INSTALLATION AND MAINTENANCE INSTRUCTIONS For Chemline EC & EK Series Characterized Control Valves Sizes 1/2 6 Installation (all sizes) 1. Before installation, check the stainless steel reinforcing rods as well as the bolts on the actuator. If necessary tighten them. 2. Make sure the piping and valve body are clean and free of any solid foreign material. 3. The valve should be mounted between full-face flanges. The valve housing can be damaged by improper installation and/or improper tightening of bolts. Follow bolt pattern diagram below. 4. You will find the valve number on the valve body. Shown on these tags are the valve working pressures and temperatures. Should working conditions change, check whether the material of the actuator or other parts are still appropriate. 5. Manual or actuated shut-off valves are recommended in front and behind the control valve for installation and future maintenance. Strainers are recommended to avoid damage to the seat and plug. 6. The valve can be installed in any position, but it is recommended mounting with the actuator in an upright position, if necessary the actuator should be supported. 7. Use low torque flange gaskets and washers to protect housing and flange surfaces. Chemline fullface flange gaskets require lower torques. Use chart as show below if using Chemline gaskets: RECOMMENDED BOLT TIGHTENING TORQUE CHART NOMINAL SIZE RECOMMENDED TORQUE 1/2 3/4 7 11 (ft-lbs) 1-1-1/4-1-1/2 11 15 (ft-lbs) 2 2-1/2 15 18 (ft-lbs) 3 4 22 29 (ft-lbs) 5 6 29 36 (ft-lbs) 09/19/01 Page 1
CHEMLINE Installation & Maintenance Instructions Characterized Control Valves cont. 8. Flow direction is indicated on the valve housing by an arrow. Normal flow direction is with pressure against the plug. 9. Never exceed the maximum working pressure which is indicated on the name plate. The maximum working pressure decreases with increased temperature, as in the following chart. 10. The installation of a compressed-air conditioner is recommended. The maximum admissible air pressure is indicated on the name plate and dependent on the size of the actuator. IMPORTANT NEVER EXCEED THE MAXIMUM AIR PRESSURE. 11. The air connection at the actuator housing is G 1/4. It is fixed on the lower or upper cover of the actuator housing depending on the function of the actuator. Operating Specs, EC-Series: Air Filtration: 40 to 50 micron recommended Air connection: ¼ Body: Single seat globe-type Control signal: 3 15 psi, max 35 psi Installation: No limit on mounting orientation. Max Temp:PVC: 60C, PP:80C, PVDF/PTFE: 120C Nominal sizes: ½ to 4 Operation: NO, NC or DA Pressure rating:90 psi Spring range: 3 15 psi Sealing: Teflon PTFE Valve plug: Linear or equal percentage Valve lift: ½ -3/4 :15mm, 1-2 :25mm, 2-1/2-4 :40mm 09/19/01 Page 2
CHEMLINE Installation & Maintenance Instructions Characterized Control Valves cont. Operating Specs, EK-Series: Air Filtration: 40 to 50 micron recommended Air connection: ¼ Body: Single seat globe-type Control signal: 3 15 psi, max 90 psi; 4-20 ma Installation: No limit on mounting orientation. Max Temp: PVC:60C, PP:80C, PVDF/PTFE: 120C Nominal sizes: ½ to 4 Operation: NO, NC or DA Pressure rating:150 psi Spring range: 3 15 psi Sealing: Teflon PTFE Valve plug: Linear or equal percentage Valve lift: ½ -3/4 :15mm, 1-2 :25mm, 2-1/2-4 :40mm Weight: 5.2 kg Maintenance Refer to DRAWING IOD-104a: 1. On spring return closed valves, apply 15 psi air pressure to the actuator air connection. This must be done to avoid damaging the threads on the plug (14). 2. Remove body (15) from bonnet (10) by unscrewing nuts (6), washers (5) Remove threaded rods (7), ensure that rods are not loosed from the mounting plate (3). A strap wrench may be used. Avoid using a metal wrench on plastic valves or damage may occur. 3. 1. Remove bonnet (10) from mounting plate (3). 2. Remove and replace body O-ring (12), and bellows O-ring (18). 4. Remove (unscrew) plug (14) from the stem (1). Bellows must be held while undoing the plug (14). Screw new plug into bellows hand-tight. IMPORTANT DO NOT ATTEMPT TO PULL BELLOWS OFF THE STEM OR DAMAGE WILL OCCUR TO THE THREADS 5. Remove seat (16) by inserting a tool into the holes (two small allen keys and a screwdriver work well). Turn counterclockwise. Remove and replace the seat O-ring (17). Use tool to replace seat by turning clockwise until hand-tight. Make sure seat (16) is flush against body (15). Check by looking through valve inlet. 6. Change or replace all O-rings and check all parts for wear and or abrasion, replace as necessary. 7. It is recommended that the spare parts be exchanged only by experienced personnel as different structural dimensions have to be taken into account during the assembly of the valve. Should major repairs be necessary, we recommend you send the valve back to Chemline. 8. To re-assemble valve, repeat steps 1 through 6 in reverse. 09/19/01 Page 3