OM2-8193-0200 Corrosion-Resistant Teflon Control Valve Model : HIT User's Manual
NOTICE While the information in this manual is presented in good faith and believed to be accurate, Azbil Corporation disclaims any implied warranty of merchantability or fitness for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer. In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice. 1993 2013 Azbil Corporation All Rights Reserved.
1. GENERAL This manual comprises a general overview of the structure, operating procedures, and maintenance of Model HIT Corrosion-Resistant Teflon Control Valves. 1.1 Structure A Corrosion-resistant Teflon Control valve consists of three major sections: valve body, actuator, and positioner as shown in Figure 1.1. Acturator Positioner Valve body Figure 1.1. Basic Structure of Control Valve 1
1.1.1 Valve Body There are two types of valve bodies: regular and bellows, classified by type of plug. The parts in contact with fluid, such as valve body interior, valve plug, and guides, are made of highly corrosion-resistant PTFE. The outer frame of valve body, the bonnet, and the valve stem are made of stainless steel. 1.1.2 Actuator The model HIT valve employs the Model PSK1 actuator, a multi-spring diaphragm motor. By its diaphragm and springs, it converts a pneumatic signal into a position signal with which to drive the valve plug via a valve stem. For manual operation, a manual handwheel can be installed on top of the control valve. 1.1.3 Positioner (optional) Refer to the relevant operator's manual: OM2-8310-0400: Single-acting Pneumatic Valve Positioner, Model VPE OM2-8313-0100: Single-acting Electric/Pneumatic Valve Positioner, Model HEP CM1-AVP300-2001: Smart Valve Positioner, Model AVP 1.2 Control Valve Specifications A nameplate as shown in Figure 1.2, is attached to each control valve. The nameplate indicates the model number, product number, date of manufacture, valve size, parts materials, and other major specifications. Before using the control valve, be sure its specifications conform with your intended use. When making any inquires on the control valve, such as for requesting information on modifications of the valve or ordering replacement parts, please mention the product number. Figure 1.2. Control Valve Nameplate 2
2. STRUCTURE 2.1 Structure of Valve Body 2.1.1 Regular The structure of the regular valve body is shown in Figure 2.1. 1 2 3-1 3-2 4 5 6 2 4 7 8 9 10 12 13 14 15 16 17 18-1 18-2 18-3 11 19 20 21 No. Parts Material No. Parts Material 1 Valve stem SUS316 12 Bonnet SUS304 2 O-ring(P10) FEPM 13 Guide holder PTFE 3-1 Packing compression nut SUS316 14 Screw(M6x10L) SUSXM7 3-2 Lock nut SUS304 15 Valve plug PTFE 4 O-ring(P16) FEPM 16 Valve body SUS304 5 Spring SUS316 17 Rubber seat FPM 6 Packing ring SUS316 18-1 O-ring FEPM 7 V PTFE retainer PTFE 18-2 PTFE ring PTFE 8 V PTFE packing PTFE 18-3 O-ring FEPM 9 V PTFE receiver PTFE 19 Flow direction indicator SUS304 10 Retainer SUS304 20 Driving screw SUS304 11 Screw SUS316 21 PTFE main body PTFE Figure 2.1. Structure of the Regular Valve 3
2.1.2 Bellows Type Structure of the bellows-type valve body is shown in Figure 2.2. 3 4 5 6 7 8 9 1 2-1 15 16 2-2 10 11 17 18-1 18-2 18-3 19 12 13 20 21 14 22-1 22-2 22-3 23 24 No. Parts Material No. Parts Material 1 Valve stem SUS316 15 Bonnet SUS304 2-1 Packing compression nut SUS316 16 Tape liner PTFE(V-7980) 2-2 Lock nut SUS304 17 Screw(M6x10L) SUSXM7 3 O-ring(P10) FEPM 18-1 O-ring FEPM 4 O-ring(P16) FEPM 18-2 PTFE ring PTFE (For upper guide spacer) 5 V PTFE retainer PTFE 18-3 O-ring FEPM 6 V PTFE packing PTFE 19 Guide spacer PTFE 7 V PTFE receiver PTFE 20 Valve plug PTFE 8 Spring SUS316 21 Rubber seat FPM 9 Packing ring SUS316 22-1 O-ring FEPM 10 Vent plug SUS316 22-2 PTFE ring PTFE (For lower guide spacer) 11 Vent bushing SUS316 22-3 O-ring FEPM 12 Valve body SUS304 23 Flow direction indicator SUS304 13 Retainer SUS304 24 Driving screw SUS304 14 PTFE main body PTFE Figure 2.2. Structure of Bellows-type Valve 4
3 5 6 Pneumatic actuator 2 1 4 Valve body No. parts 1 Stem connector (pointer) 2 Bolt 3 Actuator stem 4 Valve stem 5 Yoke 6 Setscrew (hex socket head) Figure 6.1. Parts for Removing the Actuator 6.3 Disassembly of Valve Body 6.3.1 Disassembly of Regular Valve Body For disassembly of the regular valve body, refer to Figure 2.1 and proceed as follows: (1) Loosen the packing compression nut -1. (2) Loosen the four hex-socket-head setscrews (M6) around the bonnet by using a hex bar wrench (nominal size 3 mm). Loosen the bonnet from the valve body by using a wrench (nominal size 65 mm). Pull up the bonnet to remove it from the valve stem. (3) Remove the guide holder. Remove the valve stem together with the valve plug. CAUTION Never remove the seal retainer, PTFE main body, or rubber seat from the valve body. (4) Remove the packing compression nut -1, spring, packing ring, V PTFE retainer, V PTFE packing and V PTFE receiver from the bonnet and guide holder. (5) Remove the gland. O-ring and guide O-ring. 10
6.3.2 Disassembly of Bellows-type Valve Body For disassembly of the bellows-type valve body, refer to Figure 2.2 and proceed as follows: (1) Loosen the packing compression nut -1. (2) Loosen the four hex-socket-head setscrews (M6) around the bonnet by using a hex bar wrench (nominal size 3 mm). Loosen the bonnet from the valve body by using a wrench (nominal size 65 mm). Pull up the bonnet to remove it from the valve stem. (3) Remove the valve stem together with the valve plug. Remove the guide spacer. CAUTION Never remove the seal retainer, PTFE main body, or rubber seat from the valve body. (4) Remove the packing compression nut -1, spring, packing ring, VPTFE retainer, V PTFE packing and V PTFE receiver from the bonnet. (5) Remove the gland. O-ring and guide O-ring. 6.4 Disassembly of Actuator 6.4.1 Disassembly of Direct-acting Actuator For disassembly of the direct-acting actuator, refer to Figure 6.2 and proceed as follows: (1) Disconnect the air piping and accessories from the actuator. (2) Remove the stem connector. (3) Remove the bolts (except the eyebolts) of the diaphragm case. (4) Loosen the nuts of the two eyebolts gradually and evenly. [These two bolts determine the initial spring compression setting when assembling the actuator.] (5) Remove the diaphragm case. Remove the rod and diaphragm unit upwards. (6) Remove the springs. 6.4.2 Disassembly of Reverse-action Actuator For disassembly of the reverse-acting actuator, refer to Figure 6.3 and proceed as follows: (1) Disconnect the air piping and accessories from the actuator. (2) Remove the stem connector. (3) Remove the bolts (except the eyebolts) of the diaphragm case. (4) Loosen the nuts of the two eyebolts gradually and evenly. [These two bolts determine the initial setting of spring compression when assembling the actuator.] (5) Remove the diaphragm case. Take out the springs. (6) Remove the rod and diaphragm unit upwards. 11
7. ASSEMBLY OF CONTROL VALVE CAUTIONS Before starting assembly, fully inspect all parts. If you find any damaged parts, replace them with new ones. Never re-use old gland packing. Be sure to use fresh gland packing whenever assembling the control valve. When ordering parts, please also mention the product number of the control valve, which is indicated on the nameplate. 7.1 Assembly of Valve Body For assembly of the valve body, as a general rule, follow the disassembly procedures in the reverse order. Thoroughly clean all parts before starting assembly. Be sure they do not carry dust, dirt or other foreign matter. All sealing parts and mating surfaces should be covered with grease or another appropriate sealing lubricant that will not be attacked by the process fluid. When control valves are shipped from the factory, silicone grease is applied as sealing lubricant (except for oil-free control valves.) 7.1.1 Assembly of Regular Valve Body For assembly of the regular-type valve body, refer to Figure 2.1 and proceed as follows: (1) Set the O-ring -1, 3 and PTFE ring -2 in the valve body. (2) Set the valve plug with valve stem in the guide holder, and set them in the valve body. (3) Setting so that the valve stem passes through the center of the bonnet, couple the bonnet to the valve body using the threads. Turn the bonnet with the specified torque until the threading shoulder of the bonnet is brought into contact with the top plane of the valve body cylinder. For the tightening torque of the bonnet, see Table 7.1. (4) Apply Loctite to the four M6 hex-socket-head screws and drive them into the bonnet so that the bonnet is securely fixed and does not become loose. (When the valves are shipped from the factory, Loctite #602 is applied as the locking agent.) For the tightening torque of the setscrews, see Table 7.1. (5) Set the gland parts,,,,, and in this order. (6) Tighten the packing compression nut -1 until it is brought into contact with the bonnet. For the tightening torque of the nut, see Table 7.1. 7.1.2 Assembly of Bellows-type Valve Body For assembly of the bellows-type valve body, refer to Figure 2.2 and proceed as follows: (1) Set the O-ring -1, 3 and PTFE ring -2 in the valve body. (2) Set the guide spacer in the valve body. 13
(3) Set the O-ring -1, 3 and PTFE ring -2 in the guide spacer. Set the valve plug with valve stem into a position that the brim section of the valve plug is aligned with the centering location of the guide spacer. (4) Apply the tape liner on the bore of the bonnet. (The tape liner acts as a guide for the valve stem.) (5) Setting so that the valve stem passes through the center of the bonnet, couple the bonnet to the valve body by means of the threads. Turn the bonnet with the specified torque until the threading shoulder of the bonnet is brought into contact with the top plane of the valve body cylinder. For the tightening torque of the bonnet, see Table 7.1. (6) Apply Loctite to the four M6 hex-socket-head screws and drive them into the bonnet so that the bonnet is securely fixed and does not become loose. (When the valves are shipped from the factory, Loctite #602 is applied as the locking agent.) For the tightening torque of the setscrews, see Table 7.1. (7) Set the gland parts,,,,, and in this order. (8) Tighten the packing compression nut -1 until it is brought into contact with the bonnet. For the tightening torque of the nut, see Table 7.1. Table 7.1. Tightening Torques (N m {kgf cm}) Valve Size Bonnet Hex-socket-head Setscrews Packing Compression Nut 3/4" & 1" 250 ± 37 {2500 ± 375} [M68 1.5] 300 ± 45 {3000 ± 450} [M90 2] 350 ± 51 {3500 ± 525} [M100 1.5] 1-1/2" 8 ± 1.2 {80 ± 12} [M6 screw] 80 ± 12 {800 ± 120} [M26 1.5] 2" 7.2 Assembly of Actuator Before starting assembly, be sure the parts are perfect without any flaws, deformation, peeling of paint, or other defects, To assemble the actuator, proceed as follows: 7.2.1 Assembly of Direct-acting Actuator To assembly the direct-acting actuator, proceed as follows: (l) Set the bearing (together with the dust seal) to the yoke. Fix the bottom diaphragm case to the yoke with the four M10 bolts. (2) Fix the spring plate (sec Figure 7.1) and set the springs on the spring plate. (3) Insert in to the bearing the rod to which the diaphragm has been set. When doing this, be careful not to damage the bearing and dust seal with the threaded section of the rod. (For example, cover the threaded section with adhesive vinyl tape.) 14
235 ø218 (28) H A Figure 7.4. Overall Dimensions Table 7.3. Overall Dimensions and Weights Valve size (inch) 3/4 1 1 1/2 2 A (mm) 140 140 200 240 H (mm) PSK1D 425 425 455 455 PSK1R 445 445 475 475 Weight (kg) 15 15 18 23 19
8. DIRECT/REVERSE-ACTING CONVERSION AND SPRING RANGE MODIFICATION 8.1 Conversion To Direct- or Reverse-acting Type When you want to convert your control valve into a reverse-action type or a direct-action type, it is recommended to change the whole actuators. However, if you want to convert your actuator by replacing required parts only, you need the parts shown in Table 8.1 or 8.2. In these tables, + denotes the new parts which you need to acquire for the conversion and - denotes the parts which you don't need for the conversion and which will become surplus parts. Table 8.1. Parts for Direct to Reverse Conversion PSK1D PSK1R Parts Q'ty Parts No. Seal washers +4 82521069-101 Rod packing +1 82521067-102 Rain cap +1 82553334-101 Table 8.2. Parts for Reverse to Direct Conversion PSK1R PSK1D Parts Q'ty Parts No. Seal washers -4 82521069-101 Rod packing -1 82521067-102 Rain cap -1 82553334-101 For the conversion procedure, refer to Chapter 6 DISASSEMBLY OF CONTROL VALVE and Chapter 7 ASSEMBLY OF CONTROL VALVE. 8.2 Spring Range Modification To change spring ranges of Model PSK1 Actuator, refer to Table 8.3 which indicates the color coding, dimensions and the required quantities of actuator springs. Table 8.3. Actuator Springs Spring range kpa {kgf/cm 2 } Color coding Free length of springs mm Q'ty 80-240 {0.8-2.4} 120-290 {1.2-3.0} Yellow 89 4 Orange 73 4 20
10. OVERALL DIMENSIONS AND WEIGHTS (1) Main Unit of Model PSK1 235 ø218 240 M9 1 ø34.9 Stroke: 20 mm Effective diaphragm area: 160 cm 2 Maximum capacity of diaphragm chamber: 700 cm 2 Weight: 8 kg Table 10.1. Overall Dimensions (Main Unit) (2) Actuator with Top Handwheel Stroke mm Overall dimensions mm øb B ød H Maximum handwheel operating force N {kgf} Weight (kg) 20 218 235 140 390 160 {16} 9.5 Table 10.2. Overall Dimensions (Actuator with Handwheel) 24
Document Number: Document Name: OM2-8193-0200 Corrosion-Resistant Teflon Control Valve Model : HIT User's Manual Date: 1st edition: Nov. 1993 2nd edition: Dec. 2013 Issued/Edited by: Azbil Corporation