Baumann Sanitary Diaphragm Angle & In-Line Control Valve Instructions

Transcription

1 Instruction Manual D103370X Control Valve Baumann Sanitary Diaphragm Angle & In-Line Control Valve Instructions CONTENTS Introduction...1 Scope...1 Safety P recautions...1 Maintenance...2 Flow D irection...3 Installation...3 Air P iping...3 Body R emoval...3 Actuator Removal...3 Bonnet Disassembly...4 Bonnet R eassembly...4 Valve Calibration...4 Parts List...7 Flow Directions Dimensions and Weights INTRODUCTION The Baumann sanitary control valve is designed to satisfy the stringent demands of the pharmaceutical and biotechnology industries. These valves are in compliance with 3-A Sanitary Standards, Inc. requirements. SCOPE OF MANUAL This instruction manual includes installation, maintenance, and parts information for the sanitary control valve. any questions about these instructions contact your Fisher NOTE: Neither Emerson, Emerson Process entities assumes responsibility for the! of pressure retaining parts may result refer to the WARNING at the beginning of the Maintenance section in this instruction No person may install, operate or maintain a control valve without first being fully trained and operation and maintenance, and carefully reading and understanding the contents of this manual. If you have

2 84000 Control Valve Instruction Manual MAINTENANCE of the control valve or loss of control of Do not expose this product to service conditions or variables other than those for which the product was intended. sales! Refer to the relevant actuator Maintenance If hoisting the valve, take precautions to!! maintenance operations: the process to isolate the valve from the pneumatic actuator spring pre- the relevant actuator instructions in this manual to perform safe removal of the 2

3 Instruction Manual Control Valve FLOW DIRECTION in the illustrations on pages 8 and 9. INSTALLATION 1. Before installing the valve in the pipeline, thoroughly clean the line of all dirt, welding chips, scale, oil or grease, and other foreign material. the valve. 2. through the valve body in the direction selected in Figures 5 through 10 on pages 8 or 9. Leak detection port should be located at the lowest point in the installed position. 3. A three-valve bypass must be used to permit removal of the control valve from the line without shutting down the system. 4. To detect if leakage or breakage of the diaphragm has occurred, a pressure gauge may be installed in the 1/8 NPT port (14) in the bonnet, see Figures 1, 2, and 3, on page 6.! WARNING AIR PIPING 1. For an air-to-extend actuator (air-to-close action), connect the actuating air pressure line to the 1/4 NPT opening in the upper diaphragm case. For an air-to-retract actuator (air-to-open action) connect the actuating air pressure line to the 1/4 NPT opening in the lower diaphragm case. 2. Use 1/4 in (6.4 mm) O.D. tubing or equivalent for all air lines. If air line exceeds 25 ft (8 m) in length, 3/8 in (9.5 mm) tubing is preferred. Air lines must not leak. Air pressure should not exceed 35 psig (2.5 barg). BODY REMOVAL (Not Required For Actuator Reversal) through 4 below. DO NOT SQUEEZE BODY IN VISE 1. For Fail-Closed Action (air-to-open), stroke actuator up to take pressure off from the diaphragm pushing against seat. For Fail-Open Action (air-toclose), no need to stroke actuator. 2. Remove bonnet screws (18) for size NPS 1 or clamp (11) for sizes NPS 1-1/2 or Lift bonnet assembly (2) with actuator from valve body (1). 4. Once disassembled; for Fail-Closed Action ONLY, release pressure from actuator to be able to unscrew diaphragm, for Fail-Open Action you must pressurize actuator to unscrew diaphragm. This is the only action required for inspection or cleaning. 5. Stroke actuator down to exert some pressure and remove the diaphragm (8) by unscrewing diaphragm (8) from compressor (5). Remove bonnet o-ring (15) (NPS 1-1/2 and 2 valves only). Wipe diaphragm (8) with a clean soft cloth and examine for wear. 6. Inspect body sealing surfaces. If valve leakage becomes excessive, replacement of diaphragm (8) may be necessary, ACTUATOR REMOVAL To remove actuator, unscrew drive nut (9) and loosen jam nuts (27). Unscrew piston stem (3) from actuator stem. 3

4 84000 Control Valve BONNET DISASSEMBLY Remove diaphragm (8) and bonnet o-ring (15) (NPS 1-1/2 and 2 valves only) per instructions under Body Removal section above. Proceed as follows: 1. Turn bonnet assembly (2) over. 2. Pry out retaining ring (7) using a small flat screwdriver. 3. Remove wave springs (6), compressor (5) and drive mechanism (4). 4. Next push out piston-stem assembly (3). Clean and replace as required. BONNET REASSEMBLY For correct orientation of sub-assemblies to bonnet refer to Figure 4, page 6, exploded view. 1. Insert piston stem assembly (3) into bonnet (2). 2. Orient drive mechanism as shown in Figure Verify that machined surfaces at the end of the rectangular plates are in full contact with the machined recess inside bonnet (2). IMPORTANT: Verify that the recessed roller bearings in the drive mechanism (4) rest against the of the piston stem assembly (3). 5. side resting against the extended roller bearings. 6. Drop wave springs (6) into place, prongs down; the NPS 1 valve requires two (2) wave springs. The NPS 1-1/2 and 2 valves require three (3) wave springs. Oppose spring opening 180 o when installing wave springs. 7. Retain all parts by installing retaining ring (7) into bonnet groove. 8. Gap in retaining ring (7) should align with crest of wave spring (6). 9. Push down on bonnet assembly to drive piston Instruction Manual to provide some tension. 10. Insert o-ring (15) (NPS 1-1/2 and 2 valves only), so that it rests on the retaining ring (7). 11. Lubricate screw thread and cone of diaphragm (8) with sterile food grade lubricant. 12. Screw diaphragm (8) onto compressor (5) snugly. 13. Place complete bonnet assembly onto the valve body (1). for proper centering. B. 1 bolted flange configuration should be tightened for metal-to-metal contact between tightening body bolts on the NPS 1. C. For NPS 1-1/2 and 2 valves, apply clamp (11) and tighten the nut gradually, checking for even amount of PTFE over the body, between the bonnet and clamp, for proper centering. D. The gap between the clamp ends should be approximately 1/2 or less for proper diaphragm compression. DO NOT OVERTIGHTEN E. Examine through port B to be sure diaphragm is centered on seating area. VALVE CALIBRATION After valve is assembled per previous instructions, install properly configured actuator (see ACT.IM actuator instructions), making sure to engage piston stem (3) as much as possible into actuator stem. Tighten drive nut (9). (Refer to Figure 5, Pages 8 & 9 1. Calibration of Fail-Close (air-to-open) Actuator. Apply 50 psi air or nitrogen to port B. Apply 3 psi air signal to actuator. A. Slowly turn piston stem assembly (3) out of 4

5 Instruction Manual B. Check valve for leaks with 50 psi air under diaphragm (port B ), leakage should be less than 1 cc/min. The valve should start to leak the actuator. If it takes more than minimum pressure to open, then screw piston stem assembly (3) further into actuator stem. If valve is not tight at 3 psi signal, screw the piston stem assembly (3) out of the actuator stem some more. Next, calibrate zero on travel indicator scale with minimum pressure signal to actuator. Check for full travel at maximum pressure signal. If leak persists, increase the force on the clamp (11) to compress the diaphragm (8) by tightening clamp nut. If size NPS 1 valve, tighten bolts Control Valve to compress the diaphragm (8) by tightening clamp nut. If size NPS 1 valve, tighten bolts CLOSE PROPERLY, INCREASE CLAMP COMPRESSION AROUND THE DIAPHRAGM CLOSE PROPERLY, INCREASE CLAMP COMPRESSION AROUND THE DIAPHRAGM 2. Calibration of Fail-Open (air-to-close) Actuator. Apply 50 psi air pressure or nitrogen to port B. Apply 15 psi air signal to actuator. A. Slowly turn piston stem assembly (3) out of B. Check valve for leaks with 50 psi air under diaphragm (port B ), leakage should be less than 1 cc/min. The valve should start to leak the actuator. If it takes more than maximum pressure to open, then screw piston-stem (3) further into actuator stem. If valve is not tight at 15 psi signal, screw the piston-stem (3) out of the actuator stem some more. Next, calibrate zero on travel indicator scale with maximum pressure signal to actuator. Check for full travel at minimum pressure signal. If leak persists, increase the force on the clamp (11) 5

6 84000 Control Valve Instruction Manual EB0073 EB0074 Figure NPS 1 Angle Body Sub-Assembly Figure NPS 1 In-Line Body Sub-Assembly EB0075 EB0076 Figure NPS 1-1/2 and 2 Body Sub-Assembly Figure Linkage Mechanism 6

7 Instruction Manual Control Valve Table 1. COMMON PARTS KEY QTY DESCRIPTION VALVE SIZE 1 1 Valve Body, < 30 Ra Microinch Valve Body, < 20 Ra Microinch Bonnet Piston Stem Sub-Assembly Cv = * 1 Piston Stem Sub-Assembly Cv = Piston Stem Sub-Assembly Cv = Piston Stem Sub-Assembly * 1 Drive Mechanism Sub-Assembly * 1 Compressor * 2 Wave Spring Wave Spring * 1 Retaining Ring * 1 Diaphragm, Closure Member Drive Nut, Actuator Yoke Bonnet Flange Clamp * 1 O-Ring, Stem Tell Tale Port * 1 O-Ring, Bonnet Hex Head Cap Screw Jam Nut Travel Indicator Type 32 Actuator Type 54 Actuator * Recommended Spare Parts 7

8 84000 Control Valve Instruction Manual Preferred Flow Directions for Self-Draining (Pages 8 and 9). A A B B EB0077 EB0078 Figure 5. NPS 1 Angle Valve Body Positioned for Forward Flow Self Draining Port A to B Figure 6. NPS 1 In-Line Valve Body Positioned for Forward Flow Self Draining Port A to B B B EB0077 A EB0078 A Figure 7. NPS 1 Angle Valve Body Positioned for Forward Flow Self Draining from Port B to A (Bonnet rotated 90 o to show tell-tale port) Figure 8. NPS 1 In-Line Valve Body Positioned for Forward Flow Self Draining from Port B to A (Bonnet rotated 90 o to show tell-tale port) 8

9 Instruction Manual Control Valve B A B A EB0079 EB0080 Figure 9. NPS 1-1/2 & 2 Angle Valve Body* * Recommended for processes where atmospheric or slight vacuum is present downstream of Port "B" (Ports A & B MUST be drained separately!) Figure 10. NPS 1-1/2 & 2 Angle Valve Body Positioned for Self Draining from Port B to A 9

10 84000 Control Valve Instruction Manual Down Travel Stop Down Travel Stop Up Travel Stop Up Travel Stop EB0182 EB Angle Body with Type 32 Actuator ATO/FC Action In-Line Body with Type 32 Actuator ATC/FO Action, Dual Stop EB Angle Body shown with Type 32 and DVC In-Line Body shown with Type 32 and 3660/3661 Positioner Figure 11. Dimensional Drawings for Size NPS 1 Angle and In-Line, inches [millimeters] NOTE: Actuator requires 4-1/2 inches (115 mm) vertical clearance. For proper adjustments to dual travel stops, please refer to actuator instructions. 10

11 Instruction Manual Control Valve EB0184 EB NPS1-1/2 and 2 Angle Valves with Type 54 Actuator /2 and Angle Bodywith Type 54 Actuator and DVC6000 Figure 12. Dimensional Drawing for Size NPS 1-1/2 and 2 Angle: inches [millimeters] NOTE: Actuator requires 4-1/2 inches (115 mm) vertical clearance. For proper adjustments to dual travel stops, please refer to actuator instructions. Table 2. VALVE SIZE C D E F G NPS in mm in mm in mm in mm in mm 1-1/ Table 3. WEIGHTS, VALVE ASSEMBLIES AND ACTUATORS VALVE SIZE ANGLE ASSY IN-LINE ASSY ACTUATOR WEIGHTS NPS lbs kgs lbs kgs TYPE lbs kgs / N/A N/A

12 84000 Control Valve Instruction Manual FIELDVUE, PlantWeb, Fisher and Baumann are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson and the Emerson logo are a trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or more patents or under pending patent applications. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user. Emerson Process Management Marshalltown, Iowa USA Sorocaba, Brazil Chatham, Kent ME4 4QZ UK Dubai, United Arab Emirates Singapore Singapore Fisher Controls International LLC All Rights Reserved.