), – Drill through the plug-stem assembly.

10.2.1.1 Unpinning the Plug Stem

•

Pull and hold the plug (16) out of the bonnet extension (29) to allow access to the plug pin (17). Place the plug guide on a V-block. Note: A lower mechanical stop has been provided to prevent damage of the bellows during this step.

•

Using a drift punch, drive out the existing pin (17). Note: If it is necessary to drill out the pin, use a drill bit slightly smaller than the pin diameter. Be careful not to damage the hole of the plug guide.

•

If the plug guide area has a center mark, Place the plug guide on a V-block and use a suitable size drill to either:

Be careful not to damage the plug seating surface during pin removal and assembly operations.

•

If the plug is already fully drilled,

If the plug guide area has no hole or any center mark,

– Measure Dimension D based on the plug guide diameter and stem diameter (see Figure 18). – Place the plug guide on a V-block, and make a center mark on the plug guide area using a center punch. – Drill through the plug-stem assembly using a suitable size drill bit.

Lock two nuts against each other on the end of the plug stem, and use a flat spanner on the lower nut to prevent rotation while unscrewing the plug from the stem. The plug is removed by turning it counter-clockwise.

In all cases after drilling: Remove any burrs from the plug guide hole by making a slight chamfer. C. Pinning the Plug-Stem Assembly

•

Remove the two nuts fromthe plugstem. Complete step 10.1.1.

– Select the correct size pin based on the plug guide diameter and stem diameter (see Figure 18). Apply a small amount of grease on the pin and hand-assemble it into the hole in the plug.

•

Inspect the parts and carry out any necessary repairs, then reassemble the stem-bellows subassembly (30) through the upper hole in the bonnet extension (29) (see section 10.2.1.2).

– Press fit the pin into the hole using a hammer. Complete the pinning operation by ensuring that the pin is recessed by the same amount from both sides (see Figure 18).

10.2.1.2 Mounting of the Plug-Stem/Bellows S/A into the Bonnet Extension •

Clean all contact surfaces of the bonnet extension

•

(29) and the plug-stem/bellows S/A. Assemble a new gasket (28) on the upper flange of the bonnet extension.

•

Insert the new stem-bellows S/A through the top hole into the bonnet extension (29).

•

Pin the plug on the stem (See section 10.2.1.3).


Replacing Stem/Bellows S/A Only A. Screw Stem into Plug – Refer to paragraph A of the previous section “REPLACING PLUG AND STEM/BELLOWS S/A .” B. D rilling the New Stem – Place the plug guide on a V-block and use a suitable size drill bit to drill the stem (use the hole in the plug as a guide).

15

Plug Guide Plug Stem Dia. “E” Dia. “F” in. 7/8

mm

in.

mm

Pin Hole Dia. “C” in.

mm

“ D” in.

in.

mm

22.22 1/2 12.70 .138

3.50 1.65 42

.70

18

1 1/2 38.10 1/2 12.70 .138

3.50 2.17 55

1.25

32

2 3/8 60.32 3/4 19.05 .197

5.00 2.75 70

2.00

50

2 3/4 69.85 3/4 19.05 .197

5.00 2.75 70

2.00

50

Cylindrical machining diameter of the jaws = plug guide diameter “E”

Pull plug out of the Bonnet Extension (29) for access to the plug pin

“ L”

mm

29 16

30

17

Lower Mechanical Stop to Protect the Bellows

28

D

=

L

C Dia.

E Dia.

=

Soft metal or plastic vise jaws

F Dia.

Plug and Plug Stem-Bellows S/A Stem Figure 18 - Unpinning and Pinning of t he Plug to Stem

Note: If the hole in the plug guide has been slightly damaged while removing of the old pin, choose a drill bit and a pin with a slightly larger diameter than the normal pin.

Refer to table in Figure 11 for proper bolt torque and tightening sequence.

10.5 Valve Body Reassembly

C. Pinning

Refer to instructions stated in Section 8 for the specific trim type involved.

– Select the correct size pin based on plug guide diameter and pin hole diameter. Proceed as described in Paragraph C above, taking care not to damage the plug guide area.

10.6 Actuator to Body S/A and Plug Stem Adjustment Refer to instruction No. ER 8788.

10.3 Plug and Seat Ring Seating Surfaces It is not possible to lap the plug and seat ring seating surfaces after the bellows has been assembled to the stem. If the seat ring shows signs of minor wear, it should be turned on a lathe to clean up the worn area. The seating surface of the seat ring is 30 degrees from centerline axis. However, no more than 0.010 in. (0.25 mm) of material should be removed. In cases where the seat ring cannot be repaired, or if the plug is also damaged the only alternative is to replace both parts.

10.4 Bonnet Reassembly Place new gasket (28) into the groove of the bonnetspacer. Install the bonnet (25) and assemble nuts (27) and studs (26). Bonnet must be positioned so the packingflange studs are at a 90° angle to the flow centerline.


16

Assembly of the No. 6 actuator on a bellows seal valve requires a three-sectioned coupling. Follow coupling instructions as described for the No. 10, 16 and 23 actuators.

CAUTION The bellows assembly cau ses a “spring back” effect.Measure this plug spring back before referring to Instruction No. ER 8788. Be sure to add this spring back length to the over seat adjustment.

22

2 3 4

19 5 6 25 31

a

a

28 28 Section a

27 26

30

( )

(

)

29 DETAIL OF THE PLUG STEM ANTI-ROTATION DEVICE

9 10 17

11

18

12 13 14

16

15

QuickChangeTrim

ThreadedTrimdetail

Figure 19 — 21000 BS Valve

PARTS REFERENCE Ref.

Part Name

1

Plug Stem 2 Packing Flange Stud. 3 Packing Flange Nut 4 Packing Flange 5 Packing Follower 6 Packing 9 Body Stud 10 Body Stud Nut 11 Body Gasket 12 Guide Bushing 13 Cage 14 Seat Ring Recommended Spare Parts


Ref. 15 16 17 18 19 22 25 26 27 28 29 +

Part Name

Ref.

Seat Ring Gasket Plug Plug Pin Valve Body Drive Nut Plug Stem Locknut Valve Bonnet Bonnet Stud Bonnet Stud Nut Bonnet Spacer Gasket Bonnet Extension Assembly Upper Flange

+ These parts included in welded subassembly

17

+

Part Name

Spacer + Lower Flange 30 Bellow and Stem Assembly + Stem Guide Bushing + Bellows + Upper Adapter (Bellows) + Lower Adapter (Bellows) 31 1/8" NPT Plug

Quick change trim only


ITALY Phone: Fax:

+39-081-7892-111 +39-081-7892-208

BRAZIL Phone: Fax:


+81-43-297-9222 +81-43-299-1115

CANADA Ontario Phone: +905-335-3529 Fax: +905-336-7628

KOREA Phone: Fax:

+82-2-2274-0748 +82-2-2274-0794

CHINA

MALAYSIA

Phone: Fax:

+55-11-2146-3600 +55-11-2146-3610

+86-10-8486-4515 +86-10-8486-5305

FRANCE Courbevoie Phone: +33-1-4904-9000 Fax: +33-1-4904-9010 GERMANY Viersen Phone: +49-2162-8170-0 Fax: +49-2162-8170-280 INDIA Mumbai Phone: Fax: New Delhi Phone: Fax:

+91-22-8354790 +91-22-8354791







+60-3-2161-0322 +60-3-2163-6312


+52-5-310-9863 +52-5-310-5584

SPAIN Phone: Fax:

+34-93-652-6430 +34-93-652-6444





Fax: +1-281-671-1735 California Phone: +1-562-941-7610 Fax: +1-562-941-7810

+91-11-2-6164175 +91-11-5-1659635

About Dresser, Inc.


Dresser Inc. is a global leader in providing highlyengineered infrastructure products for the global energy industry. Leading brand names within the Dresser portfolio include Dresser Wayne® retail fueling systems, Waukesha® natural gas-fired engines, Masoneilan® control valves, Consolidated ® pressure relief valves, and ROOTS ® blowers and rotary gas meters. The company has manufacturing and customer service facilities strategically located worldwide and a sales presence in more than 150 countries. www.dresser.com




EH21000 09/10

www.dresser.com

ns r uc o n s

Masoneilan Models 496-1 and 496-2 Rotary Electric Switches Instructions

09/96

description and operation Series 496 switches may be mounted on the CamflexII rotary valves (35002 Series) or Varimax (30000 Series), Control BallII valves (36002 Series), butterfly valves as MiniTork II (37002 Series) or HPBV (39002 Series) valves.

Description (Figure 2) Series 496 rotary switches are used for electrically indicating one or two predetermined positions in the stroke of a control valve. They may be connected to audible alarms or signal lights for warning of valve or system malfunction. These switches may also be used to actuate solenoids, relays and other electrical devices.

Also, they may be used on valves as the 11000, 21000 and 41000 Series and all other linear motion valves. A parts list for the Series 496 switch appears in page 4.

Basic switches (4) in the unit are single pole, double throw snap acting and are individually adjusted by cams (13) on the rotating shaft (11). Vernier adjustment is made by means of locking type set screws (Nylock) (2) in the cams and these screws actuate the switches by contacting the switch spring levers (5).

Operation (Figure 2) The motion of the control valve turns (by means of a linkage the switch shaft (11). Cams (13), fastened to the shaft by screws (1), actuate microswitches (4) by pushing levers (5).

The spring levers provide overtravel protection and allow maintained contact when required. The series 496 is available with either one or two switches, each with an adjustable cam to actuate it.

Each switch may be wired to either open or close the circuit when the lever is depressed.

The housing and cover are of anodized aluminum, epoxy painted.

NUMBERING SYSTEM OF THE 496 SERIE

496 Instrument Type

1st

2nd

Protection

1. Mechanical switch with one singlepole, double throw contact arrangement

55. Weatherproof (E)

2. Mechanical switch with two single poles, double throw contact arrangement

environment (E) 57. Explosionproof and weatherproof (E) 58. Intrinsically safe and weatherproof (E)

3. Potentiometric Position Transmitter 4. Electronic switch with one proximity

detector 5. Electronic switch with two proximity detectors 6. Mechanical switch with one double pole, double throw contact arrangement 7. Mechanical switch with two double poles, double throw contact arrangement 8. Optoelectronic Position Transmitter

3rd

Additional Switch* (if any) 1. Mechanical switch with one single pole,

double throw contact arrangement

56. Weatherproof, oxygen

2. Mechanical switch with two single poles,

double throw contact arrangement 4. Electronic switch with one proximity

detector

5. Electronic switch with two proximity

detectors

These two digits are used only when European standards are concerned.

6. Mechanical switch with one double pole,

Otherwise the instrument is explosionproof and weatherproof (US)

7. Mechanical switch with two double poles,

E= European standards

double throw contact arrangement double throw contact arrangement *

This digit and its oblique bar is only used when the transmitter is provided with an auxiliary switch

Caution: Electrical protection of some of the above mentioned equipment combinations, can be not in accordance with all protection standards. Consult Masoneilan.

2

installation and adjustments The cable entry is also available in 3/4”NPT threaded connection form. This can be designed to answer most of the customer requests.

Installation Electrical Protection

Each microswitch has three terminals (“common”, “normally open” and “normally closed”), (See Figure 3). Electrical rating of switches is stamped on serial plate.

The microswitches and other parts are protected by a flameproof housing EN 50014 & 50018

EExdIICT6 (ambient temperature EExdIICT5 (ambient temperature

≤ ≤

The installation in hazardous locations should be according to the regulations in force concerning

70°C) 80°C)

flameproof material.

Beside, a tight degree up to IP65 following to standard CEI 144 and IP657 following to standard NFC20.010 is ensured by the O-rings (7& 10) locat ed between body and cover and on the switch shaft.

Coupling

The coupling of the switch shaft to the valve is made by means of a back lever and a motion linkage proper to each valve configuration. The back lever is fastened to the switch shaft (11) with a washer and a hex. head screw. Figures 3 to 6 show install ation details on the various valves.

in tr in s ic Installation of the rotary limit switches into according to following European standards (CENELEC):

safety circuit

EN 50014 & 50020

EExiaIICT6 (ambient temperature –55°C +80°C) Note : The load must be controlled through a certified transistorized relay located outside the hazardous area.

Electrical Connection-Wiring (Figure 1)

A cable entry is integrated at the bottom of the housing and includes a cable clamping device. Dif ferent leakproof packings allow the adaptation of diameters of unarmed cables from 6 to 15mm.

Figure 1 Wiring Diagram and Dimensions for Mounting

3

This assures that when the valves is throttling, the screw (2) is completely free of the lever. The concave part of the lever is only to maintain contact the cam during over-travel (if any). Similarly,

Adjustments The Series 496 switch is normally mounted and adjusted on a control valve at the factory. To adjust the instrument in the field, proceed as follows: 1.

operating the left -hand switch shou ld make con tact with lever (5) only at the end o fa clockwise rotation. (Refer to face view of the

The concave part of the levers (5) shou ld be exactly concentric with th e cams (13 ) when the switch is actuated.

Figure 2). If there is only one switch (Model 496-1) it may be necessary to reverse the position of the switch from left to right or vice versa depending on the rotation and stroke position.

This is an important step to assure that once the lever is depressed, it stays depressed when the screw (2) is completely free. If not, loosen screws (3 and 17) and slide the levers up or down slightly. Tighten screws.

5. Turn the c am (1 3) on the sh aft un til th e swit ch is activated. (If the click switch cannot be heard, use a voltmeter). Lock the cam (13) with screw (1). 6. Make a fine adjustment with screw (2) using a 1 /16” Allen wrench. The screw (2) must extend out from the cam far enough to assure sufficient depression of lever (5).

2. Unscrew slightly the cam locking screws (1) using a 3/32” Allen wrench. 3. Actuate the valve to the desired position (usually the full opened or full closed position). 4. It is important to note that

the cam operating the right- hand switch sh ould make contact with lever ( 5) only at the end of a coun terclockwise rotation. (Refer to detail of the Figure 2).

Contact point for left switch

Figure 2 Cutaway Views of Types 496-1/2 Switches

Contact point for right switch


 

*

1 2 3 4 5 6 7

ParN t am e

Screw Screw Fastening Screw (only one switch) Microswitch Lever Body O-Ring

Ref.



8 9 10 11 12 13 14

ParN t am e

Snap Ring Screw O-Ring Shaft Cover Cam Serial Plate

Ref.

ParN t ame

15 Drive Screw 16 Insulator 17 Fastening Screw (second switch on 496-2) 18 Washer *19 Spacer (Not shown)

Recommended Spare Parts Only on 496-2 Model

4

Mounting arrangements 6. Mount switc h (1) on bra cket ( 3) using th e four cap screws (4) and the four hex. nuts (8).

On 35002 Series Camflex II Valves (Figure 3):

1. Remove shaft cover, or if equipped with a positioner, remove positioner and mounting plate.

7. For 3” (80mm) valve and larger, slip slotted bottom cover (2) over the lever (10) and push in place.

2. Remove bottom cover (2).

8. Place slotted end of the back lever (9) over pin (12) of the switch lever (10). Secure with washer (13) and clip (14).

3. Insta ll mo untin g bra cket ( 3) us ing tw o fla t head screws (7). 4. Screw pin (12) to switch lever (10).

9. Attach the back lever (9) to the switch shaft using lock washer (5) and cap screw (6).

5. Remove cap screw (11) from switch lever (10) and slide switch lever onto shaft, behind the main lever of the valve. Position switch lever (10) in line with main lever. Replace and tighten cap screw (11).

10. Refer to pages 3 & 4 to proceed with wirin adjusting switches.

g and

CamflexII Valve Opening by Air Failure

Valve

Valve

The linkage parts are shown WHEN NO SUPPLY PRESSURE ON ACTUATOR

CamflexII Valve Closing by Air Failure

Figure 3 35002 Serie Camflex II Valve

On valve size


1 2 3 4 5

ParN t ame

496 Rotary Switch Bottom Cover Mounting Bracket Cap Screw Lock Washer

Ref.

6 7 8 9 10

ParN t ame

Cap Screw Flat Head Screw Hex. Nut Back Lever Switch Lever

5

Ref.

ParN t am e

11 12 13 14

Cap Screw (Switch Lever) Lever Pin Washer Retaining Clip

≥

3”

4. Install the m ounting bracke t (3) by mea ns of the spacer (15) and the two flat head screws (7). 5. Mount switc h (1) on bracket (3) using t he fou r cap screws (4) and the four hex. nuts (8).

On 30000 Series Varimax Valves (Figure 4):

1. Remove shaft cover, or if equipped with a positioner, remove positioner and mounting plate.

6. Attac h the back l ever ( 9) to the sw itch sh aft using lock washer (5) and hex. head screw (6).

2. Screw the i ndex- screw (17), with i ts lo ck was her (18), into one of the two threaded holes of the switch lever (10).

7. Connect the back lever (9) to the switch lever (10) by means of link (20), two driving pins (12), four washers (13) and two retaining clips (14). 8. Refe r to pa ges 3 & 4 to pr ocee d with wiri ng an d adjusting switches.

Note : T he h ead of the index-screw (17) will be engaged in the slot located on the valve shaft end to ensure the proper position of the switch lever (10). The proper hole to the used con guration can be easily identi ed referring to the below Figure 4 and presenting the lever in the shown position.

3. By means of the hex. head screw (19), fit the switch lever (10) on the valve shaft end in the proper position relating to the valve operating way.

Varimax Valve Opening by Air Failure


Varimax Valve Closing by Air Failure

Figure 4 30000 Series Varimax Valves

Ref.

1 3 4 5 6 7

ParN t am e

496 Rotary Switch Mounting Bracket Cap Screw Lock Washer Hex. Head Screw Flat Head Screw


8 9 10 12 13 14

ParN t am e

Hex. Nut Back Lever Switch Lever Lever Pin Washer Retaining Clip

6

Ref.

ParN t am e

15 17 18 19 20

Spacer (Mounting Bracket) Index-screw (Switch Lever) Lock Washer Hex. Head Screw Link

6. Install front cover. 7. Insta ll mou nting plate (3) u sing t he two flat h ead screws (1). 8. Moun t swit ch (2) to pla te (3) usin g the f our h ex. head screws (5) and four nuts (12). 9. Assemble back lever (14) to the switch shaft using cap screw (15) and lock washer (16). 10. Replace the bottom cover (4 ) having proper holes. 11. Screw the clevis (11) on the turnbuck le (10). Rotate clevis to equalize the length of two engaged threaded ends. 12. Insert the clevis (11 ) through the prope r hole of bottom cover (4) and connect to back lever (14)

On 36002 Series Ball II, 37002 Series MiniTork II and 39002 Series HPBV Valves (Figure 5):

1. Remove shaft cover, or if equipped with a positioner, remove positioner and mounting plate. 2. Remove plastic panels for access, bottom, front and sides. 3. Admit supply pressure on actuator until the actuator pivot pin (8) is in intermediate position, such that every load is removed from the pin. 4. Remove existing pivot pin and install special pin (8) with switch mounting pivot pin. 5. Assemble take off link (6), locknut (9) and turnbuckle (10), without tighten. Slide assembly over pivot pin (8) and push on retaining clip (7).

(13) andonretaining 13. using Admit clevis suppl pin y pressure actuatorclip unt(7).il the travel indicator is on mid-stroke position. Turn the turnbuckle one way or another until the back lever (14) is parallel to bottom cover (4). Lock the locknut (9). Replace the side covers. 14. Refer to pages 3 & 4 to proceed with wiri ng and adjusting switches.

Ball II and MiniTork II Valves Opening by Air Failure

HPBV Valves Closing by Air Failure


Ball II and MiniTork II Valves Closing by Air Failure

HPBV Valves Opening by Air Failure

Figure 5 36002 Series Ball II Valves 37002 Series MiniTork II Valves 39002 Series HPBV Valves


1 2 3 4 5 6

ParN t ame

Flat Head Screw 496 Rotary Switch Mounting Bracket Bottom Cover (Actuator) Hex. Head Screw Take Off Link

Ref.

7 8 9 10 11 12

ParN t ame

Retaining Clip Pivot Pin (Actuator) Locknut Turnbuckle Clevis Hex. Nut

7

Ref.

ParN t am e

13 14 15 16

Clevis Pin Back Lever Hex. Head Screw Lock Washer

On No 37 and 38 Spring Diaphragm Actuators (Figure 6):

The back lever (9) is fastened to the end of the switch shaft with spring washer (15) and cap screw (17).

The 496 switch is rigidly mounted on the spring barrel of the diaphragm actuator by means of a bracket (7) fastened to the mounting pad with cap screws (8).

The turnbuckle (6) must be adjusted before adjusting the switches. Apply air pressure to the actuator until the actuator stem has traveled exactly half the rated stroke. Loosen locknut (5) and turn the turnbuckle (6) until the back lever (9) is level. Tighten lock nut (5), then proceed with wiring and adjusting switches according to instructions on pages 3 & 4


On Type 38 Actuator With Stem Extracting by Air Failure

n Type 37 Actuator With Stem Retracting by Air Failure

Actuator

Actuator

Valve

FASTENING OF THE CLAMP ROD

(Right Hand

Actuator Coupling FASTENING OF THE CLAMP ROD

Figure 6 No 37 and 38 Spring Diaphragm Actuators

Valve


1 2 3 4 5 6

ParN t ame

Clamp Clamp Screw Turnbuckle Screw Locknut Turnbuckle

Ref.

7 8 9 10 11 12

ParN t ame

Mounting Bracket Hex. Head Screw Back Lever Clevis Retaining Clip Clevis Pin

Ref.

ParN t am e

14 15 16 17 18

Hex. Head Screw Lock Washer Washer Hex. Head Screw Clamp Rod

4, place de Saverne - 92971 PARIS LA DÉFENSE CEDEX-Tel. (01)49 04 90 00-Telecopier (01)49 04 90 10-Tele x 620046F FRANCE PLANTS, SPARE PARTS and AFTER SALES DEPARTMENTS: 3, rue Saint–Pierre–14110 Condé–sur–Noireau Tel. 02 31 69 59 00-Teleco ier 02 31 69 38 44-Telex 170728F


Model 78 Series Air Filter Regulators

Instruction Manual EY7840 02/10

Product Description

Operation

The 78 Series pressure regulators are compact, lightweight, high-performance pressure reducing valves. They are used primarily for supplying a stable source of air to process control equipment such as current to pneumatic transducers and control valve positioners.

Prior to applying supply pressure, loosen knob lock screw (see figure 1) and turn pressure set knob counterclockwise. Turn on supply pressure. Output pressure should be zero. Slowly rotate set knob clockwise until desired pressure is reached. Tighten knob locking screw to ensure that pressure remains set at desired value. When changing output from a higher tolower pressure, initially go to lower than desired pressure, then increase to desired pressure. Re-tighten knob lock-screw.

Numbering System MODEL NO.

PRESSURE RANGE

78-4

5-40 psi (35-280 kPa), (0.35-2.8 bar)

Air Loading with Relief and Filter

Maintenance

78-40

5-100 (0.35-7 psi (35-700 bar) kPa),

Air Loading with Relief and Filter

vals to drain any fldraining uid that will mayhave havetocollected in thedripwell. The interval between be determined based on the actual rate of accumulation of fluid.

DESCRIPTION

Specifications

It is recommended that the drain cock be opened at regularinter-

WARNING

Inlet Pressure Rating

210 psi (1.5 MPa, 14.5 bar) maximum

Pressure Set Range

5-40 psi (35-280 kPa, 0.35-2.8 bar) 5-100 psi (35-700 kPa, 0.35-7 bar)

Connection

1/4NPT

Rated Cv

0.25

Filter Element

Sintered Porous Polyethylene (5µ)

Ambient Temperature Range

-40° to +83°C (-40° to +182°F)

Air Consumption

0.004 scfm (100 sccm)

Weight

14oz.(0.4kg)

Materials of Construction

See figure 2 and table 2

The relief valve feature should not be confused with any auxiliary safety valve which might be needed for complete protection of air operated equipment. It is intended only to provide more uniform controlled pressure and to permit adjusting the outlet pressure downward without venting the line.

WARNING Prior to performing maintenance on the regulator, shut off the inlet and outlet pressures and remove the spring compression by turning the setting knob fully counterclockwise. Open the drain cock carefully to relieve any retained pressure and drain the dripwell. It is recommended that the regulator be removed from the line for repairs.

WARNING Do not install this Regulator in airlines which exceed 215 psi (1.5 Mpa, 15 bar) pressure.

Installation Clean the lines thoroughly to remove all dirt, scale or other foreign matter before installing the regulator. Install with flow in direction of flow arrows on regulator body. The airset should be installed with the drain cock facing down. Regulator should be installed as close as possible to device utilizing the reduced pressure to minimize pressure drop. Do not use piping ortubing smaller than the regulator connections since this will restrict flow and reduce capacity. It is recommended that pressure gauges be installed on the inlet and outlet sides of the regulator as an aid in adjusting the pressure and in monitoring of working pressures.

2 | Dresser Masoneilan

CAUTION When draining the dripwell, open the drain cock slowly and collect the fluid in a suitable container for safe disposal. NOTE: • Considering the high labor costs involved in replacing internal parts, it may be more economical to stockcomplete units. • Care must be taken to avoid damage to the plug and stem assembly.

Troubleshooting If at any time the regulator failsto function properly it is recommended to replace rather than repair the device.

Materials of Construction NO.

PART

STANDARDMATERIAL

1

Body

AluminumDieCasting

2

Spring Casing

Aluminum Die Casting

3

Bottom Cap

Aluminum Die Casting

4

Knob

VALOX420

5

Lock Screw

StainlessSteel

6

Adjusting Screw

Stainless Steel

7

Spacer

VALOX420

8

Spring Button

Zn-Cr Plated Carbon Steel

9

Spring

CoatedSpringSteel

10*

Diaphragm

15

PlugGuide

16*

Plug

17*

Filter

SinteredPolyethylene

18*

Port Spring

Stainless Steel

19*

“O”-Ring

NBR

21

Drain Cock

StainlessSteel

22

Screw

StainlessSteel

23

Pipe Plug

Zinc Plated Carbon Steel

24

Aspirator

VALOX420

25

Nameplate

Aluminum

NBR VALOX420 Neoprene/416StainlessSteel

-

* Recommended Spare Parts

Dimensions

EY7840 / 11/09 / Model 78 Series Air Filter Regulator | 3


ITALY Phone: Fax:

+39-081-7892-111 +39-081-7892-208

BRAZIL Phone: Fax:


+81-43-297-9222 +81-43-299-1115


KOREA Phone: Fax:

+82-2-2274-0748 +82-2-2274-0794

CHINA Phone: Fax:

MALAYSIA Phone: +60-3-2161-0322 Fax: +60-3-2163-6312

SOUTH & AMERICA Phone: Fax:

CENTRAL AND THE CARIBBEAN +55-12-2134-1201 +55-12-2134-1238

MEXICO Phone: Fax:

SPAIN Phone: Fax:

+34-93-652-6430 +34-93-652-6444

+55-11-2146-3600 +55-11-2146-3610

+86-10-8486-4515 +86-10-8486-5305


+91-22- 8354790 +91-22-8354791

+52-5-310-9863 +52-5-310-5584

SAUDI ARABIA Phone: +966-3-341-0278 Fax: +966-3-341-7624 SINGAPORE Phone: +65-6861-6100 Fax: +65-6861-7172 SOUTH AFRICA Phone: +27-11-452-1550 Fax: +27-11-452-6542





UNITED STATES Massachusetts Phone: +1-508-586-4600 Fax: +1-508-427-8971 Corpus Christi, Texas Phone: +1-361-881-8182 Fax: +1-361-881-8246 Dresser Direct Deer Park, Texas Phone: +1-281-884-1000 Fax: +1-281-884-1010 Dresser Flow Technologies Houston, Texas Phone: +1-281-671-1640 Fax: +1-281-671-1735 California Phone: +1-562-941-7610 Fax: +1-562-941-7810

+91-11-2-6164175 +91-11-5-1659635

About Dresser, Inc. Dresser, Inc. is one of the leading providers of reliable,

About Dresser Masoneilan Dresser Masoneilan, headquartered in Houston, Texas,

highly engineered infrastructure products for the global

has been the leading global partner in process control

energy industry. Dresser’s highly regarded portfolio of

valves and solutions for more than 100 years. A business

brands includes Wayne® payment and fueling systems;

segment of Dresser, Inc., the company delivers customized

Waukesha® natural gas-powered engines and generator

products, services and diagnostic solutions for oil

sets, Masoneilan® control valves, Consolidated ® pressure

and gas, process and power generation applications.

relief valves, and Roots® blowers and compressors. With

www.dresser.com

locations worldwide, Dresser, Inc. serves customers in more than 100 countries. www.dresser.com.



www.dresser.com


87/88 Series Spring Diaphragm Actuator

Instruction Manual ER8788 09/10

Table of Contents

Page

........................................................................................1 IMPORTANT: SAFETY WARNING NUMBERING SYSTEM .........................................................................................................2 1.0 INTRODUCTION .............................................................................................................3 2.0 GENERAL .......................................................................................................................3 3.0 ACTUATOR DESCRIPTION...........................................................................................3 4.0 UNPACKING ...................................................................................................................3 5.0 AIR PIPING .....................................................................................................................3 6.0 ACTUATOR REMOVAL ..................................................................................................3 7.0 MAINTENANCE ..............................................................................................................5 8.0 ACTUATOR RANGE .....................................................................................................10 9.0 AIR ACTION CHANGES...............................................................................................14 10.0 VALVE MOUNTING ....................................................................................................18 PARTS REFERENCE TABLES...........................................................................................21


About this Manual

Safety Information

• The information in this manual is subject to change without prior notice.

Important - Please Read Before Installation Masoneilan model 87/88 Series actuator instructions contain DANGER,WARNING, andCAUTIONlabels, where necessary, to alert you to safety related or other important information. Read the instructions carefully before installing and maintaining your control valve. DANGER and WARNING hazards are related to personal injury. CAUTIONhazards involve equipment or property damage. Operation of damaged equipment can, under certain operational conditions, result in degraded process system performance that can lead to injury or death. Total compliance with all DANGER, WARNING, and CAUTIONnotices is required for safe operation.

• The information contained in this manual, in whole or part, shall not be transcribed or copied without Masoneilan’s written permission. • Please report anyerrors orquestions about h t e information in this manual to your local supplier. • These instructions are written specifically for the 36005 Series control valves, and do not apply for other valves outside of this product line.

Warranty Items sold by Dresser ® are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment provided said items are used according to Dresser recommended usages. Dresser, Inc. reserves the right to discontinue manufacture of any product or change product materials, design or specifications without notice.


This instruction manual applies to the Masoneilan 87/88 Series actuator.

The Control Valve MUST BE: • Installed, put into service and maintained by qualified and competent professionals who have undergone suitable training. Indicates a potentially hazardous situation which, ifnot avoided, could result in death or seriousinjury.

• Under certain operating conditions, the use of damaged equipment could cause a degradation of the performance of the system which may lead to personal injury or death. • Changes to specifications, structure, and components used may not lead to the revision of this manual unless such changes affect the function and performance of the product.

Indicates a potentially hazardous situation which, ifnot avoided, could result in serious injury.

• All surrounding pipe linesmust be thoroughly flushed to ensure all entrained debris has been removed from the system. Indicates a potentially hazardous situation which, ifnot avoided, could result in minor or moderate injury.

When used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage. Note: Indicates important facts and conditions.

Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

1

Numbering System 1st DIGIT

2nd DIGIT

8

Actuator Type 87 Air to Close (extend stem) 88 Air to Open (retract stem)


2

1. Introduction

6. Actuator Removal

The following instructions are designed to assist maintenance personnel in performing most of the maintenance required on the Model 87/88 actuator. Masoneilan has highly skilled service engineers available for start-up, maintenance and repair of our actuators and component parts. In addition, a regularly scheduled training program is conducted at the Training Center to train customer ser vice and instr umentation personnel in the operation, maintenance and application of our control valves and instruments. Arrangements for these services can be made through your Masoneilan Representative or Sales Office. When performing maintenance, use only Masoneilan replacement parts. Parts are obtainable through your local Masoneilan Representative or Sales Office. When ordering parts, always include Model and Serial Number of the unit being repaired.

Maintenance on the valve body normally requires removal of the valve actuator. The steps in removal of the actuator are different depending on whether the actuator is air to close or air to open. Note: Actuator action may be checked by referring to the valve identification tag. Model 87 indicates unit is air to close and Model 88 indicates unit is air to open. 6.1 Air to close (Model 87), size 3 (Figure 9), and size 6 (Figure 2), with or without handwheel A. Shut off air supply to actuator and rotate handwheel to the neutral position. [No force exerted on the stem flange.] B. Disconnect air piping from diaphragm case.

2. General These installation and maintenance instructions apply to the Masoneilan Model 87/88 actuator regardless of the valve body on which it is used. Actuator part numbers and recommended spare parts required for maintenance are listed in the Part Reference Table on page 21 and 22. The model number and action of the actuator are shown as part of the model number listed on the identification tag located on the actuator.

C. Check the stem position against the travel scale to ensure that the plug is up (off the seat). Note:No air pressure is required to the actuator since the spring force acts to open the valve. D. Loosen stem lock nuts (1). E. Re-tighten lock nuts (1) against each other so they will lock at a point that is not against the stem fl ange (2).

3. Actuator Description The 87/88 Series is a pneumatic spring diaphragm actuator. The multiple spring design configuration provides four standard spring ranges are achieved by varying spring quantity and placement. A molded rolling diaphragm and deep cases minimize area change, resulting a linear relationship between travel and air pressure.

At this time provisions must be made to support and lift the actuator off the body using recommended lift supports and procedures. F. Loosen and remove drive nut.

For full automatic operation, the handwheel must be placed in the neutral position. Travel will be limited If the handwheel is not in the neutral position.

4. Unpacking Care must be exercised when unpacking the equipment to prevent damage to the accessories and component parts. Should any problems arise, contact your Masoneilan Representative or District Office.

Depending on stem length, it may be required to raise the actuator off the body slightly to enable the plug stem to disengage from the actuator stem. The actuator must be raised straight off the body to prevent side loading on the plug stem. G. Turn the stem lock nut (1), counterclockwise and loosen the plug stem until it disengages from the actuator stem (10). Note:Do not allow the valve plug to drop or turn against the seat ring, as this could damage the seat and plug.

5. Air Piping

H. Remove actuator from the valve body.

The Model 87/88 actuator is designed to accept 1/4" NPT air supply connections. Accessories supplied with the actuator are mounted and connected at the factory.

Care should be taken in handling the actuator to prevent damage to gauges, tubing, and component parts. Do not exceed pressure indicated on identification tag.


3

6.2 Air to open (Model 88), size 3 and size 6, with handwheel Depending on stem length, it may be required to raise the actuator off the body slightly to enable the plug stem to disengage from the actuator stem. The actuator must be raised straight off the body to prevent side loading on the plug stem.

The stem flange (2) on these size are not fixed to the actuator stem and are loose parts with the plug stem removed. For safety, the handwheel must be in a free position and the actuator removed from the valve using procedure 6.3 Air to Open without handwheel.

H. Turn the upper stem lock nut (1) counterclockwise and unscrew the valve plug stem until disengaged from the actuator stem (10).

6.3 Air to open (Model 88), size 3 (Figure 10) and size 6 (Figure 4) without handwheel Since removal of the valve plug stem from the actuator stem connector requires that the valve plug be off the seat, special provisions are necessary to assure that the valve is in the opened position. Proceed as follows for an actuator without a handwheel.

Note:Do not allow the plug to drop or turn against the seat ring, as this could damage the seat and plug. I. Remove actuator from the valve body and shut off air supply pressure.

Note: Since air supply piping connected to the actuator is normally rigid, it is required that a manual loading panel with suitable flex tubing be used or some suitable type of flex connections be made between the supply piping and the actuator connection to accommodate movement of the actuator.

Care should be taken in handling the actuator to prevent damage to gauges, tubing, and component parts. In addition, since a flex connection is made between the actuator and air piping, care must be taken not to exert pressure on the flex tubing or air piping. 6.4 Air to close (Model 87), sizes 10, 16, and 23, with and without handwheel (Figure 3) A. Shut off air supply to actuator and rotate handwheel to the neutral position.

High stress placed on rigid piping could cause breaking of the air supply line. A flex connector is required.

B. Disconnect air piping from diaphragm case.

A. Shut off air supply to the actuator.

C. Check the travel indicator (7) against the travel scale (9) to ensure that the plug is up (off the seat).

B. Disconnect air supply piping to the actuator.

Note:No air pressure is required to the actuator since the spring pressure tends to open the valve.

C. Connect manual loading panel tubing to the lower diaphragm case or yoke (size 3) tubing connector. D. Apply required air pressure through the manual loading panel to open the valve as is indicated by the stem position relative to the travel scale (9).

D. Loosen stem lock nut (1). E. Remove cap screws (5) from stem connector (2, 4). Note: Do not allow the valve plug to drop or turn against the seat ring, as this could damage the seat and plug.

Do not exceed pressure indicated on the tag (63) on the diaphragm case.

At this time provisions must be made to support and lift the actuator off the body using recommended lift supports and procedures.

E. Loosen stem lock nuts (1). F. Re-tighten stem lock nuts (1) against each other so they will lock at a point that is not against the actuator stem flange (2).

F. Loosen and remove drive nut.

Progressively raise actuator off the body to enable the top stem connector (4) to disengage the bottom stem connector (2). The actuator must be raised straight off the body to prevent stress on the plug stem.

At this time provisions must be made to support and lift the actuator off the body using recommended lift supports and procedures. G. Loosen and remove drive nut.

G. Remove bottom stem connector parts (1, 2, 6) from plug stem. H. Remove actuator from the valve.


4

6.5 Air to open (Model 88), size 10, 16, and 23, with or without handwheel (Figure 5) Since removal of the valve plug stem from the actuator stem connector requires that the valve plug be off the seat, special provisions are necessary to assure that the valve is in the opened position. Proceed as follows:

I. Remove actuator from the valve and shut off air supply pressure.

7. Maintenance

Note: Since air supply piping connected to the actuator is normally rigid and the actuator will be moved, it is required that a manual loading panel with suitable flex tubing be used or some suitable type of flex connections be made between the supply piping and the actuator connection.

It is recommended that the actuators are placed in an upright position for all disassembly or assembly

Do not use the silicone grease for the silicone rubber of high and low temperature option.

Unreasonably high stress placed on rigid piping could cause breaking of the air supply line. A flex connector is required.

Use fluorine grease of NIPPON KOYU LTD. “LOGENEST LAMBDA” [or equal] as substitute for Dow Corning “Valve Lubricant and Sealant Compound III” [or equal].

A. Shut off air supply to the actuator and rotate handwheel to the neutral position. B. Disconnect air supply piping to the actuator. C. Connect manual loading panel tubing to the lower diaphragm case tubing connector. D. Apply required air pressure through the manual loading panel to open the valve as is indicated by the travel indicator (7) and travel scale (9).

Standard “NBR [Black]”

Do not exceed pressure indicated on the tag (63) on the diaphragm case. E. Loosen stem lock nuts (1). F. Remove cap screws (5) from stem connector (2, 4). Note:Do not allow the valve plug to drop or turn against the seat ring, as this could damage the seat and plug.

High and low temperature option “Silicone Rubber [Orange]” 7.1 Replacing diaphragm air to open actuators (Model 88) with or without handwheel (Figure 4, 5 and 10) A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed.

At this time provisions must be made to support and lift the actuator off the body using recommended lift supports and procedures.

B. If valve is equipped with a handwheel, rotate handwheel to a neutral position.

G. Loosen and remove drive nut.

C. Remove diaphragm case cap screws and nuts (20 and 19). Tension bolts (27 and 28) must be removed last. Note: Size 3 actuator – remove four diaphragm case cap screws and nuts (27 and 28) leaving the other four tension bolts equally spaced around the case.

Progressively raise actuator off the body to enable the top stem connector (4) to disengage the bottom stem connector (2). The actuator must be raised straight off the body to prevent stress on the plug stem. Spring under Load. Before removing the Actuator, ensure that the valve plug is off the seat by pressurizing the diaphragm case. It is now safe to disconnect the valve stem and clamp nut.

Diaphragm case is under spring tension and is equipped with tension bolts which must be removed last. D. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

H. Remove bottom stem connector parts (1, 2, 6) from plug stem. Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

5

E. Note position of springs (21) and spring spacers (18) [if equipped] in the diaphragm plate (26), before you remove these parts. The handwheel assembly can hold spring tension in the actuator when the diaphragm case is removed. To prevent possible injury, remove handwheel per the following procedure.

F. Remove hex nut (23) [size 3] or jam nut (23) [all other sizes]. Also remove spacer (22) [size 3] and diaphragm washer (22) [all sizes]. G. Remove diaphragm plate (26) and diaphragm (25).

A. Shut off air supply to the actuator, isolate the control process pressure to eliminate the valve plug from moving with spring tension removed. B. Rotate the handwheel (41) to a neutral position. C. For size 3 actuator, remove one of the two retaining rings (46) which are mounted on lever pin (45).

Removing the lever pin (45) will disconnect the handwheel assembly from the actuator. Support the handwheel assembly to avoid possible injury. For all other sizes, remove two cap screw (93) and washer (94), and remove two handwheel pivot pins (33) which are mounted through the yoke and secure the handwheel pivot (36) in place, (see Figure 8).

Spring coil ends Pointed towards actuator stem Figure1 H. Replace the new diaphragm (25) on the diaphragm plate (26).

D. For size 3 actuator, remove lever pin (45) and secure the handwheel holder (40) in place (see Figures 11 and 12).

I. Size 3 actuator, coat the threads of hex nut (23) and the surfaces of spacer (22) with Chesterton 725 nickel compound or equivalent. All other sizes, coat the actuator stem threads (10) and the surfaces of washer (22) with Dow Corning Sealant Compound III or equal.

For all other sizes, let the complete handwheel assembly swing down and out of the way of the top stem connector (4) [stem flange (2) on size 6 actuator]. E. Proceed with the instructions for air to close actuators without handwheel (7.3).

J. Check placement of spacer (14 and 22), reassemble diaphragm (25), diaphragm plate (26), and washer (22)

7.3 Replacing diaphragm air to close actuator (Model 87), size 3 without handwheel (Figures 9, 11 and 12)

then tighten fastener (23) in proper locations. K. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate.

A. Shut off air supply to the actuator and remove air piping from the upper diaphragm case (24).

Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure1. This step assures best actuator performance.

B. Check the travel indicator on stem flange (2) against the travel scale (9) to ensure that the plug is up (off the seat). Note:No air pressure is required to the actuator since the spring pressure tends to open the valve.

L. Replace upper diaphragm case (24) and tension bolts. Note: Tension bolts should be spaced equally around the bolt circle of the case.

C. Loosen stem lock nuts (1). D. Re-tighten lock nuts (1) against each other so they will lock at a point that is not against the stem flange (2).

M. Tighten the tension bolts in equal steps until the cases meet. Replace the remaining cap screws and nuts.

E. Turn the stem lock nut (1) counterclockwise and loosen the plug stem until it disengages from the actuator stem (10). Tighten cap screws and nuts evenly. Do not over tighten as this could possibly warp the diaphragm cases. See

Note: Depending on stem length, it may be required to separate the size 3 actuator off the valve body, as indicated in Section 6.1.

Table 3 for torque values. N. If so equipped, rotate handwheel to the desired position.

Note: Do not allow the plug to drop or turn against the seat ring, as this could damage the seat and plug.

7.2 Replacing diaphragm air to close actuator (Model 87), F. Remove four diaphragm case cap screws and nuts (27 with handwheel (Figures 2, 3, 8, 9, 11 and 12) and 28) leaving the other four installed on the case equally spaced.


6

C. Remove diaphragm case cap screws and nuts (20 and 19). Diaphragm case is under spring tension. The remaining four screws and nuts are tension bolts. G.Remove tension bolts (four remaining 27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

Diaphragm case is under spring tension and is equipped with tension bolts (27 and 28) which must be removed last.

H. Remove hex nut (23) and spacer (14).

D. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

I. Replace the new diaphragm (25) on the diaphragm plate (26). J. Coat the threads of hex nut (23) and the surfaces of spacer (14) with Chesterton 725 nickel compound or equivalent. Install spacer (14) and tighten hex nut (23) per Table 3.

E. Remove jam nut (23) and diaphragm washer (22).

K. Replace upper diaphragm case (24) and tension bolts (four cap screws and nuts 27 and 28).

G. Coat the actuator stem threads (10) and the surfaces of washer (22) with Dow Corning Sealant Compound III or its equivalent. Install washer (22) and tighten fastener (23).

F. Replace new diaphragm (25) on the diaphragm plate (26).

Note: Tension bolts should be spaced equally around the bolt circle of the case.

H. Replace upper diaphragm case (24) and tension bolts (27 and 28).

L. Tighten the tension bolts (27and 28) in equal steps until the cases meet. Replace the remaining cap screws (27) and nuts (28).

Note: Tension bolts should be spaced equally around the bolt circle of the case. I. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).

Tighten cap screws and nuts evenly. Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values. M. Screw the plug stem back into the actuator stem (10) thru the stem flange (2) and recalibrate the seated position of the valve.

Tighten cap screws and nuts evenly.Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.

Note: If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.2.

J. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve, (Section 10.2).

Note: If the actuator has a handwheel (Section 7.2), continue with the following steps: N. Hold the handwheel holder (40) in position between the yoke legs and slide the lever pin (45) through the hole in the yoke and lever. Be sure that levers (44) are above the stem flange (2).

Note Size 6 actuatorScrew the plug stem back into the actuator stem (10) thru the stem flange and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.2).

O. Secure the lever pin (45) with the second retaining ring (46).

Note: If the actuator has a handwheel (Section 7.2), continue with the following steps: 7.4 Replacing diaphragm air to close actuator (Model 87), size 6, 10, 16 and 23 without handwheel (Figures 2, K. Swing handwheel assembly back up into place. 3 and 8) L. Install the two pivot pins (33) in the yoke and engage A. Shut off air supply to the actuator and remove air piping them into the handwheel pivot (36). And install the two from the upper diaphragm case (24). washer (94) and cap scr ew (93) through the handwheel cover (57). B. Remove the two socket head cap screws (5) which hold the top and bottom stem connector (2 and 4) together.

7.5 Replace or repack handwheel bearing, size 3

Note: The size 6 actuator only has a stem flange. For actuators (Figures 11,12 and 13) diaphragm replacement, the stem lock nuts (1) must be A. Rotate handwheel to a free position. loosened. The plug stem is turned out at the actuator B. Remove handwheel cap screw (20) and washer (42). stem (10)in order to allow the actuator stem to rise with release of spring tension. Depending on stem length, it C. Remove handwheel (41) and key (47). may be required to separate the size 6 actuator off the D. Remove one of the two retaining rings (46) which are valve body, as indicated in Section 6.1. mounted on lever pin (45). Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

7

7.7 Replace or repack handwheel bearing size 16 and 23 actuators (Figures 7 & 8) A. Rotate handwheel to a free position. Removing the lever pin (45) will disconnect the handwheel assembly from the actuator. Support the handwheel assembly to avoid possible injury.

B. Remove lock pin (91), cap screw (93), and washer (94) to release handwheel cover (57).

E. Remove lever pin (45) and secure the handwheel holder (40) in place.

C. Remove pivot pins (33) which engage the handwheel pivot (36) thru the yoke.

F. Remove the complete handwheel assembly from the actuator.

D. Remove snap rings (46) and remove lever pin (45) to release complete handwheel assembly.

G. Remove both cover cap screw (20) and handwheel cover (57).

E. Remove cap screw (97) and end flange (96) to release the handwheel stem (39) from the bearing.

H. Remove retaining ring (35), handwheel pivot (36) and bushing (37) to release the bearing.

F. Remove snap ring (35) to release bearing (34).

I. Remove single row ball and shaft ring bearing (34) from handwheel stem (39) and bearing ball housing ring from the handwheel pivot (36).

H. Pack bearing (34) with Mobilux No. 2 grease or equal. Note:It is important that bearing is packed with grease, and not just coated.

G. Replace or clean to repack the bearing with new grease.

J. Replace or clean to repack bearing (34) with new grease.

I. For remounting, reverse removal procedures from step (F) through (B).

K. Bearing should be packed with Mobilux No. 2 grease or equivalent.

7.8 Replace diaphragm seal and stem seal, air to open actuators (Model 88), size 3 (Figure 10)

Note:It is important that bearing is packed with grease, and not just coated.

A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed.

L. To reassemble, reverse removal procedures from step (I) through (B). 7.6 Replace or repack handwheel bearing, size 6 and 10 actuators (Figure 6) A. Rotate handwheel to a free position. B. Remove handwheel cap screw (20) and washer (42).

B. If valve is equipped with a handwheel, rotate handwheel to a free position. C. Remove four diaphragm case cap screws and nuts (27 and 28) leaving the other four installed on the case equally spaced

C. Remove handwheel (41) and lock nut (43). D. Remove lock pin (91), cap screw (93), and washer (94) to release handwheel cover (57). Remove cover. E. Remove pivot pins (33) from the yoke which hold the handwheel pivot (36).

Diaphragm case is under spring tension. The remaining four screws and nuts are tension bolts.

F. Remove snap rings (46) and remove lever pin (45) to release handwheel assembly.

D. Remove tension bolts (four remaining 27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

G. Turn handwheel stem (39) until it clears traveling nut (40). H. Remove snap ring (38) and bearing ring (37) to release the handwheel stem (39) from the bearing.

E. Note position of springs (21) and spring spacers (18) [if equipped] in the diaphragm plate (26), before you remove these parts.

I. Remove snap ring (35) to release bearing (34).

F. Remove springs (21) and spring spacers (18) if used.

J. Replace or clean to repack bearing (34) with new grease.

G. Loosen lock nuts (1). Re-tighten lock nuts against each other so they will lock at a point that is not against the stem flange (2). By means of a wrench, hold the nuts (1) and plug stem. Turn the actuator stem (10) subassembly until it disengages from the plug stem and remove completely from actuator.

K. Bearing should be packed with Mobilux No. 2 grease or equal. Note:It is important that bearing is packed with grease, and not just coated.

H. Remove case cap screws (16) and spring guide (29).

L. To reassemble, reverse removal procedures from step (I) through (B).

I. Remove lower diaphragm case (17) to gain access to O-ring (13). Note: Mark orientation of the case to the yoke. Note: If diaphragm case O-ring (13) replacement is the only maintenance, proceed to Step N.


8

J. Remove stem wiper (11) and O-rings (12). K. Clean stem wiper and O-ring grooves of the yoke (31). L. Apply a generous coating of Dow Corning Compound III (or equivalent) to a new O-ring (12) and insert it into the yoke (31).


M. Insert a new stem wiper (11) into the lower groove of the yoke (31).

D. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

N. Clean cap screws (16) and their threaded holes on the yoke (31).

E. Note position of springs (21) and spring spacers (18) [if equipped] in the diaphragm plate (26).

O. Coat a new O-ring and the stem bushing (30) and O-ring (12) in the yoke with Dow Corning Compound III (or equivalent).

F. Remove springs (21) and spring spacers (18) if used. On size 6 actuator:

P. Insert a new O-ring (12) in the yoke groove.

G. Loosen lock nuts (1). Re-tighten lock nuts against each

Q. Place the diaphragm case (17) on the yoke.

other so they will lock at a point that is not against the stem flange (2). By means of a wrench, hold the lock nuts (1) and plug stem. Turn the actuator stem (10) subassembly until it disengages from the plug stem and remove completely from actuator.

R. Apply Never-Seez (anti-seize compound or equivalent) to cap screw threads (16). S. Assemble spring guides (29) and cap screws (16). T. Re-install the actuator stem (10) sub-assembly into the yoke bushing. Turn actuator stem on the plug stem after installing the stem flange (2). Turn until stem spacer (14) contacts the lower diaphragm case (17). U. Lock the stem flange (2) and the two lock nuts (1) against the lower part of actuator stem. V. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate.

On size 10,16 and 23 actuators: G. Loosen lock nut (32) on actuator stem (10). Hold the connector device (2, 4, 6). Turn the actuator stem(10) sub-assembly and remove it when it clears the connector insert (6), (on size 10), or the top stem connector (4), (on sizes 16 & 23). On size 6,10,16 and 23 H. Remove case cap screws (16) to gain access to seal washers (15).

Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure1. This step assures best actuator performance.

Note: If seal washers (15) replacement is the only maintenance, proceed to Step M.

W. Replace upper diaphragm case (24) and the tension bolts (four cap screws 27 and 28).

I. Remove lower diaphragm case (17).


Note:Mark orientation of the case to the yoke. J. Replace stem wiper (11) and O-rings (12 and 13).

X. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (27) and nuts (28).

K. Coat O-rings (12 and 13) and inside of yoke O-ring groove (31) with Dow Corning Compound III (or equivalent). L. Place the diaphragm case (17) on the yoke. M. Coat the surface of the spring guides (29) in contact with the diaphragm case with Dow Corning Sealant Compound III or equivalent. Assemble spring guides (29), new seal washers (15), and cap screws (16) in this order.

Tighten cap screws and nuts evenly. Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values. Y. If necessary, recalibrate the seated position of thevalve (Section 10.1). 7.9 Replace diaphragm seal and stem seal, air to open (Model 88) actuators (Figure 4 and 5) A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed.

O. Tighten lock nut (32) against connector insert (6), (size 10), or against the top stem connector (4), (on sizes 16 & 23). In case of size 6 actuator, lock the stem flange (2) and the two lock nuts (1) against the lower part of actuator stem.

B. If valve is equipped with a handwheel, rotate handwheel to a free position. C. Remove diaphragm case cap screws and nuts (20 and 19). Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

N. Re-install the actuator stem (10) sub-assembly into the yoke bushing. Turn actuator stem into insert (6), (size 10), or into the top stem connector (4), (size 16 & 23). In case of size 6 actuator, turn actuator stem on the plug stem after installing the stem connector(2). Turn until stem spacer (14) contacts the lower diaphragm case (17).

9

P. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate.

C. Remove diaphragm case cap screws and nuts (20 and 19). Tension bolts (27 and 28) must be removed last.

Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance.

Note: Size 3 actuator – Remove four diaphragm case cap screw and nuts (27 and 28) leaving the other four tension bolts equally spaced around the case.

Q. Replace upper diaphragm case (24) and the tension bolts (27 and 28). Note: Tension bolts should be spaced equally around the bolt circle of the case.

Diaphragm case is under spring tension and is equipped with tension bolts which must be removed last.

R. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).

D. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). E. Position springs (21) [and spring spacers (18) if new range use them] in the diaphragm plate. F. Refer to Tables 1, 2 and 4 for spring information:

Tighten cap screws and nuts evenly. Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.

a. For 11 and 21 psi (0,759 and 1,448bar) initials, the springs are placed directly on the upper pedestals in the diaphragm plate (26).

S. If necessary, recalibrate the seated position of the valve (Section 10.1).

Size 3 actuator -For 11 and 21 psi (0,759 and 1,448bar) initials, the springs are installed with spring spacers (18). The spring spacers (18) are placed as shown in the cross sectional view, Figure 10.

8. Actuator Range

b. For 3 and 6 psi (0,207 and 0,414bar) initials, the springs are placed in the bottom cavity in the diaphragm plate.

Do not use the silicone grease for the silicone rubber of high and low temperature option. Use fluorine grease of NIPPON KOYU LTD. “LOGENEST LAMBDA” [or equal] as substitute for Dow Corning “Valve Lubricant and Sealant Compound III” [or equal].

Size 3 actuator - For 3 and 6 psi (0,207 and 0,414bar) initials, the springs are installed without spring spacers. c. For 11 and 21 psi (0,759 and 1,448bar) initials and travel ranges larger than 0.8 " (20mm), the spring spacers placed as shown in the cross sectional (18) view, are Figure 5. Note: Spring spacers (18) are not required for the No.6 actuator. Note:Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure1. This step assures best actuator performance.


G. Replace upper diaphragm case (24) and tension bolts (27, and 28). Note: Tension bolts should be spaced equally around the bolt circle of the case. H. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19) [Screw (27) and nuts (28) for size 3].

High and low temperature option “Silicone Rubber [Orange]” 8.1 Actuator range change, air to open (Model 88). A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed.


B. If valve is equipped with a handwheel, rotate handwheel to a free position.

I. If so equipped, rotate handwheel to the desired position.


10

8.2 Actuator range change, air to close (Model 87), size 6,10,16 and 23

L. Replace upper diaphragm case (24) and the tension bolts (27and 28).

Note:If actuator is equipped with a handwheel, please follow steps 7.2 A, B, C and D to disengage this assembly.



M. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).

B. Remove the two socket head cap screws (5) which hold the top and bottom stem connector (2 and 4) together. Note: The size 6 actuator only has a stem flange (2). For access to springs, the stem lock nuts (1) must be loosened. The plug stem is turned out at the actuator stem (10)to allow the actuator stem to r ise with release of spring tension. Depending on stem length, it may be required to separate the size 6 actuator off the valve body, as indicated in Section 6.1. C. Remove diaphragm case cap screws and nuts (20 and 19).

N. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve (Section 10.2). Note: Size 6 actuator-Screw the plug stem back into the actuator stem (10) thru the stem flange (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.2).


Note: If the actuator has a handwheel (Section 7.2), continue with the following steps:

D. Remove tension bolts (27 and 28) and compression nuts (28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). E. Remove jam nut (23) and diaphragm washer (22). F. Remove diaphragm plate (26) and diaphragm (25). G. Place springs (21) over the spring guides (29). H. Refer to Tables 1, 2 and 4 for spring information: a. For 11 and 21 psi (0,759 and 1,448bar) initials, the springs are placed directly on the upper pedestals in the diaphragm plate (26). b. For 3 and 6 psi (0,207 and 0,414bar) initials, the springs are placed in the bottom cavity in the diaphragm plate. c. For 11 and 21 psi (0,759 and 1,448bar) initials and travel ranges larger than 0.8 " (20mm), the spring spacers (18) are placed as shown in the cross sectional view, Figure 5. Note: Spring spacers (18) are not required for 0.8" (20mm) travel ranges. Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure1. This step assures best actuator performance. I. Replace the diaphragm plate (26) on the actuator stem (10) and over the springs. To ensure the springs are properly located, check the view hole in the diaphragm plate. A spring should be visible. J. Install the diaphragm (25). K. Coat the actuator stem threads (10) and the surfaces of washer (22) with Dow Corning Sealant Compound III or equivalent.


Tighten cap screws and nuts evenly. Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.

11

Ta1b l e ACTUATOR TRAVEL in. (mm)

Ta2b l e SPRING RANGE NO.OF SPRINGS SPRING SPACER Psi (bar) REQUIRED (18) REQUIRED

SPRING COLOR RED

3-15 (0.207-1.034)

3

NO

1.5 (38)

BLUE

6-30 (0.414-2.069)

6

NO

2.0 (51)

GREEN

11-23 (0.759-1.586)

3

YES*

YELLOW

21-45 (1.448-3.103)

6

YES*

0.8 (20)

2.5 (64)

* A spring spacer (18) is required on Size 10 for 1.5 in. (38mm) travel only, and on Size 16 and 23, for 1.5 in. (38mm), 2.0 in. (51mm) and 2.5 in. (64mm) travels.

Table 3 – ACTUATOR ASSEMBLYTORQUES ACTUATOR SIZE R E F. N O.

D E S C R IP T I O N

3 f t - l bs

HexNut.500 20 - UNF

25

34

6 N-m

f t - l bs

25

34

10 N- m 25

Hex Nut .625 18 UNF -

34

55

16

f t - l bs

N- m 25

74

34

55

23

f t - l bs

N -m

25

74

f t - l bs

34

55

74

1 Hex Nut .750 16 -UNF

95

129

Hex Nut 1.00 14 UNS 5

ConnecterCapScrew

16

Yoke Cap Screw Case Bolting or Tension Bolting

19,20,27,28 23

Jam Nut, Hex Nut

32

Stem Lock Nut

33

Pivot Pin

20

HandwheelCapScrew

97

Handwheel Stem Cap Screw

95 150

35* 22

30 22

48

53**

37 30

65

35

50 21

37

6

47*

50

150

125

50 25

95

203

47

37 28

129

169

59 34

125

80 30

59 40

80 31

42

66

90

95

129

150

203

74

95

129

150

203

60

81

60

81

80

108

80

25

34

25

34

66

90

66

300

12

169

55

407

* Torque shown is for size 6 actuator with Bellows Seal design requiring Stem Connector Option. ** Torque value in units of in-lbs. Listed values are nominal torques. Tolerance is +/- 10%.


129 203

300

108 90 407

N-m

Actuator Travel & No. Color Code

3

0.8" (20mm) Red

6

0.8" (20mm) Red 0.8" (20mm) Red

10

1.5" (38mm) Blue 0.8" (20mm) Red 1.5" (38mm) Blue

16 2.0" (51mm) Green 2.5" (64mm) Yellow 0.8" (20mm) Red 1.5" (38mm) Blue 23 2.0" (51mm) Green 2.5" (64mm) Yellow

Range (psi)

Qty.

Springs Position

3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45

3 6 3 6 3 6 3 6 3 6 3 6

A B E F A B C D A B C D

3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23 21-45 3-15 6-30 11-23

3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3

A B E F A B C D A B E F A B E F A B E F A B C D A B E F A B E F A B E

21-45

6

F TABLE 4 Diaphragm plate Spring arrangement


13

8.3 Actuator range change, air to close (Model 87), size 3 O. Replace upper diaphragm case (24) and tension bolts (four cap screws and nuts 27 and 28). Note:If actuator is equipped with a handwheel, please follow steps 7.2 A, B, C and D to disengage this assembly. Note: Tension bolts should be spaced equally around the bolt circle of the case. A. Shut off air supply to the actuator and remove air piping from the upper diaphragm case (24). P. Tighten the tension bolts (27 and 28) per Table 3 in equal steps until the cases meet. Replace the remaining B. Check the travel indicator on stem flange (2) against the cap screws (27) and nuts (28) and tighten per Table 3. travel scale (9) to ensure that the plug is up (off the seat). Note: No air pressure is required to the actuator since the spring pressure tends to open the valve. C. Loosen stem lock nuts (1). Tighten cap screws and nuts evenly.Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.

D. Re-tighten lock nuts (1) against each other so they will lock at a point that is not against the stem flange (2). E. Turn the stem lock nut (1) counterclockwise and loosen the plug stem until it disengages from the actuator stem (10).

Q. Screw the plug stem back into the actuator stem (10) thru the stem flange and recalibrate the seated position of the valve.


Note: If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.2. Note: If the actuator has a handwheel (Section 7.2), continue with the following steps:


R. Hold the handwheel holder (40) in position between the yoke legs and slide the lever pin (45) through the hole in the yoke and lever. Be sure that levers (44) are above the stem flange (2).

F. Remove four diaphragm case cap screws and nuts (27 and 28) leaving the other four installed on the case equally spaced.

S. Secure the lever pin (45) with the second retaining ring (46).

9. Air Action Changes

Diaphragm case is under spring tension. The remaining four screws and nuts are tension bolts. G.Remove tension bolts (four remaining 27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). H. Remove hex nut (23) and spacer (14).

Do not use the silicone grease for the silicone rubber of high and low temperature option.

I. Remove diaphragm (25) and diaphragm plate (26).

Use fluorine grease of NIPPON KOYU LTD. “LOGENEST LAMBDA” [or equal] as substitute for Dow Corning “Valve Lubricant and Sealant Compound III” [or equal].

J. Place springs (21) over the spring guides (29). K. Refer to Tables 1, 2 and 4 for spring information: a. For 11 and 21 psi (0,759 and 1,448bar) initials, the springs are installed with spring spacers (18). The spring spacers (18) are placed as shown in the cross sectional view, Figure 9. b. For 3 and 6 psi (0,207 and 0,414bar) initials, the springs are installed without spring spacers.


Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure1. This step assures best actuator performance. L. Replace the diaphragm plate (26) on the actuator stem (10) and over the springs. M. Install the diaphragm (25). N. Coat the threads of hex nut (23) and the surfaces of spacer (14) with Chesterton 725 nickel compound or equivalent. Install spacer (14) and tighten hex nut (23) per Table 3.


High and low temperature option “Silicone Rubber [Orange]”

14

9.1 Air to open to air to close (Model 88 to Model 87), size 6,10,16 and 23

Note: Tension bolts should be spaced equally around the bolt circle of the case. O. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).

A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed. B. If valve is equipped with a handwheel, rotate handwheel to a neutral position. C. Remove snap rings (46) and remove lever pin (45) to allow handwheel assembly to swing away from the stem connector (2-4).


D. Remove the two socket head cap screws (5) which hold the top and bottom stem connector (2 and 4) together. Note: The size 6 actuator only has a stem flange (2). For changing of action, the stem lock nuts (1) must be loosened. The plug stem is turned out at the actuator stem (10)in order to allow the actuator stem to rise with springs installed in Model 87. Depending on stem length, it may be required to separate the size 6 actuator off the valve body, as indicated in Section 6.3. E. Remove diaphragm case cap screws and nuts (20 and 19) and vent cap (59).

P. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve (Section 10.2). Note Size 6 actuator– Screw the plug stem back into the actuator stem (10) thru the stem flange (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.2. Note: If the actuator has a handwheel, continue with the following steps: Q. Swing handwheel assembly back up into place. The handwheel (41) may have to be turned in order to position the lower pivot pins (33).

Diaphragm case is under spring tension and is equipped with tension bolts (27 and 28) which must be removed last. F. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). Remove springs (21) and spacer (18) [if equipped].

R. With the pivot pins positioned on top of the stem connector (2 and 4), replace the lever pin (45) and snap rings (46). 9.2 Air to close to air to open (Model 87 to Model 88), size 6,10,16 and 23 with handwheel

G. Remove jam nut (23) and diaphragm washer (22) and travel stop (71) [if equipped]. H. Remove diaphragm plate (26) and diaphragm (25). I. Place springs (21) over the spring guides (29). J. Refer to Tables 1, 2 and 4 for spring information. Refer also to Section 8.2 H Note: Spring spacers (18) are not required for 0.8 " (20mm) travel ranges Note: Arrange springs so that the coil ends are pointed toward the actuator as shown in Figure 1. This step assures best actuator performance.

The handwheel assembly can hold spring tension in the actuator when the diaphragm case is removed. To prevent possible injury, remove handwheel per the following procedure. A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed. B. Rotate the handwheel (41) to a neutral position. C. Remove snap rings (46) and lever pins (45).

K. Invert and replace the diaphragm plate (26) on the actuator stem (10) and over the springs.

D. The complete handwheel assembly can now swing out of the way of the top stem connector (2 and 4) [stem flange (2) on the size 6 actuator].

Note:To ensure the springs are properly located, check the view hole in the diaphragm plate. A spring should be visible.

E. Proceed with the instructions for actuators without handwheel (9.3 Step B). 9.3 Air to close to air to open (Model 87 to Model 88), size 6,10,16 and 23 without handwheel

L. Install the diaphragm (25). M. Coat the actuator stem threads (10) and the surfaces of washer (22) with Dow Corning Sealant Compound III or equivalent. Then place and tighten the jam nut (23).


N. Replace upper diaphragm case (24) and tension bolts (27 and 28).

B. Remove the two socket head cap screws (5) which hold the top and bottom stem connector (2 and 4) together.


15

Note: The size 6 actuator only has a stem flange (2). For changing of action, the stem lock nuts (1) must be loosened. The plug stem is disconnected from the actuator stem (10)in order to allow the actuator stem to rise with release of spring tension during disassembly. Depending on stem length, it may be required to separate the size 6 actuator off the valve body, as indicated in Section 6.1.

Actuator Size

Stroke

Air to open Model 88

6

20.32 mm [0.8"]

Jam nut (23)

20.32 mm [0.8"]

Jam nut (23) and Travel stop (71)

38.1 mm [1.5"]

Jam nut (23)

10

C. Remove diaphragm case cap screws and nuts (20 and 19).

Air to close Model 87

20.32 mm [0.8"]

16 Diaphragm case is under spring tension and is equipped with tension bolts (27 and 28) which must be removed last.

38.1 mm [1.5"

63.5 mm [2.5"]

D. Remove tension bolts (27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). 23

38.1 mm [1.5"]

H. Coat the actuator stem threads (10) and the surfaces of washer (22) with Dow Corning Sealant Compound III or equivalent.

Jam nut (23)

Travel stop (71)

50.8 mm [2.0"] 63.5 mm [2.5"]

G. Invert the diaphragm (25) and diaphragm plate (26).

Jam nut (23)

20.32 mm [0.8"]

E. Remove jam nut (23) and diaphragm washer (22). F. Remove the diaphragm (25), diaphragm plate (26), spring (21) and spring spacers (18) [if used].

Travel stop (71)

50.8 mm [2.0"]

Jam nut (23)

J. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate. K. Refer to Tables 1, 2 and 4 for spring information. Refer also to Section 8.1 F.

I. Checking placement of spacer (14) reassemble diaphragm (25), diaphragm plate (26), washer (22), jam nut (23) or travel stop (71) [see Note] in proper locations.

Note: Spring spacers (18) are not required for 0.8 " (20mm) travel ranges.

Note: The maximum stroke of each actuator size for

Note: Arrange springs so that the coil ends are pointed

model 88 uses Jam nut (23). For other stroke, the travel stop (71) is used to replace the Jam nut (23).

toward the actuator stem as shown in Figure1. This step assures best actuator performance. L. Replace upper diaphragm case (24) and tension bolts (27 and 28).

Note:The model 88 size 10, 20.32mm [0.8 "] stroke only uses Jam nut (23) and Travel stop (71).

Note: Tension bolts should be spaced equally around the bolt circle of the case. M. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).

Tighten cap screws and nuts evenly.Do not over tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values. N. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve, (Section 10.1). Note Size 6 actuator –Screw the plug stem back into the actuator stem (10) thru the stem flange (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.1). Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

16

M. Install spacer (22) on the actuator stem (10).

Note: If the actuator has a handwheel, continue with the following steps.

N. Invert and replace the diaphragm plate (26) on the actuator stem (10) and over the springs.

O. Swing the handwheel assembly back into place. P. It may require turning the handwheel (41) to position the lower pivot pins (33) under the stem connector (2-4), [stem flange (2) on the size 6 actuator].

O. Install the diaphragm (25). P. Coat the threads of hex nut (23) and the surfaces of spacer (14) with Chesterton 725 nickel compound or equivalent. Install spacer (14) and tighten hex nut (23) per Table 3.

Q. Install the lever pin (45) and snap rings (46). R. Add the vent cap (59) to the top of upper diaphragm case. 9.4 Air to open to air to close (Model 88 to Model 87), size 3

Q. Replace upper diaphragm case (24) and tension bolts (four cap screws and nuts 27 and 28), and tighten per Table 3. Note: Tension bolts should be spaced equally around the bolt circle of the case.


R. Tighten the tension bolts (27 and 28) per Table 3 in equal steps until the cases meet. Replace the remaining cap screws (27) and nuts (28) and tighten per Table 3.

B. If valve is equipped with a handwheel, please follow steps 7.2 B, C and D to disengage this assembly. C. Check the travel indicator on stem flange (2) against the travel scale (9) to ensure that the plug is up (off the seat). D. Loosen stem lock nuts (1).


E. Re-tighten lock nuts (1) against each other so they will lock at a point that is not against the stem flange (2). F. Turn the stem lock nut (1) counterclockwise and loosen the plug stem until it disengages from the actuator stem (10).

S. Screw the plug stem back into the actuator stem (10) thru the stem flange and recalibrate the seated position of the valve.


Note: If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.2. Note: If the actuator has a handwheel, continue with the following steps:


T. Hold the handwheel holder (40) in position between the yoke legs as shown in Figure 12 and slide the lever pin (45) through the hole in the yoke and lever. Be sure that levers (44) are above the stem flange (2).

G. Remove four diaphragm case cap screws and nuts (27 and 28)spaced. leaving the other four installed on the case equally

U. Secure the lever pin (45) with the second retaining ring (46). 9.5 Air to close to air to open (Model 87 to Model 88), size 3 with handwheel

Diaphragm case is under spring tension. The remaining four screws and nuts are tension bolts. H. Remove tension bolts (four remaining 27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

The handwheel assembly can hold spring tension in the actuator when the diaphragm case is removed. To prevent possible injury, remove handwheel per the following procedure.

I. Remove hex nut (23) and spacer (22), Figure 10. J. Remove diaphragm plate (26), diaphragm (25), and spacer (14), Figure 10. K. Place springs (21) [and spring spacers (18) if new range uses them] over the spring guides (29), Figure 9. L. Refer to Tables 1, 2 and 4 for spring information. Refer also to Section 8.3 K. Note: Spring spacers (18) are not required for 0.8 " (20mm) travel ranges

B. Rotate the handwheel (41) to a neutral position. C. Remove one of the two retaining rings (46) which are mounted on lever pin (45), Figure 12.

Note: Arrange springs so that the coil ends are pointed toward the actuator as shown in Figure 1. This step assures best actuator performance. Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator


17

N. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate. O. Refer to Tables 1, 2 and 4 for spring information. Refer also to Section 8.1.

Removing the lever pin (45) will disconnect the handwheel assembly from the actuator. Support the handwheel assembly to avoid possible injury.

Note: Arrange springs so that the coil ends are pointed toward the actuator as shown in Figure 1. This step assures best actuator performance.

D. Remove lever pin (45) and secure the handwheel holder (40) in place (see Figures 11 and 12). The handwheel assembly will be disconnected from the actuator.

P. Replace upper diaphragm case (24) and tension bolts (four cap screws and nuts 27 and 28). Note: Tension bolts should be spaced equally around the bolt circle of the case.

E. Proceed with the instructions for actuators without handwheel (9.6 Step B). 9.6 Air to close to air to open (Model 87 to Model 88), size 3 without handwheel A. Shut off air supply to the actuator and remove air piping

Q. Tighten the tension bolts (27 and 28) in equal steps until the cases meet. Replace the remaining cap screws (27) and nuts (28).

from the upper diaphragm case (24). B. Check the travel indicator on stem flange (2) against the travel scale (9) to ensure that the plug is up (off the seat). C. Loosen stem lock nuts (1).


D. Re-tighten lock nuts (1) against each other so they will lock at a point that is not against the stem flange (2).

R. Screw the plug stem back into the actuator stem (10) thru the stem flange and recalibrate the seated position of the valve.

E. Turn the stem lock nut (1) counterclockwise and loosen the plug stem until it disengages from the actuator stem (10).

Note: If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.1.


Note: If the actuator has a handwheel, continue with the following steps:


S. Hold the handwheel holder (40) in position between the yoke legs as shown in Figure 12 and slide the lever pin (45) through the hole in the yoke and lever. Be sure that levers (44) are below the stem flange (2).

F. Remove four diaphragm case cap screws and nuts (27 and 28) leaving the other four installed on the case equally spaced.

T. Secure the lever pin (45) with the second retaining ring (46).

10. Valve Mounting Diaphragm case is under spring tension. The remaining four screws and nuts are tension bolts. G.Remove tension bolts (four remaining 27 and 28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).

These installation and plug stem adjustment procedures are for mounting of the 87/88 Actuators on most metal seated reciprocating valves. Refer to the specific valve instructions for other trim types, such as pilot operated valves (41405) and soft seat designs.

H. Remove hex nut (23) and spacer (14), Figure 9. I. Remove the diaphragm (25), diaphragm plate (26), spacer (22), spring (21) and spring spacers (18) [if used], Figure 9.

The stem flange (2) on the size 3 and 6 is not fixed to the actuator stem and is a loose part with the stem nuts (1) backed off. For safety reasons, adjustments should only be made pneumatically.

J. Install spacer (14) on the actuator stem (10), Figure 10. K. Invert the diaphragm (25) and diaphragm plate (26), Figure 10.

10.1 Air to open (Model 88)

L. Coat the threads of hex nut (23) and the surfaces of spacer (22) with Chesterton 725 nickel compound or equivalent.

A. Connect manual loading panel tubing to the lower diaphragm case or yoke connection (size 3). B. Apply required air pressure through the manual loading panel to completely retract the actuator stem (10).

M. Check placement of spacers (14 and 22), reassemble diaphragm (25), diaphragm plate (26), and spacer (22) then tighten hex nut (23) per Table 3.


C. Install actuator on the valve body with drive nut. Tighten the drive nut.

18

F. Unscrew the stem 1/2 turn and lock the stem in place by tightening the lock nuts (1) against the stem connector (2 or 6).

Note: Size 3 and Size 6 actuator – Screw the plug stem into the actuator stem (10) thru the stem flange (2). Depending on stem length, it may be required to progressively lower the actuator forwards the body while screwing the plug stem into the actuator stem.

Note: Size 3 and Size 6 actuator – Lock the plug s tem in place by tightening the lock nut (1) against the stem flange (2).

D. On size 10, 16 and 23 actuat ors: Apply initial air pressure and position top stem connector (4). Refer to Figure 14 and 16 for stem connector positioning.

H. Line up the travel scale (9) with the pointer and check actuator for proper operation.

On size 3 and 6 actuators: Apply initial air pressure. Adjust the plug stem to position of stem flange (2) as shown in Figure 14.

DO NOT TURN the plug against the seat as damage to the parts can occur. E. Release air pressure. F. Using the stem lock nuts (1), unscrew the plug stem until the plug touches the seat. G. Pneumatically or with the handwheel, stroke the actuator to raise the plug off the seat. Unscrew the plug stem one full turn and lock the stem in place with the lock nut(s) (1) against the stem connector or flange (2 or 6). H. Line up the travel scale (9) with the pointer and check actuator for proper operation. 10.2 Air to close (Model 87) A. Install actuator on the valve body with drive nut. Tighten the drive nut. B. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5).Turn the plug stem as far6). asRefer possible into lower partFigure of the16 stem connector (2 or to Figure 15 and for stem connector positioning. Note: Size 3 and Size 6 actuator – Screw the plug stem into the actuator stem (10) thru the stem flange (2). Depending on stem length, it may be required to progressively lower the actuator forwards the body while screwing the plug stem into the actuator stem. Refer to Figure 15 for size 6 stem connector positioning. C.Pneumatically or with the handwheel, stroke the actuator to the rated spring range or stroke (if using the handwheel). D. Using the stem lock nuts (1) unscrew the plug stem until the plug touches the seat.

DO NOT TURN the plug against the seat as damage to the parts can occur. E. Release the pressure in the actuator or back off the handwheel to raise the stem.


19

Figure 3

Figure 2

Size 10, 16 and 23 Actuator Air to Close (Model 87)

Size 6 Actuator Air to Close (Model 87)

Figure 5

Figure 4

Size 10, 16 and 23 Actuator Air to Open (Model 88)

Size 6 Actuator Air to Open (Model 88) Instructions ER8788 – 09/10 87/88 Series Spring Diaphragm Actuator

20

Figure 6

Figure 7

Size 6 and 10 Actuator with optional Handwheel

Size 16 and 23 Actuator with optional Handwheel Parts Reference Table

R ef.No 1 2

3

D es cription

R e f .N o

Ref. No

D e s cr i pt i on

Lock Nut

22

Washer-Flat

43

StemConnector-Bottom

23

Nut-Jam

44

Description HW LimitationNut HWLever

CapScrew-Pointer

24

UpperDiaphragmCase

45

LeverPin

5

Stem Connector-Top CapScrew-Connecter

25 26

Diaphragm DiaphragmPlate

46 57

RetainingRing-LeverPin HWCover

6

ConnectorInsert

27

CapScrew-Comp

59

VentPlug



4

28



7

Pointer

CompressionNut

60

8

Screw-PanHead

29

SpringGuide

9

Travel Scale

30

Bushing

67

Warning Seal

10

ActuatorStem

31

Yoke

68

WarningSeal Arrow -

63

Pipe Fitting InformationSeal

11

StemWiper

32

LockNut

69

WarningSeal

12

Oring

33

Pivot Pin

88

Plate-Rotation Arrow

13

Oring

34

ThrustBearing

90

PivotPin-HWLock

Spacer

35

RetainingRing

91

14 15

SealWasher

36

HWPivot

92

HandwheelLockPin InformationPlate-HW

16

Cap Screw-Yoke



37

BearingRing

93

CapScrew-HexHead

17

Lower Diaphragm Case



38

RetainingRing

94

Washer-Flat

18

Spring Spacer

39

HW Stem

96

End Flange

19

HexNut

40

TravelingNut

97

CapScrew-HWStem

20

CapScrew-HexHead

41

Handwheel

21   

Spring Recommended Spare Parts Not provided for Size 6 Stem Flange on Size 6 Actuator


42 

Washer-Flat Not provided for Size 16 and 23

21



Not provided for Size 6 and 10

Figure 9

Figure 10

Size 3 Actuator Air to Close (Model 87)

Size 3 Actuator Air to Open (Model 88)



Figure 11

Figure 12

Size 3 Actuator Air to Close

Size 3 Actuator Handwheel

With optional Handwheel

sectional view


22



Figure 13 Size 3 Actuator Air to Open With optional Handwheel

Parts Reference Table – Size 3 Ref. No

Description

Ref. No

2

StemFlange

27

20

Cap Screw, Hex head

28

Hex Nut

22

Spacer

30

Bushing

23

HexNut

35

Description

Ref. No

Description

Ref. No

Description

Cap Screw, Hex head

37

Bushing

44

Handwheel Lever

Handwheel Holder

47

Key

40 43

LeverAssembly

RetainingRing

Underlined: Optional Handwheel Only. Note: All other Ref. Numbers and Description are the same as listed for other size.


23

49

RetainingRing

“X” at 0 PSI

“X” at Initial

ACTUATOR SIZE

Figure 14

Figure 15

Model 88 Actuator Air to Open Actuator

Model 87 Actuator Air to Close Actuator

S T R OK E

3

0.8"(20mm)

6 10

0.8"(20mm) 0.8"-1.5" (20-38mm)


ACTUATOR SIZE

“ X ” a t In i t i a l P S I 3.55"(90.2mm)

3

3.54"(89.9mm) 4.62" (117.4mm)

6 10

24

S TR O K E

“X ” at 0l PS I

0.8"(20mm)

4.56"(115.7mm)

0.8"(20mm) 0.8" (20mm)

4.48"(113.9mm) 5.12" (130.0mm)

1.5" (38mm)

5.44" (138.2mm)

ACTUATOR SIZE 16 & 23

Figure 16

Figure 17

Model 88 Actuator Air to Open

Model 87 Actuator Air to Close

S T RO K E 0.8"-2.5 (20-64mm)

ACTUATOR SIZE

“ X ” a t In i t i a l P S I 7.02" (178.3mm)

16

23


25

S T RO K E

“ X ”a t 0 P S I

0.8" (20mm)

8.00" (203.2mm)

1.5" (38mm)

8.50" (215.9mm)

2.0" (51mm) 2.5" (64mm)

9.28" (235.7mm) 9.50" (241.3mm)

0.8" (20mm)

8.25" (209.6mm)

1.5" (38mm)

8.62" (218.9mm)

2.0" (51mm)

9.12" (231.6mm)

2.5" (64mm)

9.59" (243.6mm)


ITALY Phone: Fax:

+39-081-7892-111 +39-081-7892-208

BRAZIL Phone: Fax:


+81-43-297-9222 +81-43-299-1115


KOREA Phone: Fax:

+82-2-2274-0748 +82-2-2274-0794

CHINA

MALAYSIA

Phone: Fax:

+55-11-2146-3600 +55-11-2146-3610

+86-10-8486-4515 +86-10-8486-5305


+91-22-8354790 +91-22-8354791







+60-3-2161-0322 +60-3-2163-6312


+52-5-310-9863 +52-5-310-5584

SPAIN Phone: Fax:

+34-93-652-6430 +34-93-652-6444





Fax: +1-281-671-1735 California Phone: +1-562-941-7610 Fax: +1-562-941-7810

+91-11-2-6164175 +91-11-5-1659635

About Dresser, Inc.


Dresser Inc. is a global leader in providing highlyengineered infrastructure products for the global energy industry. Leading brand names within the Dresser portfolio include Dresser Wayne® retail fueling systems, Waukesha® natural gas-fired engines, Masoneilan® control valves, Consolidated® pressure relief valves, and ROOTS® blowers and rotary gas meters. The company has manufacturing and customer service facilities strategically located worldwide and a sales presence in more than 150 countries. www.dresser.com




ER8788 09/10

www.dresser.com

Masoneilan Manual

Recommend Documents