Contents 1.0 General 1.1 Model Number........................... 2 1.2 Specifications............................ 2 1.3 Dimensions.............................. 3 Repair Kit Materials & Part Numbers........ 3 Valve Materials & Part Numbers............ 4 2.0 Installation................................. 5 3.0 Maintenance 3.1 Preventive Maintenance................... 5 3.2 Troubleshooting........................... 5 Mallard Control 1500 S.E. 89th Street Oklahoma City, OK 73149 USA Phone: (405) 631-1533 Fax: (405) 631-5034 E-mail: sales@circorenergy.com www.circorenergy.com Mallard-5127IOM-Nov-11-2up-HP 2011 CIRCOR Energy Mallard Control is a Brand of CIRCOR Energy Litho USA Mallard reserves the right to change designs, materials or specifications without notice or without obligation to furnish or install such changes on products previously or subsequently sold. Viton is a registered trademark of DuPont Dow Elastomers. Inconel is a registered trademark of Special Metals Corporation, USA
1.0 General 1.1 Model Number Information 1.2 Specifications Body Style Angle Process Connections 2" MNPT x 1" FNPT Pressure Rating 3000 psig (200 bar) Assembled Valve Temperature Limits -50 to 200 F (-46 to 93 C) ANSI Leakage Rating Class IV Materials of Construction Description Material Valve Body LCC Bonnet 1018 Steel, Electroless-Nickel Coated Hammer Nut Carbon Steel Trim 17-4Ph Stainless Steel,Tungsten Carbide (Optional) Valve Stem 303 Stainless Steel, 316 Stainless Steel (Optional) Packing PTFE V-Ring Seals Buna, Viton (Optional) Diaphragm Housings Steel Diaphragm Buna Reinforced with Nylon Fabric Actuator Spring Steel Approximate Weight with Actuator / Pressure Ratings Actuator Weight (lbs., kg) Max. Differential Pressure Size lbs. kg (psig) (bar) No. 35 25 11.3 1500 103 No.70 35 15.8 3000 200 Page 2
1.3 Dimensions Repair Kit Materials & Part Numbers 316SS Trim Repair Kits 0.25 QO Buna-N 80071 0.38 QO Buna-N 80072 0.50 QO Buna-N 80073 0.25 QO Viton 80081 0.38 QO Viton 80082 0.50 QO Viton 80083 Meets NACE MR0175 Specifications Carbide Trim Repair Kits 0.25 QO Buna-N 80074 0.38 QO Buna-N 80075 0.50 QO Buna-N 80076 0.25 QO Viton 80084 0.38 QO Viton 80085 0.50 QO Viton 80086 Carbide / 316SS Trim Repair Kits 0.25 QO Buna-N 80087 0.38 QO Buna-N 80088 0.50 QO Buna-N 80089 0.25 QO Viton 80090 0.38 QO Viton 80091 0.50 QO Viton 80092 Valve Repair Kits (Less Trim) #35 Buna-N 80077 #35 Viton 80078 Complete Valve Topworks (Less Trim) Description Part No. #35 Fail Open 80079 #35 Fail Close 80080 Replacement Hardware Materials & Part Numbers Qty. 1 Adjusting Screw 316SS 51424 1 Jam Nut SS 55306 12 Diaphragm Housing Screw 316SS 51420 12 Diaphragm Housing Nut 316SS 51422 Qty. 2 Hex Nut SS 51805 1 Lock Washer SS 51807 1 Packing Plug 316SS 51262 1 Snap Ring SS 51436 Page 3
Valve Materials & Part Numbers Item Qty. 1 1 Adjusting Screw CS 51300 2 1 Jam Nut CS 51303 3 1 Upper Spring Retainer CS 51296 4 1 Spring OTMB 51292 5 1 Diaphragm Plate CS 51284 6 1 Upper Diaphragm Housing CS 51280 7 1 Lower Spring Retainer CS 51288 *8 1 Diaphragm Neoprene 51276 9 1 Lower Diaphragm Housing CS 51272 10 1 Diaphragm O-Ring Buna 51310 Viton 51312 11 2 Washer Bearing Steel 51837 12 12 Diaphragm Housing Screw CS 51314 13 12 Diaphragm Housing Nut CS 51316 14 2 Hex Jam Nut CS 51259 15 2 Hex Jam Nut CS 51444 16 1 Position Indicator Assembly CS 51313 17 1 Lock Washer CS 51322 *18 1 Stem O-Ring Buna 51268 Viton 51270 19 1 Packing Plug CS 51260 20 1 Snap Ring CS 51311 21 1 Hammer Nut CS 51195 22 1 Travel Stop CS 51831 23 1 Stem 303SS 51414 316SS 51416 *24 1 Lower Housing O-Ring Buna 51264 Viton 51266 *25 B Packing Kit Includes: B1 1 Upper Packing Retainer Brass 51203 B2 1 Packing TFE B3 1 Lower Packing Retainer SS 51210 *25 SS Packing Kit Includes: SS1 1 Upper Packing Retainer SS 51204 SS2 1 Packing TFE SS3 1 Lower Packing Retainer SS 51210 26 1 Packing Spring *27 1 Packing Plug O-Ring SS Inconel Buna Viton 51197 51193 28 1 Plug Guide SS 29 1 Cage CS 51830 *30 1 Seat O-Ring Buna 60078 Viton 60080 31 1 Valve Plug,.25-.38 QO 316SS 51844 Carbide 51845 1 Valve Plug,.5 QO 316SS 51839 Carbide 51840 Item Qty. 1 Seat,.25 316SS 51835 Carbide 51841 32 1 Seat,.38 316SS 51838 Carbide 51842 1 Seat,.50 316SS 51836 Carbide 51843 33 1 Body CS 51443 34 1 Seat / Cage O-Ring Buna 51833 Viton 51834 35 1 Lock Washer CS 10080 *Recommended Spare Parts Meets NACE MR0175 Specifications Page 4
2.0 Installation 1. Prior to valve installation, inspect the unit for damages which might have occurred during shipment and handling. Remove any items covering the process connections of the valve. Inspect the inlet and outlet connections to assure that no debris has become lodged inside the valve. 2. Install valve using good piping practices. 3. Connect instrument air to the actuator. WARNING: Working pressure of control valve body does not necessarily reflect the shut-off pressure of which the actuator is capable. Check actuator shut-off charts or call the factory. 3.0 Maintenance WARNING: System pressure must be bled off to 0 psig prior to any maintenance involving disassembly of the valve or valve actuator. 3.1 Preventive Maintenance 1. Seat and Valve Plug Normal Service: Check for wear or damage every six months. Severe Service: Check for wear or damage every sixty days. 2. Valve Stem O-Ring Inspect once a year. 3. Actuator Diaphragm Inspect once a year. 4. Body Check for wear or damage every time the actuator is removed. 3.2 Troubleshooting Problem Possible Cause Fix Debris between the plug and seat preventing tight shut-off. Remove debris. Valve leaks when closed. Plug and seat are worn out. Replace trim. Increase actuating air pressure to 20 psig. Valve will not open. Pressure drop across valve seat is too great. If this does not solve the problem, then the orifice is too large. Contact factory. Supply air leaking out of Diaphragm is worn or torn. Remove pressure and disassemble. diaphragm housing breather Diaphragm plates have worked loose If diaphragm is damaged, replace. plug during operation. and need to be tightened. If nuts that hold diaphragm are loose, tighten. Page 5