Document No. :KE-1001-05 WITS Operation Manual For Floating Type Ball Valves (Flanged Ends) ‘Thank you for having chosen KITZ products. For safe and trouble-free function and performance of the product, ensure to read and understand all items of this manual before valve mounting and operation. Keep this manual in @ conveni lace for your valve operators” IKiITZ CORPORATIONDocument No. :KE-1001-05 ‘This manual applies to the KITZ flanged ends floating type ball valves. This manual is prepared for manual valve operation. For electric or pneumatic valve operation, refer to the operation manual prepared by the manufacturers of relevant valve actuators CAUTION AND WARNING To ensure safe and trouble-free function and performance, please read all the contents of this manual before handling, snsportation, mounting and operation of valves. Keep this manuel to the place accessible to the operator, ‘The signal words “WARNING” and “CAUTION” are defined as follows: AAWARNING | Forint earncas cn oe ence QA CAUTION | ese ey ie ecenst oc roney Santee tach canons sal be ignored NOTES TO USERS Tris manual covers the normal usage of the product. Technical data and instructions for operation, maintenance and inspection of the product are prepared in consideration of safety. However, they are good only to cover typical applications as a general guideline to users. If technical assistance beyond the scope of this manual is required, contact KITZ Corporation or its distributors, The illustrations given in this manual do not introduce all details. If more detailed da refer to our relevant valve assembly drawings. 3 Any information provided in this operation manual is subject to revision at any time without notice. This edition cancels all previous issues. IKiTZ CORPORATIONDocument No. :KE-1001-05 CONTENTS Sheet I Construction and Design Features 1 0 Valve Operating Device 1+ es sssseiess 4 0 Transportation and Storage 1 v Valve Installation 10 v Valve Operation 15 w Periodic Inspection 20 Ww Disassembly and Reassembly s+ s0sssseses 24 IKiITZ CORPORATIONDocument No. :KE-1001-05 Sheet:1/29 CHAPTER I Construction and Design Features IKiTZ CORPORATIONDocument No, :KE-1001-05 Sheet2/29 Construction and Design Features 1. Construction and Design Features 1.1 The typical valve design is as illustrated below. 1.2 The rotation of the stem by 90° fully opens or closes of the valve, 1.3. Valves are serviceable only in fully open or closed position, 1.4 The ball is hold with two ball seats placed in the valve body and body cap. ‘The upstream pressure pushes the ball, which compresses the down stream side ball seat to completely shut off the fluid flow. 1.5 Fluid can flow through valve port in both directions, | a) a‘ \ Lever bande r rs — Pacing wher ~ Bos one ~ Gasket - -——-| - Sten ea a lustration introduces a typical construction. IKIT2 CORPORATIONDocument No. :KE-1001-05 Sheet’3/29 Construction and Design Features 2. Design Features 2.1. Stem Blowout Proof ‘The lower end of the stem is designed with an integral collar to be stem blowout proof. It also functions as the back seat to minimize the external leakage from the stem area, if the gland packing is deterior by a plant Fre. 22 Body Seal ‘The metal-to-metal body seat as the secondary body seat minimize the external leakage, if the non-metallic gasket is deteriorated by a plant fire, 23 Integral Seat ‘The integral seats on the body and body cap minimize the internal leakage, if the rron-metallc ball seats are deteriorated by a plant fire. Before fre ‘ar fre IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet-4/29 CHAPTER I Valve Operating Device IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet5/29 TI_Valve Operating Device 1. Lever Handle 1.1. The lever handle is directly mounted on the valve stem. 1.2 Rotation of the lever handle by 90° fully opens and fully closes the valve, Turning the lever clockwise closes the valve, and turning the lever counterclockwise opens the valve, IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 6/29 TI_Valve Operating Device 2. Worm Gear Operator 2.1 The worm gear operator is mounted on the valve. Refer to the approval drawing position of the handwheel the When re-orientation of worm gear operator is required, it shall be specified in the purchase order and take advice from KITZ Corporation 22 According to the arrow or letter on the handwheel, turning the handwheel clockwise closes the valve, and turning the handwheel counterclockwise opens the valve. 2.3 Handwheel operating torque depends on the size of valves, the direction for opening or closing, pressure in piping, and the tightening condition of the gland packing. 24 Worm gear operator is to transmit a large torque to valve stems, converting a torque from Grive shaft by means of reduction gearing unit using worm gears. Handwhee! gas: Open Close Worm Gear IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 7/29 CHAPTER II Transportation and Storage IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 8/29 1. Transportation ‘II_Transportation and Storage 1.1 Cautions for Safety Z\ WARNING |" Keep off the valve lifting area to prevent personal injury caused by unsecured valves, A\ CAUTION ) @ Take care not to damage painting surface of valves during transportation, Which may subsequently cause corrosion and get the valve rusty. If the valve is damaged, touch up paintings should be done, Take care the handling and storage of the carton packed product ‘The high humidity may damage the cartons. 1.2. Transportation 1.21 Keep packages as they are delivered just before installation, Ff the protective covers are found missing during transportation, provide appropriate type of protective covers. 1.22 Handle valves carefully so tha wey may not fall or drop on the ground. Any extraordinary mechanical impact should be avoided IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 9/29 ‘II_Transportation and Storage 2. Storage 2.1. Cautions for Safety A\ CAUTION (1) DO NOT store valves in a corrosive environment, which may cause corrosion on threaded portions of valves. (2) DO NOT remove protective covers unti installation, This will prevent the intrusion of any foreign object which could cause Q damage to the closure elements such as ball and seats. (8) DO NOT place any other objects on valves, and DO NOT step on them. Overloading may damage valves. (A) DO NOT carelessly pile up products to avoid risk of product damage and personal injury caused by unstable piling (5) Keep the valves in the open position during storage. Storing the valves in halfway position may deform the ball seats, leading to the internal leakage. 22 Storage 221 Store valves at a dust-free, low humidity and well ventilated places. Indoor storage is recommended 222 Storage of valves directly on the ground or conerete floor is not recommended, 223 Take appropriate measures to prevent valves from direct exposure to dust, rain and sunlight, if valves would be stored outdoors. IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:10/29 CHAPTER IV Valve Installation IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:11/29 WW_Valve Installation 1. Flange Type 1.1 Cautions for Safety Z\ WARNING (1) The sealing materials determines the characteristic of service fluid and service range of pressure and temperature, Check the valve specifications with the catalogs and/or the attached nameplate. Services beyond the valve specifications may cause fluid leakage and valve malfunctions. A\ CAUTION (3) Piping should be properly supported, if needed 1.1.1 Allow sufficient room for safe and easy operation, installation and subsequent maintenance of valves. 1.12 For smooth operation, inspection and maintenance, take appropriate measures for valves which are forced to be installed in small places. 1.13 Try not to install valves in the places where valve functions may be hampered by such outer forces as vibrations and others. 1.14 Tis recommended to install valves on horizontal pining in a upright position IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:12/29 WW_Valve Installation 1.2. Cautions for Safety Z\ WARNING QO? eee re ert ema ener valves (1) Take care not to atch fingers in anges during mounting work (2) Take care not to damage anges, balan ball seats surfaces (2) Pipes shouldbe propery supported, f needed | @ raisin sands tore operation. Packing tein presse may be lowered due to the stress relaxation which may take place during traneportatin and storage, leading to the occurrence of leakage through the and area (8) Be sue to insert new gaskets for valve mounting IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:13/29 WW_Valve Installation 1.2.1. Check the following items before valve mounting (1) Service conditions should be within the valve specifications. (2) Valve flanges should correspond with piping flanges. (@) Gasket contact surfaces of pines and valve flanges must be thoroughly inspected to make sure no scratch or any other indication of flaw is found, (4) The appropriate length should be kept between pipe flanges for the valve face-to-face dimensions including gasket thickness. 6 ‘The valve and pipe center should be aligned accurately. (6) Bolt holes of flanges should be arranged symmetrically such that they are lined up against the center line of flanges. 1.22 Before installation, the connecting pipes should be cleaned to remove any foreign object such as sand, dust and welding spatters from the connecting pipe interior. 1.23 Handle valves carefully so that they may not fall or drop on the ground. Any extraordinary mechanical impact should be avoided 1.24. Remove flange covers from valves just before installation. 1.25. Cheok all threaded areas after installation and retighten them, if needed 1.26 Piping should be flushed before test operation, with valves open, to assure removal of any foreign object that could damage valves. DO NOT operate valves during flushing IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:14/29 WW_Valve Installation 1.3. Installation Procedures 1.3.1. Make sure that pipes are aligned accurately. 1.32 The length between piping flanges should correspond with the valve face-to-face dimensions including gasket thickness. 1.33 Insert the valve between pipe flanges. Thread bolts through bottom bolt holes and tighten bolts lightly. 1.34 Insert gaskets between valve and pipe flanges. It is recommended to apply the gasket paste to gasket faces. ao 1.35 Make sure the correct alignment of gaskets, which are held by bottom bolts between valve and pipe flanges. 1.3.6 Thread bolts through the other bolt holes and tighten them lightly 1.3.7 Tighten botts evenly. gradually and alternately in a star pattern as shown below. The ends of all tightened bolts should protrude equally beyond the nuts, 1.38 Raise the line temperature and pressure gradually on test operation Retighten the threaded portions, if needed IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:15/29 CHAPTER V Valve Operation IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:16/29 1 2 24 22 V_Valve Operation Cautions for Safety A\ CAUTION a S 7 @ DO NOT apply excessive torque by using a pipe or any other device to operate the valve DO NOT loosen bolts and nuts of gland and flange area of pressurized valves. Avoid the services in intermediate position for long period, which may damage ball seats and cause seat leakage. @ @ © a @, Retighten the gland bolts and nuts before operation of the valve. Check a handle torque while retightening the bolts and nuts so that the operation won't become too difficut due to over-tightening The gland bolts should be altemately tightened with an even force. Valve should be kept fully open during the line test or pressure test. Tho ball seats may be deformed, if the valve is fully closed during test. Possible internal though-bore leakage may occur under such conditions. When service temperature fluctuates, retighten the gland bolts and nuts after the temperature is stabilized in preparation for the occurrence of stress relaxation of the gland packing (Open the valve gradually to prevent damages of pines, when the valve handles high temperature fluid such as steam. Take appropriate measures to prevent freezing. as needed Operation Lever handle Rotation of the lever handle by 90° fully opens and fully closes the valve. To close the valve, tum the operating handle clockwise according to the letters and the mark indicating the direction, Counterclockwise rotation will open the valve, Worm gear operator ‘According to the arrow or letter on the handwheel, turing the handwheel clockwise closes the valve, and turning the handwheel counterclockwise opens t \e valve, IKiTZ CORPORATIONDocument No. :KE-1001-05 3. Daily Inspection V_Valve Operation Sheet:17/29 In order to operate your valves safely and satisfactorily, daily inspection is very important Here are the inspection items ems to be Areas to be Inspection Inspected inspected Method Remedial Measure Gland Visual check Retighten gland bolts. land area With soap solution | Replace the gland packing. Visual check Retighten flange bolts Flange areas With soap solution | Replace gaskets. External Retighten each threaded leakage Visual check areas. Threaded areas With soap solution | Replace the parts as needed. Body and Body Cap | Visual check Replace the valve. surface With soap solution | Replace the vals Valve body Auditory check —_| Consult a piping engineer. Abnormal | Loosened bolts Auditory check _| Retighten bolts. Pipe vibration Auditory check —_| Consult a piping engineer Loosened alte ang | BOs and nuts Visual check Retighten bolts and nuts. Tactile check nuts Remove the foreign object. Internal Disassemble and inspect thrurbore = = the valve components. leakage (Replace the ball seats) Replace the valve. ven operating | Visual check Make sure that the valve is Position in predetermined position. Valve operation Tactile check Disassemble and inspect Disturbed operation | auditory check | the valve components, IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet:18/29 V_Valve Operation 4, Remedial Measures AX caution (1) Wear the protective items such as goggles, gloves and working boots. @)_ Take safety measures against toxic, flammable or corrosive fluids. (@) Reduce the line pressure to the atmospheric level before retightening gland (6) Reduce the line pressure to the atmospheric level, when the packing and aaskets are replaced or bolts and nuts are loosened. Operator should take protective measures to prevent direct exposure to the ‘lud, when the fluid spouts out from valves, 4.1. Leakage from the Gland Area Retighten the gland bos or nuts ifthe leakage from this area is detected . Evenly tighten the bolts or nuts alternately as shown below. Adequate torque should be applied when retightening the bolts or nuts so that the valve operation won't become difficult If it does not stop the leakage, the packing rings should be replaced. ith ath l J ABP 4.2 Leakage from the Flange Area Tighten bolts evenly, gradualy and alternately in a star pattern as shown below. IKiTZ CORPORATIONDocument No. :KE-1001-05 5. Troubleshooting V_Valve Operation Sheet:19/29 Defect Possible causes Remedial measure Disturbed valve operation Foreign objects may have choked up the valve body cavity and stuck around the ball seats, Disassemble and inspect the valve components. Excessive valve torque Foreign objects may have stuck to the stem Remove the foreign objects and check the valve. Foreign objects may have choked up the valve body cavity and ‘stuck around the ball seats Flush the valve bore with the fluid with the valve slightly open to remove the built-up objects or disassemble and inspect the valve The gland bolts may have been overly tightened. ‘Once loosen the gland bolts and adequately retighten them to an extent that the leakage does not Leakage from the gland area Loose gland bolts. Retighten the gland bolts. Uneven tightening of the gland bolts. ‘Once loose the bolts and evenly retighten them, Damage on the gland packing Replace the gland packing Internal through-bore leakage Damage on the ball seats, Disassemble and inspect the valve. Replace ball seats. Abnormal noise or vibration Loose bolts and nuts, Retighton the bolts and nuts. IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet20/29 CHAPTER VI Periodic Inspection IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet21/29 MI_Periodie Inspection 1. Periodic Inspection 1.1. Carry out the periodic inspection on the valve in use at least once a year 1.2. Examine the valve to ensure the smooth operation and sufficient function 1.3 See Chapter V “Valve Operation” for inspection items and inspection methods. 1.4 Where valves and adjoining piping are not inspected daily or not operated for a long period, a periodic inspection is also recommended. (A periodic inspection should be carried out on all valves.) 1.5 Itis particularly important to thoroughly check the valves used for the following service ) Where performance failure of valves could result in a major shutdown of an entire plant unit b) Where the clogaing of pipes with the fuids is likely to occur. ©) Where corrosion or/and wear by the fluids is expected 16 Its recommended to replace the gland packing at the time of periodic inspection 2. Inspection and Maintenance In case pipelines or facilities where valves are installed are shut down for the pipeline inspection, remove the valves from the pipelines and perform the body and seat pressure tests as well as operation tests, if needed. If any defect is found, disassemble the valves for further inspection. The valves must pass required inspections before being sent back to the pipelines or facilities for reinstallation IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet22/29 MI_Periodie Inspection 2.1 Care for the removal from and installation to pipelines of valves. Z\ WARNING @ @ o 6) Discharge the fluid from the pipes and reduce the line pressure to the atmospheric level when disassembling valves. Trapped pressure of fluid is very dangerous and could cause accidents resulting in personal injury In case of installation of pipe end service, the fluid might enclose between the valve and the blank flange. Open the valve and discharge the fluid from the pipe before the blank flange removal. Discharge the fluid and pressure trapped within the valve body with the valve intermediate position before disassembling. In case fluid is toxic, inflammable or corrosive, remove the fluid completely ‘rom pipes and internal valves. Take protective measures to prevent direct exposure to the fluid and catching fire Keep off the working area to prevent personal injury if valves are installed at higher places. A\ CAUTION M @ @ o 6) Wear the protective items such as gogdle, gloves and working boots. Keep a secure footing for valve cismantle and installation Piping and valves should be properly supported, if needed, Before dismantling valves from the pipeline, mark the valve end flanges and coupled pipe flanges with their orginal positions. Reinstall the valve on pipes according such marks after reassembly. Be sure to insert new gaskets for valve mounting 22 Disassemble & Assemble Refer to Chapter VIl for assembly and disassembly procedure. IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet23/29 MI_Periodie Inspection 23. Test and Inspection Refer to the following procedure for test and inspection. 28.1 Operation Test (1) Check smooth operation of valves without galling or sticking of internal valve ‘components. (2) Check that the stem is firmly assembled with the ball (3) Ensure that there should be no offset of the ball port and ball seats in the fully open position. The ball should not be protruded into the valve port other than the rounded surface of the ball port edges. 232. Shell Test and Seat Leakage Test (1) Care for shell test and seat leakage test A\ CAUTION (1). Wear the protective items such as goggle, gloves and working boots. e (2) Take sufficient precautions before shell test and seat leakage test for (2) Shell Test and Seat Leakage Test All valves are subjected to a hydrostatic or pneumatic shell test and seat leakage test at the required test pressure after assembly. Refer to the JIS 82003, JPI-7S-39 or API-598 for test methods. IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet24/29 CHAPTER VI Disassembly and Reassembly IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 25/29 1 Disassembly V_Disassembly and Reassembh 1.1 Cautions for Safety Z\ WARNING (1) Operator must take protective measures to prevent direct exposure to the fluid or catching fire (1) Wear the protective items such as goggle, gloves and working boots. e (2) Take care not to catch fingers in flanges during disassembly. (3) When disassembling valves of large sizes, use an appropriate machine to lift up 1.2. Before Disassembly Note: see sheet 29/29 for reference figure, 1.2.1 Disassemble the valve at dust~free place, 1.22 Take care not to damage the flange surfaces, ball and stem. 1.23 Give identification marks on edges of the coupled flanges for adequate and easy coupling of the body cap on subsequent reassembly. 1.24 Since the ball seats (30) and seat retainers (150) of valves, class 600 and 1500 are ccaulked, they cannot be separated IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 26/29 V_Disassembly and Reassembly 1.3. Disassembly procedure 134 132 133 134 135 138 137 138 139 Note: see she: 29/29 for reference figure. Full close the valve. Remove the snap ring (48) and stopper (49) from the stem (3) Remove the cap nuts (32) Disassemble the body (1) and body cap (2). For class 600 and 1500, the body cap(2) and seat retainer (150) might be lifted together. Pay attention not to drop the seat retainer (150) and its assembly. Remove the gasket (19) or O-Ring (45A) from the body (1) or body cap (2) Remove the ball) from the body (1) For class 1500, remove the plug (85), Remove the stem(3) from inside the body (1). Remove the stem bearing (67) from the stem (3) or body (1) 1.3.10 Remove the ball seats (30) from the body (1) and body cap (2). 13 For class 600 and 1500, remove the assemblies of the ball seat (30) and seat retainer (150) , and the seat springs (143) from the body (1) and body cap (2). Remove the (O-ring (45B) from the seat retainer (150). | Remove the gland bolts (36) to disassemble the gland (7) and gland packing (8) IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet27/29 V_Disassembly and Reassembh 2. Reassembly procedure 2.1 Caution for reassembly M @ @ 6) 6) © A\ CAUTION Wear the protective Romesh rote, doves ard waning bok Wo open fine osotng shel be ons inthe werk ares Te care na to etch gh in neo ding asa leakage. When assembling valves of large size, use appropriate machine to lift up valves. DO NOT apply the lubricant to valve wet areas, when the valves handle oxygen, 22 Before reassembly 22.1 222 223 224 225 228 227 Check all parts before reassembly. If any unsatisfactory function is found, replace the The consumables such as ball seats, gland packing, gasket, o-rings, stem bearing and ete. should be prepared before reassembly Clean all parts for rouse to thoroughly remove dust and other foreign objects. ‘Assemble the valve in a dust-free place. Take care not to damage the flange surfaces, ball, ball seats and stem Ensure to assemble the valve in accordance with the marks given during disassembly. Keep in mind all bolts, nuts and plugs should be securely tightened IKiTZ CORPORATIONDocument No. :KE-1001-05 Sheet 28/29 V_Disassembly and Reassembly 23. Reassembly procedure 23.1 232 233 234 235 238 237 238 239 23. 234 23.1 Note: see she: 29/29 for reference figure. Mount the gland packing (8) and Gland (7) in the body (1), temporary tightening the gland bolts (36), Mount the ball seats (30) in the body (1) and body cap (2) For class 600 and 1500, frst attach the o-ring (45B) to the seat retainer (150) and assemble the seat spring (149) to the body (1) and body cap (2), and then mount the assembles of the ball seat (30) and seat retainer (150) to the body (1) and body cap (2) Assemble the stem bearing (67) to the stem (3). Insert the stem (3) from inside the body (1) Make sure that the stem collar contacts the body, and set the stem (3) in fully closed position of the valve. Mount the ball (4) in the body‘). Mount the gasket (19) or o-ring(45A) to the body) Mount the body cap (2) to the body (1). Make sure to place the ball seat (30) or seat retainer (150) in the correct position without dropping them from the body(1) and body cap (2). For class 1800, screw the plug (85) into the body<1) Fasten the body (1) and body cap (2) with the cap bolts (33). Evenly tighten the cap bolts (33) alternately and gradually in a star pattern. Once the bolts are properly tightened, the end of the bolts should evenly protrude beyond the nuts. }0 Mount the stopper (49) in the stem (3) and fix it with the snap ring (48). 1 Tighten the gland bolts (36) adequately for trouble-free operation 2 All threaded areas should be securely tightened. Retighten them, if found loosened. IKiTZ CORPORATIONDocument No. :KE-1001-05 V_Disassembly and Reassembly 3. Cross-sectional assembly drawing oD Sheet29/29 1 [oor [eyo > [i Paine 3 [ern ] [east ] 33 cast 35 [Gap Bok | Sap fre | Stoo a1 [Sten Boning | 2th [Serre Pn j This illustration introduce a typical construction for Class 150 and 300, Refer to the approval drawing before disassembly and assembly 3 [Sten [oa 20 | Packing Wshor 36_[ land Bok 5A_[ One | Snes be 4 [ Ste 14S Sest Sorin 150_[ Seat Retainer ‘This illustration introduce a typical construction for Class 600 and 1500 Refer to the approval drawing before disassembly and assembly. IKiTZ CORPORATIONDocument No.: KE-1059-00 KITS Operation Manual For Floating Type FILLTITE Seated Ball Valves UTDZ1H = SCTDZ1H [Conform to ISO, Flanged Ends} Thank you for having chosen KITZ products, For safe and trouble-free function and parformance of the product, ensure to read and understand all itens of this mrual before valve mounting and operation Keen tis manualin a converien place for your valve operator’ easy access IKiITZ CORPORATIONDocument No.: KE-1059-00 ‘This manual applies to the KITZ flanged end floating type FILLTITE seated ball valves. This manual is prepared for manual valve operation. For electric or pneumatic valve operation, refer to the operation manual prepared by the manufacturers of the relevant valve actuators. CAUTION AND WARNING To ensure safe and trouble-free function and performance, please read all the contents of this manual before handling. transportation, mounting and operation of valves. Keep this manual to the place accessible to the operator. “The signal words “WARNING” and “CAUTION” in this manual are defined as follows: Indicates potentially hazardous conditions which may result in ZX WARNING | st try permet foun werner Indicates potentially hazardous conditions which may result in AX CAUTION _| rit te rece! or poverty damage if sich cans ae ignored. NOTES TO USERS This manual covers the normal usage of the product Technical data and instruction for operation, ‘maintenance and inspection of the product are prepared in consideration of safety. However, they are od only to cover typical applications as general guidelines to the users. If technical assistance beyond the scope of this manual is required, contact KITZ Corporation or its distributors. ‘The ilustrations given in this manual do not show all details. more detailed data are needed. refer to our relevant valve assembly drawings * Any information provided in this manual is subject to change without notice. This edition cancels al previous issues IKiITZ CORPORATIONDocument No.: KE-1059-00 CONTENTS Page L Construction and Design Features 1 I. Valve Operating Device 4 IIL Transportation and Storage 7 IV. Valve Installation 10 V. Valve Operation ---~ 15 VI. Periodic Inspection 20 VI. Disassembly and Reassembly 24 IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 1/31 I Construction and Design Features IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 2/31 1 Construction and Design Features 1. Construction and Design Features 1.1 The typical valve design is as illustrated below. 1.2. Rotation of the stem by 90° fully opens or closes the valve. 1.8 This valve is designed for use in the full open or closed position only. 1.4 The ball in the valve body is not fixed to any parts such as the stem but it is held with two ball seats placed on each side of the upstream (inlet) and downstream (outlet) in the valve body. When the valve is closed, the upstream pressure pushes the ball to the ball seats on the downstream side to shut off the line fluid 15. Fluid can flow through the valve port in both directions. wourTiNa Lance \ aL ‘LANO PacKaG y Tr eau ~ - - This illustration shows a typical construction of the floating type carbon seat ball valve IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 3/31 1 Construction and Design Features 2. Design Features 2.1 Stem Blowout Proof ‘The lower end of the stem incorporates an integral collar to prevent a blowout of the stem. Packing and its adjoining component parts are made of fire-retarding material and its firesafe structure minimizes leakage in case of a plant fire. ano x _- Lawn Bus! x Le eo maser = PACKING stew 22 Body Seal Sealing of the connection part of the body and the body cap are doubly ensured with gaskets and metal-to-metal contact sealing to prevent leakage through the ‘connection part in case of a plant fire. = ed eau See || ae caseer rea we SH Before fro Atectre 2 Integral Seat ‘The integral seats incorporated in the body work as the secondary sealing and prevent leakage in case the ball seats are thermally deteriorated by a plant fire IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 4/31 Il. Valve Operating Device IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 5/31 IL Valve Operating Device 1. Lever Handle 11 Alever handle is directly mounted on the valve stem. 1.2. Rotation of the lever handle by 90° fully opens and fully closes the valve. Turning the lever clockwise closes the valve and turning the lever counterclockwise opens the valve. | ||| cen i I +—> Phitd flow direction +—> Phi flow direction IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 6/31 Valve Operating Device 2. Worm Gear Operator 2.1 A.worm gear operator is mounted on the valve. 22 According to an arrow or letters on the handwheel, turning the handwheel clockwise closes the valve, and turning the handwheel counterclockwise opens the valve. 23 The handwheel operating torque differs depending on the valve operating position or valve 24 The worm gear operator is a device to transmit a large torque to the valve stem by ‘converting the torque from the drive shaft by means of the reduction gearing unit. Open Chse IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 7/31 Ill. Transportation and Storage IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 8/31 Il, Transportation and Storage 1. Transportation 1.1 Cautions for Safety AX WARNING oe (1) Keep off the valve lifting area to prevent personal injury caused by unsecured valves. A\ caution (1) Take care not to damage the coated surface of valves during transportation, Which may subsequently cause corrosion or rust on valves. Any damaged eo surface should be properly repaired (2) Take care when handling and storing carton packed products. High humidity may damage the cartons, 1.2. Transportation 1.21 Keep the packages in the same condition as they were when delivered during transportation or until installation. If the protective covers are found missing during transportation, provide an appropriate type of protective covers. 1.2.2 Handle valves carefully not to drop or drag them on the ground. Any extraordinary mechanical impact should be avoided. IKiITZ CORPORATIONDocument No. 2 Storage KE-1059-00 Page: 9/31 Il, Transportation and Storage 24. Cautions for Safety A\ caution a @ @ @ ©) DO NOT store valves in corrosive environment, which may cause corrosion to the threaded areas of valves. DO NOT remove the flange protective covers until installation. The protective covers will prevent intrusion of foreign objects which could cause damage to the closure elements such as balls and seats. DO NOT place any objects on valves and DO NOT step on them, Overloading may damage valves. DO NOT carelessly pile up valves. Unstable piling may cause damage to valves or personnel injury Keep valves in the fully open position during storage. Storing valves in the half-open position may deform the ball seats, resulting in seat leakage. If valves are stored in the fully closed position and their protective covers are damaged, it will result in ball damage. 22 Storage 221 Store valves in a dust-free, least humid and well-ventilated place. Indoor storage is recommended 22.2 Do not store valves directly on the ground or a concrete floor. Valves should be kept packed and stored on a pallet 223 Take appropriate measures to protect valves from direct exposure to dust, rain and sunlight in case they have to be stored outdoors. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 10/31 IV. Valve Installation IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 11/31 IV. Valve Installation 1. Flange Type Cautions for Safety AX WARNING (1) Sealing materials determines the characteristics of the service fluid and service range of the pressure and temperature. Check the valve specifications with the catalogue and/or the attached nameplate. Use beyond the valve specifications may cause fluid leakage and valve malfunctions, such a case, use a blank flange to the pipe open end to prevent leakage. S (2) DO NOT install valves for pipe end service. It may cause external leakage. In Z\ CAUTION (1) Keep a secure footing for valve installation and operation. oe (2) Sufficient lighting should be provided for valve operation. (3) Piping should be properly supported, if needed. 11.1 Allow sufficient space for safe and easy operation, installation and subsequent maintenance of valves. 1.4.2 To ensure smooth operation, inspection and maintenance, take appropriate measures for valves installed in small spaces. 1.1.8. Try not to install valves in the place where the valve function may be hampered by outer forces such as vibration and others, 1.14 It is recommended to install valves in upright position on horizontal piping, IKiITZ CORPORATIONDocument No. KE-1059-00 Page: 12/31 IV. Valve Installation 1.2 Cautions for Safety AX WARNING Keep off the valve lifting area to prevent personal injury caused by unsecured valves. A\ caution a @ o @ Take care not to get your fingers caught in the flanges during mounting work Take care not to damage flanges, balls and ball seat surfaces. Hf needed, piping should be properly supported to align the center of the upstream and downstream lines. Retighten gland bolts before operation, Leakage through the gland area may ‘occur due to lowered tightening pressure of the packing caused by stress relaxation during transportation. Be sure to use new gaskets for valve mounting. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 13/31 IV. Valve Installation 1.2.1. Check the followings before installation. (1) The service conditions should be within the range of the valve specifications. (2) The valve flanges should correspond to the piping flanges. (2) Gasket contact surfaces of the pipes and vaive flanges must be thoroughly inspected to make sure no scratch or any other indication of flaw is found, (4) The appropriate length should be kept between the pipe flanges for the valve face-to-face dimensions including gasket thickness. (8) The center of the upstream and downstream lines should be aligned accurately. (6) The pipe flange surfaces should be parallel to each other and bolt holes of the flanges should be aligned accurately. 1.22 Before installation, remove any foreign objects such as sand, dust and welding spatters from the connecting pipe interior. 1.23 Handle valves carefully not to drop or drag them on the floor. Any extraordinary mechanical impact should be avoided 1.24 Remove the protective covers just before installation. 1.25 Check all threaded areas after installation and retighten them if needed. 1.26 Piping should be flushed before test operation, with all valves open, to assure removal of any foreign objects. DO NOT operate valves during flushing. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 14/31 IV. Valve Installation 1.3. Installation Procedures 1.3.1 Make sure that the center of the upstream and downstream lines are aligned accurately. 1.32 The length between the pipe flanges should correspond to the valve face-to-face dimensions including the gasket thickness. 1.33 Place the valve between the pipe flanges. Insert the bolts through the bottom bolt holes and tighten them lightly. 1.34 Inset the gaskets between the valve and the pipe flanges. It is recommended to apply lubricant (gasket paste) to the gasket faces. co + jra 1.3.5 Make sure the correct alignment of the gaskets, which are held by the bottom bolts between the valve and pipe flanges, 1.3.6 Thread the bolts through the other bolt holes and lightly tighten them, 1.3.7 Tighten the bolts evenly, gradually and alternately in a star pattern as shown below. Once the bolting is properly torqued, the ends of all tightened bolts should protrude equally beyond the nuts, 1.3.8 Gradually raise the line temperature and pressure during test operation. Retighten the boltings, if needed. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 15/31 V. Valve Operation IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 16/31 1 2 V. Valve Operation Cautions for Safety A\ CAUTION (1) DO NOT apply excessive torque using a pipe or any other devices to operate valves. (2) DO NOT loosen bolts and nuts of the gland and flange areas of pressurized valves. (3) DO NOT use valves in the intermediate position for long hours, which may damage ball seats and cause seat leakage, (4) Retighten gland bolts and nuts before valve operation. Check the handle torque While retightening the bolts and nuts so that the operation won't. become too difficult due to over-tightening. Gland bolts should be alternately tightened with an even forth, (8) Valves should be kept fully open during line test or pressure test. If the test is performed with the valve closed, ball seats may be deformed, resulting in seat leakage (6) Stress relaxation of gland packing is likely to occur when fluid temperature fluctuates. Retighten gland bolts and nuts after the temperature is stabilized (D Gradually open valves to prevent pipe damage when high temperature fluids such as steam are handled. (8) Take appropriate measures to prevent freezing as needed Operation 24 Lever Handle Rotation of the lever handle by 90° fully opens and fully closes the valve, To close the valve, turn the operating handle counterclockwise according to the letters and the mark indicating the direction. Counterclockwise rotation will open the valve, 22 Worm Gear Operator According to the letters and an arrow on the handwheel, turning the handwheel clockwise closes the valve and turning the handwheel counterclockwise opens the valve. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 17/31 V. Valve Operation 3. Dally Inspection during Operation In order to operate your valves safely and satisfactorily, daily inspection is very important. Inspection items are as shown below. Items to be Areas to vers 0 be be | Inspection methods | __ Remedial measures Ps inspected Retighten the gland bolt. Gland area Replace the sland packing eternal Flange Retighten the flange bolts tee Replace the gaskets leakage Visual check with Threadeg | Sap solution | Rtighton each threaded area aes Replace the parts as needed Body Bouy Replace the valve Valve body Consult piping engineer Abnormat | Loosened Retighton the bolts bolts Auditory check tighten the bolts Pipe Pie Consult a piping engineer. Loosened | potts ana | Visual check bolts and nuts | nore Tactile check __| Retighten the bolts and nuts, Remove forwan beste intemal Disassemble and inspect the through-bore - _ valve components (Replace leakage the ball seats), Replace the valve Valve Make sure that the valve isin Valve operating Visual check the predetermined position. position operation Disturbed | Tactile check Disassemble and inspect the operation | Auditory check | Jaive vomponenes IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 18/31 V. Valve Operati 4, Remedial Measures A\ CAUTION (1) Wear protective items such as goggles, gloves and working boots. (2) Take safety measures against toxic, flammable or corrosive fluid (3) Reduce the line pressure to the atmospheric level before retightening gland oe (4) Operators should take protective measures to prevent direct exposure to (5) Reduce the line pressure to the atmospheric level when packing and gaskets are replaced or bolts and nuts are loosened. Operators should take protective measures to prevent direct exposure to fluid in case fluid spouts out from the valve S (6) DO NOT apply any lubricant to piping and valves that handle oxygen. 4.1 Leakage from Gland Area Retighten the gland bolts and nuts if leakage from the gland area is detected. Evenly tighten, ‘the bolts and nuts altemately as shown below. Adequate torque should be applied when retightening the bolts and nuts so that the valve operation won't become difficult. If it does riot stop the leakage, the packing should be replaced, 42 Leakage from Flange Area Tighten the bolts evenly, gradually and alternately in a star pattern as shown below. até eet x IKiITZ CORPORATIONDocument No.: KE-1059-00 5, Trouble Shooting V. Valve Operation Page: 19/31 Defects Possible causes Remedial measures Valve operation failure Foreign objects may have choked up the valve body cavity and stuck around the ball seats. Disassemble and inspect the valve components. Excessive valve torque Foreign objects may have stuck to the stem Remove the foreign objects and check the valve, Foreign objects may have choked up the valve body cavity and stuck around the ball seats. The gland bolts may have been overly tightened Flush the valve bore with the fluid with the valve slightly open to remave the built-up objects or disassemble and inspect the valve Loosen the gland bolts and then adequately retighten them to the extent that the leakage does not occur. Leakage from gland Loose tightening of the gland bolts, Retighten the gland bolts. Uneven tightening of the gland Loosen the bolts and nuts and area bolts. then evenly retighten them. Damage on the gland packing _| Replace the gland packing. Internal Disassemble and inspect the through-bore Damage on the ball seats valve. \ leakage (Replace the ball seats.) Abnormal noises or vibration Bolts and nuts are coming loose. Retighten the bolts and nuts, IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 20/31 VI. Periodic Inspection IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 21/31 VI. Periodic Inspection 1. Periodic Inspection 1 12 Carry out a periodic valve inspection with valves mounted on the piping once a year. Examine valves to ensure their smooth operation and sufficient function, See “V. Valve Operation’ for inspection items and inspection methods. Where valves and adjoining piping are not daily inspected or not operated for a long period of time, a periodic inspection is also recommended. (A periodic inspection should be carried cout on all valves.) Its particularly important to thoroughly check the valves used for the following service: a) Where performance failure of valves could result in a major shutdown of the entire plant unit. b) Where clogging of piping with fluid is likely to occur. ©) Where corrosion and/or wear by fluid is expected It is recommended to replace gland packing at the time of periodic inspection. Inspection and Maintenance In case pipeline or facilities where valves are installed are shut down for an inspection of, the pipeline, remove the valves from the pipeline and perform body and seat pressure tests as well as operation tests, if needed. If any defect is found, disassemble the valve for further inspection. The valves must pass required inspections before being sent back to the pipelines or facilities for reinstallation. IKiITZ CORPORATIONDocument No. 2A KE-1059-00 Page: 22/31 VI. Periodic Inspection Cautions for Valve Removal from and Installation to Pipelines (1) Discharge fluid from pipelines and reduce the line pressure to the atmospheric level when gismantling valves. Trapped pressure or fluid is very dangerous and will cause accidents resuking in personal injury. In case a valve is installed on the end of @ pipeline, fluid might be enclosed between the valve and the blank flange. Open the valve and discharge the fluid from the pipe before the blank flange is removed. (2) Fluid and pressure may be trapped within the valve body while the valve is in oe the fully closed position. Partially open the valve and discharge the fluid and pressure before dismantling the valve from the pipeline (3) In case fluid is toxic, inflammable or corrosive, remove the fluid completely from the pipeline and valve interior. (4) Take protective measures to prevent direct exposure to fluids or catching fire (5) Keep off the working area to prevent personal injury if valves are installed in a high place. 1) Wear protective items such as goggles, gloves and working boots, (2) Keep a secure footing for valve dismantling and installation, (3) Piping and vaives should be properly supported if needed. the pipe flanges and valve flanges to make the subsequent reassembly work (5) Be sure to use new gaskets when mounting valves. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 23/31 VI. Periodic Inspection 22 Disassembly and Assembly Rofer to “ VIL Disassembly and Reassembly” for the procedures. 23 Test and Inspection Refer to the following procedures for test and inspection. 23.1 Operation test (1) Check smooth operation of the lever handle and gear handle without galling or sticking to the internal valve components (2) Check that the stem is firmly assembled with the ball (3) Ensure that ther is in the fully open position. The ball should not be protruded from the valve port other than the rounded surface of the ball port edges. should be no offset of the ball ports and ball seats when the valve 23.2 Shell Test and Seat Leakage Test (1)_ Cautions for Shell Test and Seat Leakage Test A\ CAUTION (1) Wear protective items such as goggles, gloves and working boots. e (2) Take sufficient precautions for operators’ safety before shell test and seat leakage test (2) Shell Test and Seat Leakage Test Reassembled valves are subjected to a hydrostatic or pneumatic shell test and seat leakage test at the required test pressures. Refer to the JIS B 2003, JPI-7S-39 or ‘API-598 for test methods and procedures. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 24/31 VII Disassembly and Reassembly IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 25/31 VIL. Disassembly and Reassembh 1. Disassembly 1.4 Cautions for Safety AX WARNING (1) Operators must take protective measures to prevent direct exposure to fluids or catching fire. AX CAUTION (1) Wear protective items such as goggles, gloves and working boots. (3) When disassembling a large size valve, use an appropriate lifting device. 1.2. Before Disassembly 1.2.1 Place the valve in a dust-free place. 1.22 Take care not to damage the flange surfaces, ball and stem. 1.2.8 Before beginning disassembly put a matchmark on the body and the coupled cap flanges to make the subsequent reassembly work easier, IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 26/31 VIL. Disassembly and Reassembly 1.3. Disassembly procedures 1.3.1 Fully close the valve. <> 1.92 Remove the handle lock plate bolt (128A) from the stem (3) and then handle lock plate (43) and lever handle (8) or handle head (9B). For the handle head (9B) type, remove the handle bar bolt (1238) and then handle bar (9A) from the handle head (9B). 1.33 Remove the snap ring (48) from the stem(3) and then key lock plate (40) and stopper (49). 1.34 Remove the stopper plate bolts (126) from the body(1) and remove the stopper plate (51). 1.85 To common 1.3.9. <> 1.3.6 Remove the bolts (99) from the body (1) and remove the gear unit (102) together with the bracket (93). 1.3.7 Remove the connector (92) from the stem (3) or gear unit (102). 1.38 To common 1.3.8 < Common>> 1.3.9 Remove the cap nuts (33). 1.3.10 Remove the body cap (2) from the body (1) 1.3.11 Remove the gasket (19) from the body (1) or the body cap (2). 1.3.12 Remove the ball (4) from the body (1), 1.3.13 Remove the gland bolts (36) from the body (1) to disassemble the gland (7). 1.8.14 Remove the coned dise springs (145) from the gland bolts (36), IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 27/31 VIL. Disassembly and Reassembly 1.3.15 Remove the gland bush (57) from the gland (7) 1.3.16 Push the stem (3) to remove it from inside of the body (1). 1.9.17 Remove the thrust washer (47) and stem bearing (67) from the stem (3) or body (1) 1.3.18 Remove the ball seats (30) from the body (1) and body cap (2). 1.3.19 Remove the gland washer (58), gland packing (8) and packing washer (20) (up to size 832A) from the body (1). IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 28/31 2 VIL. Disassembly and Reassembh Reassembly 2.1 Cautions for Reassembly A\ caution (1) Wear protective items such as goggles, gloves and working boots. (2) No open flames or smoking should be allowed in the working area oe () Take care not to get your fingers caught in the flanges during reassembly: (4) Replace ball seats, gland packings and gaskets with new ones to ensure satisfactory sealing performance, Reuse of these components may cause leakage. (6) When reassembling a large size valve, use an appropriate lifting device 22 Before reassembly 221 Check all parts before reassembly. If any unsatisfactory function is found, replace the valve. 222 The consumables such as ball seats, gland packing, gaskets, thrust washers and stem bearings should be prepared before reassembly. 223 Clean all parts for reuse to thoroughly remove dust and other foreign objects. 22.4 Place the valve in a dust-free place. 225 Take care not to damage the flange surfaces, bal, ball seats and stem. 226 Reassemble the valve by aligning the matchmarks given during disassembly. 22.1 Keep in mind that all threads such as bolts and nuts should be securely tightened. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 29/31 VIL. Disassembly and Reassembly 23. Reassembly Procedures 23.1 232 233 234 235 238 23.1 238 239 Assemble the stem bearing (67) and thrust washer (47) to the stem (3). Insert the stem (3) from the inside of the body (1). Make sure that the stem collar securely contacts the body, and set the stem (3) in the fully closed position of the valve. Assemble the coned dise springs (146) to the gland bolts (36) with the convex side of the coned disc springs placed to the bolt head side. Assemble the gland bush (57) to the gland (7) Mount the packing washer (20) (up to size 32A), gland packing (8), gland washer (58) and sland (7) in the body (1) and temporarily tighten them with the gland bolts (36) Mount the ball seats (30) in the body (1) and body cap (2). Mount the ball (4) in the body (1). Mount the gasket (19) to the body (1). Mount the body cap (2) to the body (1). Make sure to place the ball seats (30) in the correct position without dropping them from the body (1) and body cap (2) 23.10 Secure the body cap (2) to the body (1) with the cap nuts (33). Evenly tighten the cap rnuts (33) alternately and gradually in @ star pattern. When the bolts are properly tightened, the end of the bolts should evenly protrude beyond the nuts. Refer to Table 1 for the tightening torque of the cap bolting 2.3.11 Tighten the gland bolts (36) referring to the tightening torque shown in Table 2. << Reassembly procedures for lever handle operated valve>> 2.3.12 Mount the stopper plate (51) to body (1) and fix it with the stopper plate bolts (126), 2.3.19 Mount the stopper (49) and key lock plate (40) in the stem (3), and then fix them with ‘the snap ring (48). IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 30/31 VIL. Disassembly and Reassembly 2.3.14 Mount the handle (9) or handle head (9B) in the stem (3) and set the handle lock plate (43) on the stem (3). Then fix them with the handle lock plate bolt (123A). For the handle head (98) type, mount the handle bar (9A) in the handle head (9B) and fix it with the handle bott (1238), <> 23.15 Mount the connector (92) to the stem (3) 23.16 Mount the gear unit (102), with the bracket (93) attached, to the body (1) and fix it with the bolts (99). Table 1 Tightening Torque for Cap Bol Unit: Nem UTDZIH SOTDZIH Volt size Tightening torque Tightening torque Minimum [Maximum | Minimum [Maximum MB 16.7 206 167 20.6 MIO 333 412 333 412 M2 579 706 647, 716 Mia) 932 14 93.2 14 MI6) 147 7 147 WT M20) 255 314 284 343 M24) aa 539 481 588 M27 598 716 706 868 Table 2 Tightening Torque for Gland Botting Units Nem wominat | Crate cting 7 eterance ameter Balt sie Wii Maxi i5A_20A 2 20| we 25A_ 2A 55 77] 40508 e2| 11a] wo 5A BOA iss] aia] wa 0A 1254 sis] _48| m6 150A a7] s10| mie 200% Tas] toa | —wa0 ‘All threaded areas should be tightened. Retighten them if found loosened. IKiITZ CORPORATIONDocument No.: KE-1059-00 Page: 31/31 Bear VIL. Disassembly and reassembly 3, Cross-sectional assembly drawing San © [Lever Hard A | Hare Bar (150K ard oer 36 | Hare Hess (150A and over 20 [Packing Washer Uae 2A 30 Ball Seat 36 [Gln Bot a0 [Rey Lack Pte a3 [Stopper 57 | Stor Bowring THA ok Fate Bo 45 [ Coned Die Sore This illustration shows a typical construction of the lever handle operated valve. Refer to the approval drawing before disassembly and reassembly, Bear Bal 3 [Sten t Te | Gasket 30 | Ball Seat 36 [olnd Bot a7 [Tat We 57 | Gla Bush 32 | Comecter This illustration shows a typical construction of the gear operated valve, Refer to the approval drawing before disassembly and reassembly. IKiITZ CORPORATIONDocument No:KE~4025-06 KITS Operation Manual For KITZ B Series Pneumatic Valve Actuators ‘Thork you for choosing KITZ products For tafe and trouble-free function snd performance of the product. make sure to read and understand al items inthis manual before handing the product Keop this manual accessible to all valve operating personnel IKiITZ CORPORATIONDocument No:KE~4025-06 ‘This manual applies to the KITZ B Series Proumatic Valve Actuators. For actuators of automatically operated value, refer to the operation manual of relevant actuators prepared by the manufacturers. CAUTION AND WARNING For the safe use of the product, read all of the safety precautions listed in this manual before handling the product, The safety precautions in this manual are determined to ensure safe and proper use of the product and to prevent personal injury and property damage. This manual uses two terms, “Warning” and “Caution”, according to the hazard level, to clearly indicate the extent and severity of the risk ZX WARNING | orien, ences nary ones ZN CAUTION | PSC PRE Delete re mete domege NOTES TO USERS This manual is designed to show an appropriate usage of the products for transportation, storage, installation, operation and maintenance. Be sure to read through this manual before handling the products. This manual does not cover the whole scope of conceivable usage of the products for transportation, storage, installation, operation and maintenance. If technical assistance beyond the scope of this manual is required, contact KITZ Corporation or its distributor. The specifications for transportation, storage, installation, operation and maintenance described in this manual have been determined with valve maintenance taken into consideration. 00 NOT use products beyond the specifications. The illustrations given in this manual do not show all the details. 1ore detailed information is required, refer to the relevant approved drawings. ‘*Any information provided in this operation manual is subject to change without prior notice. IKiITZ CORPORATIONDocument No:KE-4025-06 " 2 4 15 16 W7 18 Contents Note for User’ s System Design Storage and Handling + Product Type and Code Driving Mechanism Standard Technical Specifications * Cylinder Volume and Air Supply Requirement. =~ Air Tubing and Electric Wiring ~ KITZ Optional Accessories * Mounting Valve-Actuator Units on Pipe * ‘Automated Operation Manual Operation ~ Periodic Inspections and Maintenance * Troubleshooting * Disassembly and Reassembly ‘Adjustment of Valve Operating Positions ~~ Product Warranty * Consumables Contact for Technical Assistance IKiITZ CORPORATION Page " 12 4 19 2a 22 46 47 48 50Document No:KE~4025-06 1/50 1 Note for User’ s System Design \ WARNING © Holding valve position KITZ pneumatic actuators do not assure non-leakage. The actuator does not keep the valve in the predetermined open position for a long time without continuous air supply. When connecting the actuator to the air tank, it may become impossible to hold the valve opening position due to leakage from the actuator. Please periodically perform an inspection to detect leakage from the seal washer, retighten the valve and check the pressure drop in the air tank when a actuator is connected to the air tank. If you need to keep the valve in the predetermined position for a long time, please contact KITZ. (© Residual pressure in the cylinder of the spring return type actuator Output torque of the spring retum type actuator indicates the value without internal air residue remains inside the cylinders. Please design the circuit system to be able to exhaust the internal pressure from the cylinder during the spring return action. IF internal pressure remains in the cylinder, the output torque will be dropped and the valve may not be closed. © The actuator may move to the opening direction if pressure is applied to the both sides of the cylinder port of the double action type actuator. IF manual ‘operation is needed, the circuit system shall be designed to equalize the cylinder internal pressure and the atmospheric pressure, Z\ WARNING © DONOT pressurize the breathing port of the spring return type actuator. @1O © Prevent dust, rainwater or waste from entering into the actuator through the breathing port IKiITZ CORPORATIONDocument No:KE~4025-06 2/50 2, Storage and Handling A\ CAUTION © DO NOT store actuators in corrosive atmospheres such as sulfur dioxide gas or chloric gas. Actuators may rust in the corrosive atmospheres. ‘© DONT remove the dust protectors from the product before instalation. © Anti-rust coating is applied the product, but store the product in a cool and dry oe place to prevent rusting and malfunction. (© When transportation or handling or mounting a actuator-valve unit in size 3 or above, use a rope or a strap as illustrated in Fig. 1 A © Handle the product with extreme care to prevent damage to the solenoid valves, accessories or copper tubes equipped to the product. Fig.1 IKiITZ CORPORATIONDocument No:KE~4025-06 1/50 3, Product Type and Code Bs Wp bd 6 > @ o @ D Driving Mechanism @ Sie Non ">" Double aclon tne 9 S_**+ Sorneretumtype 1 @ Manual Override 2 Non +=" Nomarvaloveride 3 W +++ Manual over (Sorin retum type ony) 4 @ Cylinder Structure 5 Non ==" Sige stn 6 +++ Double piston (type B-6, +7 on) 1 IKiITZ CORPORATIONDocument No:KE-4025-06 1/50 4 Driving Mechanism 4.1 Type B Double-Aetion Actuator (Single Piston Type Cylinder) ‘The air pressure supplied into the port(A)pushes the piston to the left and energizes its movement to rotate the scotch-yoke counterclockwise. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the shaft to open or close the valve, following the preset mode. Reverse supply of the air pressure into the port(B)activates the reverse valve operation. Air failure wil cause the valve stay at the position Fig.2 / all AY Lote B Crater L sine Paton ros A seoteh yoke 42 Type BD Double~Action and Double Cylinder Actuator (Double Piston Type Cylinder) The air pressure supplied into the port(A)and(A’ ) pushes the piston to the left and energizes its movement to rotate the seotch-yoke counterclocknise. The seotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the shaft to open or close the valve, following the preset mode. Reverse supply of the air pressure into the port(B)and(B' ) activates the reverse valve operation. Air failure will cause the valve stay at the position. Fe. 3 IKiITZ CORPORATIONDocument No:KE~4025-06 5/50 42 Type BS or BSW Spring-Return Actuator ‘The air pressure supplied into the port(A)pushes the piston to the left and energizes its movement to rotate the scotch-yoke counterclockwise, compressing the spring. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the shaft, to open or close the valve, following the preset made, ‘At the moment the air is discharged to the atmosphere through the solenoid valve, the spring force pushes the piston to the right direction, and the scotch-yoke activates clockwise rotation of the shaft to reversely operate the valve. Air failure will cause the valve return to the original open or closed position automaticaly following the preset mode, unlike the value driven by Type B actuator. Type BSW actuator is combination of Type BS actuator and a hand wheel for manual operation, and its driving mechanism is exactly same as that of Type BS actuator Fie. 4 Pin Piston A Caton 44 Type BS~7 or BSW-7 Spring-Return with Manual Operatlon Equipment ‘The air pressure supplied into the port(A)and(A" )pushes the piston to the left and energizes its movement to rotate the scotch-yoke counterclockwise, compressing the spring. The scotch-yoke converts linear movement of the piston rod to counterclockwise rotational movement of the shaft, to open or close the valve, following the preset made. ‘At the moment the air is discharged to the atmosphere through the solenoid valve, the spring force pushes the piston to the reverse direction, and the scotch-yoke activates clockwise rotation of the shaft to reversely operate the valve, Air failure will cause the valve return to the original open or closed position automaticaly following the preset mode, unlike the value driven by Type B actuator. ‘Type BSW actuator is combination of Type BS actuator and a hand wheel for manual operation, and its driving mechanism is exactly same as that of Type BS actuator. Fi. 5 IKiITZ CORPORATIONDocument No:KE-4025-06 5, Standard Technical Specifications 5/50 Operating media Compressed instrumentation air Standard operating pressure (OAMPa: factory preset pressure Pressure supply range O3MPa to 07MPa Contact KITZ when other than the standard operatin pressure is required Standard durability 100,000 cycles under moderate service conditions Housing test pressure O97™MPa, Shaft rotation 90° (+5" ) Service temperature range 20°C to +60°C (No freezing of supply air) Output Torque Unit Nm Unit en ype oats Ty | operation oaMs " a 45° | 90" oF 45° 90° sof ao] sap aa a vez] sa] 107 asa oi 364] Tea] aaa Sorng [105] 67] 165 er sas[ 472] a4 son ca var[ wea] 258 ea [me |e [238 Serna [258] 161 [389 oa [ane | 203606 son Ar oo] air] 863 e5_[si7| 7a [517 Seng [ee [at 9} — 101 o-6 | ase0 | Te40 | aban wes ca 75] 0] 177 B08 | —a05| 609 | 7965 Seng tre [—inr| —a9s e7 | -aais | aeo7 | ozs con fr oa] 255 | 55, Bo? | iesse 222] aaes Ser ase] 260] m3 ira0 | —re0| 181 BS5 Spring 1150 720 1730 a ior | 72a [7768 as Sorng | “aera | 1788 [arse woo far tosre | a0] —Ta57 Sorne | To16 | —aa10 | Toeze IKiITZ CORPORATIONDocument No:KE-4025-06 Cylinder Volume Fiz. 6 Fig. 7 1/50 6 Gylnder Volume and Ak Supply Requkement 6.1 Type B Actuator [Double Action Type] Unit iter ——oynéer wu] ve Typectize 3.0 oa5| 07 8:1 o17| oa? 32 oa] 04s 3-3 104] 1.99 BA 2069 275 35 esa] 680 3-6 1590 1420 3-08 30.10] 0.10 8-7 3830] 99.00 B07 Trav] 7730 artacvs bitb=V2 be b eat i —l Qe ¥ ic ¥ ar 62 Type BS or BSW [Spring Return Type] Unit: liter Cylinder volume of Type BS or BSW actuators Cylinder v Types ——| 65-0 / 850-0 | 07 BS-1/BSW-1_| 093 88-2 /BSW-7 | 082 B8.3/8SW-3_| 225 BS-4/BSW-4 | 899 85.5 /8SW-5_| 1370 BS-6/BSW-6 | 9020 85-7 /8SW-7 | 7090 IKiITZ CORPORATION bitb=V BS and SW have the same eylinder volumesDocument No:KE~4025-06 6. Alr Supply Requirement (Flow Rate) 1/50 Actuators should be supplied with air sulicient to operate the valve through one full stroke from the open to closed position or vice versa in “t” seconds, as converted into flow rates per minute. ‘The required air volume “Q” is expressed with the folowing equation. 60 =v (P+0.1019)/0.1019) xP (N/min) where ir volume requirement per minute (NI/min) ylinder Volume (liters) V1 or V2, whichever larger, for double-action actuators P=Supply pressure (MPa in gauge) ime required per stroke (seconds) 64 Alr Consumption NE Volume of standard air ‘Sonton of standard air Air temperature: 20°C ‘Absolute pressure: 760rmHe Relative humidity: 055 Air consumption means the volume of air discharged into the atmosphere from an actuator operating “n” times forward and backward per hour as converted into volumes per minute. The valve is calculated with the following equation, ‘Type B actuator [Double action type] VI+V2}(P40.1019)/0.1013 x5 (NV ‘Type BS or BSW actuator [Spring return type] A Jt =V (P+0.1019)/0.1013)n xg (NV min) A\ CAUTION © Use clear, dry air filtered to remove dusts and moisture which will deteriorate the housing interior and cause maffunction of the actuator. Ensure to correctly calculate the required amount of air in advance and prepare compressors and reservoirs with sufficient capacity. Select solenoid valves, air iter-regulators and air supply tubes which have 2a sufficient capacity to accommodate the airflow rate calculated in advance. To determine the practical capacity of a compressor or air tank, addition of ‘extra 30% to the calculated air consumption volume is recommended ‘considering a possible air loss caused by connecting to the accessories and ‘ubes. Insufficient air supply will cause @ pulsy stroke and malfunction. IKiITZ CORPORATIONDocument No:KE-4025-06 7. Ai Tubing and Electric Wiring 7A Air Tubing for Actuators Type BO to 7 Solenoid valve energized to open valve Fi oo ey Air sup “vay slonoid valve Fier regulator 16 BD6,D7 —Sclenod valve srertied to open ve ms zi : cu} 4 00 6 AT smal ae BS~0 to 6, BSW-0 to 6 Fig. 10 Selonod valve energized to open valve lean] ‘4>vay or Sway solenoid valve ‘Type BS~7, BSW=7 Fle, 11 Solenoid va ve | | uw AGL || ile Ae sip sup 1/50 Solenoid va energized to close valve BD away steno vate Fer raatr Solenoid valve energized to close vahe esupely a-Hay oF Sway cloned iY ah IKiITZ CORPORATIONDocument No:iKE~4025-06 10/50 72 Air Supply Port Select copper tubes (covered or uncovered) for air supply and exhaust ports according to the following table: Nominal size of piping threads (Re) Aamtorswe [Oo] 1 [2]s[@[s[el7] Tyee B ahaa. Tyee SESW fief vabia lial e [ave] 72 Tubhe ‘Actuator size of [2[s[e[ste[7 Tube (Outer diameter x Inner diameter) 8x o6 10x OB 74 Specification of Solenoid Valves Type B actuators need 4-way solenoid valves, 4-way solenoid valves with one OUT port pluzzed or 3-way solenoid valves can energize Type BS or Type BSW actuators, Electric wiring should be made as shown in Fig 8 to Fig. 11, depending on the planned mode of operation KITZ B Series actuators assembled with solenoid valves at the manufacturer have been complete with copper tubing for air supply and exhaust pens. Users should make air supply tubing between air compressors and solenoid valves. 175 Pressure Equalizing Valves (By-Pass Valves) Manual operation of Type B actuators needs a pressure equalizing valve between the cylinder and the solenoid 78 Speed Controllers Mount a speed controller between the cylinder and the solencid valve. 7.1 Sllencers Install a silencer directly in the exhaust port of the solenoid valve A\ CAUTION © For manual operation of Type B actuators, the air residue in the cylinder must be discharged to the atmosphere. Ensure to install a pressure equalizing valve between the solenoid valve and the cylinder. o © Connect copper tubes (covered or uncovered) of a suitable diameter and wall thickness between actuators and pressure sources to maintain sufficient air prescure during valve operation © Securely seal all of the tubing joints to avoid air leakage through the connections, accessories or tubes, Ensure that loose sealing tape ends do rnot extend into the tube. It may block the ports and affect the air supply to the actuator. IKiITZ CORPORATIONDocument No: KE-4025-06 8, KITZ Optional Accessories 11/50 ‘The following are recommended standard accessories for KITZ B Series actuators For other accessories, please contact KITZ. ‘Aocessories & Gade ‘Spedtlatione Remark LSE Exosor proof oe [AG SA/125V 54/2509 O6:08A/1284 04A/250 Contact ert 2-Cirert double bre Dn aeparate Init ston reonomandad foreach ¢f gen and clove idetion, Sand Va Sov. We Soot ‘Comactna ive read Reve o-oo 200vs0Hz 200/602 {ey solred vebes for dautloracton actuators, {ty soled vais for spring-retum actustos, wih one OUT port plugsed or Sway solenoid Fi For Repior FR (Gane ith pressure ents) ‘annactine ibe read Re t/aie Ma bt presse For removing walstire, water wd ote Toro chiects form opering sir end for repuaine ar (6~ 1209s) Speed Goal ‘Comsectna ibe Re 1781/8172 For elucng otuntoropetna soe P rad 087M ares. Working oressure: only in spring-otum rection (Usable. only for tctustrewthostpesionra) Vale Poston ‘Comectnavbe Ro 7 For operating ectetors at any doared poston P esd Ceressure gauge Re 1/8) | ith the Non rate conzald by 9 vabe. Vale (Corplete wih pressure gine) ‘Suppl ores: Sra! Curent [Ar coneuraton G0. 4 1Otee) S0r0.NPs "155 ON nn a, Gt supply aressure ON) Fostioners, ow rate may be stab contrat Boo) aictomopon and imtarlose ectuetin rredes canbe eotatadby simply reversing a Fier ‘onseetne ive Ro W7AI72 For removing acura, water wd ober Toro 057M ewe chiects rom ener Revommunded uivelnt fr when actuators are ebioted to Pih operating Frequency for lone etioss of tine, eatin is IKiITZ CORPORATIONDocument No:KE-4025-06 12/50 4. Mounting Vabe~Atutor Uns on Pe A\ CAUTION © Chock the valve and actuator for possible damage, belt loosening or other failures caused during transportation or storage. © KITZB Series actuators assembled with KITZ valves can be mounted on the horizontal or vertical piping, or at any angle, depending on the piping or ‘operational convenience. However, the air filter-regulator must be always horizontally positioned against the ground. © To use an automated valve with a positioner for control services, specify the piping positions when ordering the product. If the piping position is changed. the control position of the vale should be readjusted. Contact. KITZ for the operation manual for adjustment. © When a positioner is used for piping which vibrates, controllability may be impaired due to the resonance of the inside parts. Use supporters and ‘support stands to firmly hold the valve and actuator, especialy in size 5 or above of BS/BSW actuators, and minimize the influence of vibration (See Fig, 12). © Allow sufficient space around the unit mounted on the pipe for convenience {500 mm downward and 300 mm each for the right and left is recommended, © -20°C to +60°C is the recommended range of applicable atmospheric temperature. Take appropriate insulating or cooling measures for installation in low or high temperatures. © Take appropriate measures when the unit is installed in @ corrosive (ulfurous acid gas, chlorine gas, etc.) or dusty environment, © Ensure that valves are free from rust. Particularly when cast iron or cast steel valves are used for water supply line, rust may be generated and get stuck to the seat surfaces of the valve. © BS and BSW actuators have breathing ports to discharge the internal residual air to the atmosphere. A dust cap is installed on the breathing port Remove the dust cap before running the automated operation. If the dust cap is not removed, actuator speed may become slow. If an exhaust port of the actuator which is installed outdoors is positioned horizontally to the around, fit an elbow and a nipple to the exhaust port to prevent the intrusion of rainwater (See Fig 13) the predetermined open and close positions. Do not disassemble and cchange the valve open and close positions. It may cause an inconsistency between the actual valve operating position and the valve position indicator. © The delivered KITZ B Series actuators and valves are properly assembled in IKiITZ CORPORATIONDocument No:KE~4025-06 13/50 Fie. 12 ae = U 10 Automated Operation KITZ 8 Series actuators are designed for operating at the pressure ranging from 0.3MPa (40psi) to 0.7MPa (100psi) and the standard operating pressure is set to OAMPa (60psi) for trouble-free operation, or use the product within the pressure range specified at the time of order placement, Operating media must be compressed air or Nitrogen gas. A\ CAUTION “No leakage from the air tubing (Use soap solution) “Adequate line voltage of the solenoid valve “Sufficient air supply (Use air fiter-regulator) “Adequate operating pressure “Adequate operating speed. which may be adjusted with a speed controller. “Check the specified valve operating position according to the change of the ‘specific signal, when a positioner is provided. (Contact KITZ for adjustment of positioner) “If the actuator has not been operated for 3 months or longer, or when the actuator ie operated for the first time, the operation torque may exceed the specified torque. In this case, manually operate the valve a few times as a preparatory operation, (Type BS actuators cannot be manually operated, Please specify Type BSW actuators) IKiITZ CORPORATIONDocument No:KE~4025-06 14/50 11, Manual Operation 11.1 Type B (Double Action Type) Type B-0 to B~4 actuators can be manually opened or closed by tuming an operating device such as @ spanner wrench or lever handle properly fitted to the top of the shaft (Fig. 14). Turn the shaft clockwise to close the valve and counterclockwise to open the valve. Top of the shaft Fie. 14 Z\ WARNING © Before energizing Type B actuators, make sure to remove the spanner wrench or lever hhandle used for manual operation. Starting the operation without removing such a ‘manual operating device is extremely dangerous A\ CAUTION © Before operating a Type B actuator manually, open the pressure equalizing valve to e discharge the residual air from the actuator housing to the atmosphere, Residual air wll disturb the manual operation of the actuator. © Ensure to securely ft the operating device to the top of the shaft of Type B actuator for manual operation. Manual operation with a spanner wrench or a lever handle is not available for Type B-5 to B-7 actuators, Please order an actuator with manual operation unit if you need manual operation for these actuators. Actuator Manual operation unit vom et IKiITZ CORPORATIONDocument No:KE~4025-06 Parts Construction of B-5 to B=7 Actuators Manual Operation Unit Some parts are diferent depending on the type of the manual operation unit (Manual operation unit for Bis lustrated) IKiITZ CORPORATION 15/50 [Gear case [Gear cover [Shaft IHandle [Hexagon headed bolt aA [0 ring 458 [o ving 450 [0 ving 45D [O-ring 45E [0 ring oF [0 ring a7 [Thrust bearing aA [Snap ring 488 [Snap ring 60A Key. 608 Key. 76 [Thrust bearing 5 Plug 4 [Hexagon headed bolt 7 Indicator 110 [Pin assembly 116 [Spindle 1244 [Spring pin 1248 ISpring pin 135A jorm wheel 1358 |Worm 183 [Chain 388 [HookDocument No:KE~4025-06 16/50 Manual Operation Method of B-5 to B-7 Actuators Manual Operation Unit. ZX WARNING S DO NOT insert your finger in pin hole of the manual operation unit, A strong force is applied to the internal parts. A\ CAUTION S DO NOT operate the valve automatically while a pin is inserted into the pin hole. It may damage the manual operation unit. Insert the pin into the pin hole completely for manual operation. The manual ‘operation unit will be damaged if the pin is inserted halfway. When the valve is operated automatically, make sure to insert a plug into the pin hole, Without plug, rainwater, dust, ete will enter the manual operation Unit and corrode the interior (1) Manual Operation ® Stop supplying air to the actuator. Open the pressure equalizing valve Remove the plug ‘Adjust the ingicator position to the pin hole by rotating the handle. Insert the pin into the pin hole completely Operate the valve with the handle. (2) Automated Operation @ Remove the pin form the pin hole. UF the pin is not easily removed, rotate the handle a litte to free the pin.) ® Insert the plug into the pin hole. @® Close the pressure equalizing valve. ® Supply air to the actuator. IKiITZ CORPORATIONDocument No:KE-4025-06 ‘Troubleshooting of the manual operation unit 17/50 Trouble Possible Causes Remedial Measures @ Operate the valve with | @D Remove the pin from the pin hole and Not the pin is inserted into | insert a plug into it sitomstically the pin hole. ® Close the pressure equalizing valve. operated @ The pressure equalizing |) Supply air to the actuator. valve is opened. @®_No airis supplied Automated @ Malfunction of the valve | @ Disassembly/check/clearing the valve operation ® Malfunction of the and replacement of valve seats actuator Disassembly/replacement of actuator ‘The operation | @ Air pressure is low. parts or replacement of the actuator speed is slow. | @) Excessive throttling of | @ Readjustment of the fiter regulator sneed controler Readjustment of the speed controller 688 8 © Corrosion of internal Replacement of the manual operation unit, parts @ The pin is not inserted | D Insert the pin into the pin hole completely into the pin hole. ® Stop supplying air to the actuator and Not manually | @ Air is supplied to the ‘open the pressure equalizing valve. operated actuator. @ Open the pressure equalizing valve, ® A pressure equalizing v alve is closed. @ Indicator is not adjusted | @D Adjust the indicator to the pin hole to the pin hole rotating handle. Manual | The pin cannot | @ A pin hole on a worm | @ Adjust the pin hole on the worm wheel cmenation | be inserted Whee! and a pin hole on a and the pin hole on the shaft by rotating Ps into the pin shaft are not aligned, the handle little by litte, hole. @ Foreign objects are stuck | @ Clean the pin. fon the pin ® Replace the pin. @ The pin is deformed. Impossible to | @ The pin is caught in the |G Free the pin from the internal parts by remove the pin internal part rotating the handle litle by little from the pin | @ Airpressure is supplied, | @ Stop supplying the ait hole. IKiITZ CORPORATIONDocument No:KE-4025-06 Spring Return Type 11.2 Type BS-0 to BS-7 Type BS actuators cannot be manually operated due to the required, select Type BSW actuators. 113 Type BSW-0 to BSW-7 Turing the handwhee! counterclockwise opens the valve and tur (Fig. 15). (Specification for arless-close) 18/50 pring in the actuator. If a manual operation is ining the handwheel clockwise closes the valve Vale stam tation Fie 18 Handwheet tse —== Sf Handwhee! J A\ CAUTION © To switch from manual operation of BSW-0 to BSW-7 to automated oe operation, tum the handwheel clockwise until the handwheel stops and the spindle portion completely gets in the spring case and the spring retainer returns tothe rod guide side. A © Type BS-0 to BS-7 actuators cannot be operated manually IKiITZ CORPORATIONDocument No: KE~4025-06 19/50 12 Periodio Inspections and Maintenance of Valves and Actuators Periodic inspection (at least twice a week, depending on the service conditions) must be carried out for safe and trouble-free operation, 121 Valve Operation (1) Open-Close Operation Check that the valve ean be fully opened and closed according to the ON-OFF control of the actuator. Ensure that the valve opening or closing degree is adequately maintained in response to the signal pressure or signal currency of the actuator and the accessories. (2) Noiseless and Vibration-Free Operation If an abnormal noise is detected, air passage through the actuator and the tubing or fluid through the valve bore might have been disturbed by dusts or other foreign objects. Find the source of the noise and vibration, and take appropriate preventive measures. 12.2 Sealing Functions (1) External Leakage Apply soap solution over the sealing areas of valve, actuator and air tubing joints. External leakage may result in the replacement of O rings, gaskets and/or packing rings. (2) Internal Leakage Check the air exhaust port of the solenoid valve or the air supply port of the actuator to ensure that the air pressure is satisfactorily sealed within the actuator. Internal leakage may result in the replacement of O rings of the actuator. (3) Firmly Tightened Boing Bolts and nuts used to assemble the valve, actuator and accessories must be periodically retightened, because they may become loose during operation. (4) Many pieces of O rings are used for the critical sealing areas of the B Series actuators. O rings are subject to frictions with moving parts such as pistons, which reduce the life of O rings and the consumables. We recommend a periodic replacement of © rings. Refer to “Chapter 17 Consumables” in thie operation manual for ordering specifications, (5) Seal washer is used for the stopper bolts of the cylinder. Leakage may occur from the seal washer after a long term use, Retighten the nut as required or replace the seal washer, (®) Leakage test from the breathing port should be done in 15 to 30minuts after pressurizing the actuator. 123 Partial Stroke Test ‘A partial stroke test (PST) shall be carried out on the automated valves equipped with a partial stroke test. device periodically to keep the required safety level. See the operation manual of the partial stroke test device for details of the procedures. IKiITZ CORPORATIONDocument No:iKE~4025-06 20/50 A\ CAUTION appropriate supports to the pipe and actuator (Fig. 12). IKiITZ CORPORATIONDocument No: KE~4025-06 18 Troubleshooting 21/50 Detected Trouble Causes Remedial Measures Air pressure lower than the specified Failure of compressor or lack oF ‘compressor capacity Air leakage from tubing. Inspect and repair the compressor as appropriate. No supply of air pressure, Failure of compressor Inspect and repair the compressor as appropriate. ‘Clogging, breakage or freezing of pipe Check and repair the tubes as appropriate. Failure of fiter regulator Disassembly/check/repair/replac Valve ement of fier regulators Malfunction orcign objects stuck to the Foreign objects stuck to th Disassemble and clean the valve. valve seats Failure of actuators Replace the part or actuator No activation or No acta Tnerease of vale operating torque | Disassemble/check/clean the Gsurbed | due to foreian objects stuck tothe | valve and readjust the actuator Shute indy fetenteor —_| mrt ful ar pressure, _| Excessively trotted of spew Readius the speed controler. Dust cap isnot removed from the Remave the dust oa exhaust port. * Disconnection of electric circuits, | Check the wiring ofthe electric circuit and voltage. Gheck the excessive valage and No tiation of Defective eloctromagnetic eas | eurency enertize Replace the cols. ‘Troubles of solenoid valve; Water In the eletromagretl i 2 Solenoid | Abnormal noise; | Mater in the electromagnetic cals | Ta. water prevention measures. Valve, Excessive or termin Check th Fed volta q vane at ne PONT SPM yet (Hz) wth the name pate “ and replace as appropriate. ‘Short crcutin the solenoid valve | Check the solenoid valve and interior. replace it as appropriate Replace the O rng, oF ‘ Wom-out of the piston O rng disassemble and reassemble the orem Air exhausts from solenoid valve, Eahaust Ar | the solenoid valve | Foreon objects Remove the foreign objects fon when actuator not operated Equalizing valves left open, Close the equalizing valve, Worn-out of the sealing parts of the solenoid valve Check the solenoid valve or replace it as appropriate. IKiITZ CORPORATIONDocument No: KE~4025-06 22/80 14, Disassembly and Reassembly Disassembly and reassembly method of the actuators differs depending on the actuator type. When disassembly of the actuator is required for maintenance or repair, follow the procedures described for each actuator type. Z\ WARNING OQ © DO NOT use compressed air when disassembling the cylinder. The cylinder may be suddenly ejected © A compressed heavy-duty spring is packed within the spring case of the ‘Type BS and BSW actuators, The spring cover may be pushed out and ‘cause personal injury if the tie rod used for fixing the spring case is loosened and removed. When disassembling the spring case, make sure to follow the instructions given in this manual. (© Take care when handing heavy parts during disassembly or reassembly. A\ CAUTION Disassembly ‘© Perform disassembly in a spacious, clean room. © After air tubing is removed, adequately cover the air supply exhaust port and the open ends of the actuator housings to prevent dust from entering, ntl reassembly of the actuator. © Prepare tie rods, spring pins and nuts specified for each size before disassembly of Type BS and BSW actuators. © Release the residual pressure from the cylinder before disassembly. © The intemal surface of the actuator cylinder is coated with fluorocarbon resin. Care should be taken not to scratch the coating during disassembly. © All sliding parts such as shafts, pistons and bearings must be carefully handled and stored to avoid scratches or damages. IKiITZ CORPORATIONDocument No:KE-4025-06 23/50 A\ CAUTION = Assombly © Assemble the actuator in a spacious, clean room. ‘© Clean the parts with light oil or acetone and airblow them but never dip the resilient materials such as © rings in acetone or other quid cleaner longer than 10 minutes. Make them completely dust-free © Apply adequate amount of lubricant (KITZ standard Shell Alvania EP2) to the sliding parts, O ring grooves and internal surface of the cylinder. © Ifany rust is found on the parts, eliminate it completely. oe © Before fixing the piston with a nut, degrease the threaded portion of the nut, and apply adequate amount of locking liquid (KITZ standard: LOCTITE No. 263) to prevent loosening, © Choose O rings for replacement, according to the dimensional information of ‘maintenance consumables provided in Chapter 17 inthis operation manual ‘© Carefully handle the sealing components to avoid scratches or damages. ‘© Assemble the piston and piston rod with care so that the sliding parts are not scratched or damaged. ‘© Firmly tighten the tie rod and bolts so that they may not get loosened. © After assembly of the actuator, check the valve opening and closing positions and attach the position indicator to the mounting bracket. IKiITZ CORPORATIONDocument No:KE-4025-06 24/50 |Construction Detalls of Type B (Double Acting Type) Fin 16 serv ——o) Indestor sy ‘Soap ring Bet Adjust serew, —o (A Trstwaster < , ———reking y Cnser a ns Sg 235 — incator plato a Housing cover eka ‘vo vn suns 8. snap sing ——€3- ~~ yuat desing Piston 5 “0 tng 1] srapsng — Rod aie 8 gS omg a vy —f aA : Pn Homing soaring soning — Roter Housing cap — —— snap ring \ Seen yoru Tha bearing Seorns Som Asus sen Bak Bracket —conctor ‘Type B-3 is ilustrated IKiITZ CORPORATIONDocument No:KE-4025-06 25/50 ‘Type BO Disassembly 1, Reduce the intemal pressure to the atmospheric level and remove the tubing. 2, Remove the hexagonal bolts(94)and disassemble the actuator from the bracket(93) 3. Fit a lever handle or a wrench on the top of the shaft(3)and rotate it counterclockwise to draw the piston (17 towards the housing(1). 4, Remove the hexagonal bolts(35A)and disassemble the eylinder(2). 5. Remove the piston nut(13)and disassemble the piston(177), A\ CAUTION oe © Remove piston nut <13> carefully Iti tightly threaded and fixed with locking liquid 6. Remove the hexagonal bolts(35B)and the housing cap( 158), 7. Draw the piston rod(103)towards the housing cap. 8. Remove the snap ring(48B)and roller(153), then pull out the pin(17). 9. Remove the snap ring(48A)and thrust bearing(47A), and push the shaft(3) downwards to remove it A\ CAUTION oe © An anchor key(60)is provided to the shaft to fix the scotch yoke(142) Be careful nt to lose it 10. Remove the scotch yoke(142)from the housing(1). Assembly 1. For reassembly of actuators, reverse the disassembly procedures. A\ CAUTION © Before fixing the piston(177)with the nut(13), degrease the nut threads and apply some locking liquid (KITZ standard: LOCTITE No. 263) to the nut threads and the piston rod to prevent loosing, 2 It is recommended to replace the piston O rings(45A)and rod guide O rings(45E)because they contact with sliding parts repeatedly 3. Apply some lubricant (KITZ standard: Shell Alvaria EP2) to O ring grooves, cylinder internal surface and all sliding parts. 4. Apply some liquid gasket (KITZ standard: Three bond 1206E) to the contact faces between the housing(1) and the housing oap(158), and between the housing(1)and the eylinder(2). 5. After assembly of the actuator, check the valve opening and closing positions with the position indicator, then mount the actuator to the bracket(93). IKiITZ CORPORATIONDocument No: KE~4025-06 26/50 Position Adjustment 1. According to the instructions in Chapter15, set the valve opening and closing positions correctly by adjusting ‘the hexagon socket head cap screw(132) 2. See Chapter 15 for details of adjustment. ‘Assembly Diagram of Type B-O Fig.17 — lam__—“a) U fn] om No | Parts [No | Parts [No | Parts | No Parts Ne. Parts 1 [Housing [358 [Bot [45 [Orne a9_| Bat 133_[ Ne 2 | Oyinder [36 [Bok | 47A | Tieustbearrw| 92 | Connector | 142 _| Sootoh yoke 3_| Shaft 39 | Serew | 48A | Snap ring 93_| Bracket 145_| Washer 13_[ Nat 45A | Oring | 488 [Srao rine 94 | Batt 153_| Roller 16A_| Plate 458 [Orne [60 [Key 97_| Indicator 155 _| Seal washer 168 [Washer [450 [Oring | 67A | Beara 98_| Indicator plate [158 _[ Housing cap 17_ [Pin 450 | Orne [678 | Bearing 103 | Piston rod 17 35A_[ Bok 45e [Orne [670 [ Bearing 132 [ap serew [== IKiITZ CORPORATIONDocument No: KE~4025-06 21/80 Disassembly 1, Reduce the internal pressure to the atmospheric level and remove the tubing. 2. Remove the hexagonal bolts(94> and disassemble the actuator from the bracket(93) 3, Fit lever handle or a wrench on the top of the shaft(3)and rotate it counterclockwise to draw the piston (17 towards the housing( 1), 4, Remove the hexagonal bolts(35a)and disassemble the cylinder(2)earefully not to seratch its internal surface. 5. For Type B-D6 and D7 actuator, remove the hexagonal bolts(35)and disassemble the cylinder{2)carefully rot to scratch its internal surface, 6. Remove the hexagonal bolts(35b) and disassemble the housing cap(158). For Type B-D6 and D7, repeat the above procedure’ and remove the another cylinder and remove the nut(13) and the piston(177). 1. Draw the piston rod(103)with piston(177)and rod guide(136)towards the cylinder side. 8. For Type B-6, 7, D6 and D7, remove the nut(141)(bolt(155)for B-7 and D7) from the rod guide(196), and draw the piston, rod guide and piston rod( 103) towards the cylinder side. 8. Remove the snap ring(48B)and roller{153)and then pull out the pin(17). 10. Remove the piston rod(103)from the rod guide( 136). A\ CAUTION © Locking liquid is used for the piston nut(13)to firmly fix the piston. Do not loosen the piston rut unless it is necessary. Keep the piston and piston rod together as a sub-assembly. Type BI to BS 11. Remove the hexagonal bolts(36)and remove the housing cover and the shaft (3) upwards carefully not to damage the O ring on the shaft A\ CAUTION oe (© An anchor key(60)is provided to fix the seotch yoke(142)to the shaft(3). Be careful not to lose it. 12, Remove the scotch yoke <142> and thrust bearing <47>from the housing, IKiITZ CORPORATIONDocument No:iKE~4025-06 28/50 ‘Type B-6, 7, D6 and D7 1, Remove the snap ring (48A)and thrust bearing(47), and then push the shaft(3) downwards to remove A\ CAUTION oe © An anchor key(60)is provided to fix the scotch yoke(142)t0 the shaft(3) Be careful not to lose 12. Remove the hexagonal bolts(36)and pull the housing cover upwards to remove. 1. Remove the scotch yoke 142)from the housing Assembly 1. For reassembly of actuator, reverse the disassembly procedure A\ CAUTION oe © If the piston nut(12)is loosened. degrease the threaded portion of the piston rod <103> and the nut <13> and apply some locking liquid (KITZ standard: LOCTITE No. 263) before retightening. 2.It is recommended to replace the piston O rings(45A)and the rod guide © rings(45E)because they contact, with sliding parts repeatedly 3. Apply some lubricant (KITZ standard: Shell Alvania EP2) to O ring grooves. oylinder internal surface and sliding parts. 4. Apply some liquid gasket (KITZ standard: Three Bond 1206E) to the contact faces between housing (1), housing cap(188), cylinder <2> and the housing cover. 5. After assembly of the actuator, check the valve opening and closing positions with the position indicator and mount the actuator to the bracket(93) mPosklon Adjustment 1. Adjust the valve opening and closing positions by adjusting the bolt <132> 2. See Chapter 15 of this operation manual for details of adjustment IKiITZ CORPORATIONDocument No-KE=#025-06 29/80 Rex [Pans [Wo [Pas | Housing 678 Bearing 2 | cslnder [670 Bearing 3 [Shaft [67D [Bearing [we 38 [Bok Tek | Pls [92 Gomer eto 168 | Wanker [93 Bracket ®, iT [Pin 34 [Bok e 35a_| Bolt 97_| Indicator 36 [Bat 36 [nestor ate 36 [Bot 10 Piston rod 38 [Seren [152 [Can Screw 9A Ova [9 [wa 458 | Ong [16 | Rod ide € 450. [Orne 142 | Secch yo 45E [0 ne [144 | Hausng cover 45° [0 ing [145 | Washer aT [Tat ee [158 | Rar “8A [Sn rr [155 | Sel washer . 465 | Snap rie [158 | Housing can ft >) 48C | Snap ring 177 | Piston ~ *] 60 | Key Some parts are diferent depending onthe sctustor types. B-6 actuator shaft parts IKiITZ CORPORATION No._| Parts 3 | Shaft 36a__| Bolt 35 | Bolt 36 | Bolt “47__| Thrust bearing “48A_| Snap ring vat | Nut 142_| Scotch yoke 144 [Housing coverDocument No: KE~4025-06 30/50 1B-7 Actuator Shaft Portion Fig 19 Ne. 35a 3b 36 47 [Thrustbearng 484 [Snap rng [75_[eye bole 265 [Pug [142 | Scotch yoke | [7144 [ Housing cover 155 | Seal washer cr B-D6 Actuator Shaft Portion Fig. 20 No. [Parts 3_| Shaft 35_| Bolt [36_[ Bor 47 [Thrust beara [484 | Snap ring 141 [Nut 142_| Scotch yoke [44 [Housing cover B-D7 Actuator Shaft Portion Fg. 21 No. [Parts 3_| Shaft F 35 | Bort 36 | Bort “47_| Theust beara “8A | Snap ring 142 [ Scotch yoke 144 | Housing cover 155_| Seal washer IKiITZ CORPORATIONDocument No:KE-~4025-06 31/50 JConstruction Detall of Type BS 7 se seo Fig. 22 Snap ing ey SS eator Adjust screw Oo neon Bat 7 ndesor pate Nt Housing cover Bot ome Rod guide (A) Sp ng Shat —— Key Housing Bearing Rod guide (8) veo Thetis eaing ‘Sprng retainer Nut Bracket a Or o_o {5} ‘js crew yee sing cove ‘Type BS-3 is illustrated. IKiITZ CORPORATIONDocument No: KE~4025-06 32/80 ‘Type BS~ \ WARNING sven in this manual Preparation Before disassembling of Type BS-0 actuator, prepare threaded rods, spring pins and nuts as shown in the table below: Parts ‘Shape and Dimensions (mm) ‘ay | Threaded rod Threaded | | - : 4 rod y ‘ Spring pin Spring pin GSR 16 long a Nut M6 P.O 4 1. Reduce the internal pressure to the atmospheric level and remove the air tubing 2, Remove the hexagonal bolts(94)and disassemble the actuator from the bracket(93), 3. Remove one of the nuts(55)and the tie rod(56). 4. Mount one of the four threaded rods in the position where the tie rod was removed and secure it on the spring cover(158)with a nut. Insert a spring pin into a pin hole driled on the threaded rod so that the threaded rod does not loosen (Fig, 29) 5, Repeat the above procedure using the remaining threaded rods, spring pins and nuts. 6. Gradually, altemately and diagonally loosen the nuts on the spring cover and remove all of them when the spring has lost its recoiling force. Then remove the spring cover(158>, spring case(100)and spring( 108). 7. Remove all of the threaded rods. 8. Move the spring retainer (150)by hand apart from the rod guide B(136B)to move the piston(177)towards ‘the rod guide A(136A). 9, Remove the hexagonal bolts(35)and disassemble the oylinder(2)from the housing(1), taking care not to scratch the intemal surface. 10, Remove the piston nut{ 13a)and the piston( 177), IKiITZ CORPORATIONDocument No: KE~4025-06 33/50 A\ CAUTION 11, Remove the hexagonal cap sorew(140A)and the rod guide( 136A). 12, Remove the spring retainer nut(13b)and the spring retainer(150). 13, Remove the hexagonal cap serew(140B)and the rod guide( 1368) 14, Pull out the piston rod(103)towards the spring case 18. Remove the snap ring(48B)and the roller(153), and pull out the pin( 17). 16. Remove the snap ring(48A)and thrust bearing(47), and push the shaft <3> downwards to remove. A\ CAUTION oe © An anchor key(60)is provided to fix the scotch yoke(142)to the shaft Be careful not to lose it 17. Remove the scotch yoke(142)from the housing( 1). WAscembby 1. For reassembly of actuator, reverse the disassembly procedure: A\ CAUTION e © Ifthe anchor nut(13a)is loosened, apply some locking quid (KITZ standard: LOGTITE No, 263) to the nut(13a) and the piston rod(103)threads before retightening, 2 It is recommended to replace the piston O ring (45A)because it contacts with the sliding parts repeatedly. 3. Apply some lubricant (KITZ standard: Shell Alvania EP2) to the O ring grooves, cylinder internal surface and sliding parts. 4. Apply some liquid gasket (KITZ standard: Three Bond 1206E) to the contact faces of the housing(1), rod guide A 136A, rod guide B <136B>, spring case <100>, spring cover <158> and cylinder <2>, 5. After assembly of the actuator, check the valve opening and closing positions with attached position indicator and mount the bracket(93), Postion Adjustment 1. Adjust the valve opening and closing positions by adjusting the bolt <132A> on the eylinder side and the bolt <182B> on the spring cover side. 2, See Chapter 16 of this operation manual for details of adjustment. IKiITZ CORPORATIONDocument No: KE~4025-06 34/50 ‘Assembly Dlagram of Type BS-O Fig. 24 No. [Parts [ No. | Parts No. | Parts No Parts No.__| Parts 1 [Housing [39 | Screw 56_[Tiered [98 | Indicator plate | 1366 | Rod wide 2_[Ovinder [45A [0 ring 0 [Key 100__|Springcase | 140A | Cap scrow 3 [Shaft [456 [0 rng GTA [Bean [108 [Pistonrod | 1408 | Cao screw Ta [Nat | 45¢ | O fing 678 [Bearing [109 _| Spring 142__| Scotch yoke 1 [ Nat | 450 [ Oring 670 [Bewing [111 [ Caution plate | 145 | Washer T6A | Piste [47 | Thrustbeorng | 89 | Bott 132A _| Adust screw | 150 _ | Spring retainer 168 | Washer | 48A | Snap rine 2 [Comector [1328 [Adjust screw [153 | Rater 17_[Pin___| 488 | Snap ring 93 [Bracket | 193A_[ Nut 155__| Seal washer 35 [Bok | 50__| Breathingport | 94 | Bolt 1338 | Nut 158 _ | Spring cover 36 [Bor [os [Nut 97 [Indicator [136A [Rodmide [177 | Piston IKiITZ CORPORATIONDocument No:iKE~4025-06 35/50 ‘Type BS=1 to BS~8 \ WARNING © A compressed heavy-duty spring is packed within the spring case of the ‘Type BS actuators. The spring cover may be pushed out and cause personal injury if the tie rod used for fixing the spring case is loosened and removed When disassembling the spring case, make sure to follow the instructions iven in this manual Prenat — Teese d we] reas se Thread | Lenath(mm) | aty | aty Bs—2 M8 P125 450 4 8 ai BS—5 Mi6_ P20 1010 4 8 sao wees isor[ [8 1 Reduce the internal pressure to the atmospheric level and remove the air tubing 2, Remove the hexagonal bolts(94)and disassemble the actuator from the bracket(93), 3. Remove one of the nuts(55)and one of the tie rod(56)from the actuator. 4. Mount one of the four threaded rods to the position where the tie rod was removed, and secure both ends with the nuts (Fig25). 5. Repeat this work with all other threaded rods and nuts, one after anther. 6, Gradually, alternately and diagonally loosen the nuts and remove all when the spring has lost its recoiling force. Then remove the spring cover 158), spring ease(100)and spring( 109). 7. Remove all of the threaded rods. 8. Move the spring retainer (150)by hand apart from the rod guide B(136B)to move the piston(177)towards the rod guide A(136A). 8. Remove the hexagonal bolts(35)and disassemble the cylinder(2)from the housing(1, taking care not to seratch the intemal surface. 10, Remove the spring retainer nut(13b)and the spring retainer(150). 11, Remove the cap serew(140b)and the rod guide( 1368). IKiITZ CORPORATIONDocument No: KE~4025-06 36/50 12, Move the piston(177)by hand apart from the rod guide 136A)and remove the cap screws 140a), 13, Pull out the sub-assembly of piston(177), rod guide A(136A)and piston rod(103) towards the cylinder. 14, Remove the snap ring(48B> on the roller and then pull out the roller(153) and the pin(17). 15. Pull out the rod guide A(136A)from the piston rod( 103). A\ CAUTION © Locking liquid is used for the piston nut(18a)to firmly fix the piston. Do not loosen the piston nut unless itis necessary. Keep the piston and piston rod together as a sub-assembly. ‘Type BS-1 to BS 16, Remove the hexagonal bolts(36)and pull out the housing cover(144)upwards and the shaft, taking care not to damage the O ring on the shaft lower end. A\ CAUTION © An anchor key(60)is provided to fix the scotch yoke(142)to the shaft. Be careful not to lose it 17, Remove the scotch yoke (142) and the thrust bearing (47) from the housing ‘Type BS-6 16. Remove the snap ring(48A)and thrust bearing(47), and push out the shaft(3)downwards, A\ CAUTION © An anchor key(60)is provided to fix the scotch yoke(142)to the shaft, Be careful not to lose it 17. Remove the bolt <36> on the housing and pull out the housing cover <144> upwards 18, Remove the scotch yoke(142)from the housing <1. Assembly 1. For reassembly of actuators, reverse the disassembly procedures. A\ CAUTION © Before attaching the piston nut(13a), degrease the threaded portion of the piston rod <103> and the nut <13a> and apply some locking liquid (KITZ standard: LOCTITE No. 263) to prevent loosening. IKiITZ CORPORATIONDocument No: KE~4025-06 37/50 2 It is recommended to replace piston O ring(45A)because it contacts with the sliding parts repeatedly, 3. Apply some lubricant (KITZ standard: Shell Alvania EP2) to the O ring grooves, cylinder internal surface and sliding parts. 4. Apply some liquid gasket (KITZ standard: Three Bond 1206E) to the contact faces of the housing(1), rod ide A <136A>, rod guide B <136B>, spring case <100>, spring cover <158>, housing cover <144> and evlinder <2. 5. After assembly of the actuator, check the valve opening and closing positions with the position indicator and mount the actuator to the bracket(93) [Position Adjustment 1. Adjust the valve opening and closing positions by adjusting the bolt <132A> on the cylinder side and the bolt <132B> on the spring cover side, 2. See Chapter 15 of this operation manual for details of adjustment. IKiITZ CORPORATIONDocument No.KE-#025-06 38/50 Assembly Diagram of Type BS ~ 1 to BS ~6 Fa, 26 a RARE iz pe oT Tf ete taf sore Bebbod ul ita Wester [os —[ soe oto tex [eae see Na 61_| Beaine 5 Rte 70 | Bowring 55 Seal washer Some parts are diferent depending conte actuator type, Le BS~6 Shaft Portlon IKiITZ CORPORATION No] Parte T__ | shat af [Bok | a1 [Thatta ae | Shep rn 142 | Seat yore | 144 [ Hosng cover]Document No:KE-4025-06 39/50 ‘Type BSW-0 \ WARNING © A compressed heavy-duty spring is packed within the spring case of the Type BSW actuators. The spring cover may be pushed out and cause personal injury if the tie rod used for fixing the spring case is loosened and removed, When disassembling the spring case, make sure to follow the instructions given in this manual. MPreparatlon Prior to disassembly of actuators, prepare threaded rods, spring pins and nuts as shown in the table below: Parte ‘Shape and dimensions (ram) Qty] Threaded rod 4 - Spi Threaded pad rod = u Spring nin DIX 16 lone 4 Fi. 27 Nut MEPTO 4 Disassembly 1. Reduce the Intemal pressure to the atmospheric level and remove the air tubing, Fully rotate the manual hand wheel(9)clockwise. Remove the hexagonal bolts(94)and disassemble the actuator from the bracket(93) 2. 3 4. Remove the hexagonal cap screw<10), spring washer{ 145),wheel washer(43)and the hand wheel(9) 5. Remove the spring cover nut(133B)and stopper( 49). 6. Remove one of the tie rod(56)and nut(55)from the actuator. 7. Mount one of the four threaded rods prepared in advance where the removed tie rod was mounted, and secure it on the spring cover(158)with a nut Insert a spring pin into a hole dried on the threaded rod for secured mounting (Fig.27). 8. Repeat this work with all other threaded rods, spring pins and nuts, one after another. 9. Gradually, alternately and diagonally loosen the nuts and remove all when the spring has lost its recoiling force. Then remove the spring cover( 158), spring case(100)and soring( 109). 10, Remove all threaded rods. 11. Move the spring retainer(150)by hand apart from the rod guide(136B)to move the piston(177)towards another rod guide 136A) 12. Remove the hexagonal cap sorew(35)and disassemble the cylinder(2)from housing(1), taking care not to scratch the intemal surface coating. 13, Remove the piston nut{ 13a)and the piston( 177), IKiITZ CORPORATIONDocument No:iKE~4025-06 40/50 A\ CAUTION oe © The piston nut <13s> is tightly threaded and fixed with locking liquid Remove the piston nut carefully 14, Remove the hexagonal cap screw 140A)and the rod guide( 136A) 15, Remove the cap screw(140C)and remove the sub-assembly of guide( 108), guide cap(78), bearing( 76)and spindle( 123). 16. Remove the spring retainer nut(13b)and the spring retainer( 150). 17. Remove the hexagonal cap screw<140B)and the rod guide B(136B). 18, Pull out the piston rod 103)towards the spring case, 19, Remove the snap ring(48B)and the roller(183), and pull out the pin(17), 20. Remove the snap ring(48A)and thrust bearing(47)and push down the shaft <3> to remove, A\ CAUTION eo © An anchor key(60)is provided to fix the scotch yoke( 142)to the shaft. Be careful not to lose it. 21. Remove the scotch yoke(142) from the housing( 1), Assembly A\ CAUTION © Before attaching the piston nut(13a), degrease the threaded portion of the piston rod <103> and the nut <13a> and apply some locking liquid (KITZ standard: LOCTITE No. 263) to prevent loosening. A\ CAUTION eo © Ensure to lubricate the threaded parts of spindle(123)with grease such as. “Shell Alvania EP2” to prevent fixing with the stopper(49). 2 It is recommended to replace piston O rings(45A), which are subject to repeated contacts with sliding parts. 3. Apply some lubricant (KITZ standard: Shell Alvania EP2) to © ring grooves, cylinder internal surface and all sliding parts and areas, IKiITZ CORPORATIONDocument No: KE~4025-06 41/50 4. Apply some liguid gasket (KITZ standard: Three Bond 1206E) to the contact faces of the housing(1), rod guide A 136A, rod guide B <136B), spring case <100>, spring cover <158> and cylinder <2>, 5, After completion of actuator assembly, check the valve opening and closing positions and attached position indicator and mount the bracket(93). Posttion Adjustment 1. Adjust the valve opening and closing positions by adjusting the bolt <132> on the cylinder side and the stopper <49> on the spring cover side. 2. See Chapter 15 of this operation manual for details of adjustment. ‘Assembly Diagram of Type BSW ~0 Fig, 28 —a ® = A ut =H [OP Oca ee ee {ss — fs Sie pH a a ee +f ieoser — fos tos ——t twas fees TofS fees fetes te fames [of oe for sr fe foto ties foie fee foo a oe ete tet ee afore =f —— fs ae pt ‘ae teem —t to ste ts te Stites foe fees IKiITZ CORPORATIONDocument No: KE~4025-06 42/50 ‘Type BSW=1 to BSWo6 \ WARNING © A compressed heavy-duty spring is packed within the spring case of the Type BSW actuators. The spring cover may be pushed out and cause personal injury if the tie rod used for fixing the spring case is loosened and removed, When disassembling the spring case, make sure to follow the instructions given in this manual MPreparatlon Prior to disassembly of the BSW-1 to BSW-6 actuators, propare the threaded rods and nuts as shown in the table below. ‘Actuator Threaded rod Nut Fe. 29 size Thread | Lenathimm) | aty | ary Threaded rod l Bs—1 | M6 P10 af 4 a Bs—2 | M8 P12 aso [ 4 a . Bs—3 | M10 PIS | 4 8 , ps—4 | wi2_P175 m4 a i Bs—s | M16 P20 woo 4 a ps—6 | M20 P25 1300 [4 8 Disassembly 1 Reduce the internal pressure to the atmospheric level and remove the air tubing Rotate the manual handwheel(9)clockwise to the fully open position Remove the hexagonal bolts(94)and disassemble the actuator from the bracket(93). 2, 3. 4. Remove the hexagonal cap screw(10), spring washer( 145A), handwheel washer(43)and handwheel(8). 5. Remove the spring cover nut(133B)and the stopper(49). 6. Remove one of the nut(S5)and tie rod(56)from the actuator. 7. Mount one of the four threaded rods in the position where the tie rod was removed and secure the both tends with the nuts (Fig.29). 8, Repeat the same procedure for the remaining nut, tie rod and threaded rods. 9, Gradually, alternately and diagonally loosen the nuts for the threaded rods on the housing side and remove all of the nuts when the spring has lost its recoling force. Then remove the spring cover(158), spring case (100)and spring( 109). 10. Remove all of the threaded rods. 11. Move the spring retainer 150)by hand apart from the rod guide B(136B)to move the piston(177)towards the rod guide A(136A). IKiITZ CORPORATIONDocument No: KE~4025-06 43/50 12, Remove the hexagonal cap screw(35)and carefully disassemble the cylinder(2)from the housing(1)not to seratch the internal surface coating. 19. Remove the hexagonal cap screw(140C)and disassemble the sub-assembly of guide(108), guide cap(78), bearing(76)and spindle(123). 14, Remove the hexagonal nut(136)and the spring retainer( 150). 15, Remove the hexagonal cap serew<140B)and the rod uide( 1368) 16. Move the piston(177)by hand apart from the rod guide 136A)and remove the hexagonal cap screws (140A), 17. Pull out the sub-assembly of piston(177), rod guide(136A)and piston rod(103)towards the cylinder. 18 Remove the snap ring(48B)and the reller(153)and pull out the pin(17). 19, Pull out the rod quide(136A)from the piston rod 103). A\ CAUTION © Locking liquid is used for the piston nut 1Ga)to firmly fix the piston, Do not loosen the piston rut unless it is necessary. Keep the piston and piston rod together as a sub-assembly. BSW-1 to BSW: 20. Remove the hexagonal bolts(38)and carefully pull out the housing cover(144)and the shaft <3> upwards not to damage the O ring on the shaft lower end. A\ CAUTION oe '® An anchor key 60)is provided to fix the scotch yoke( 142)to the shaft, Be careful not to lose it. 21. Remove the scotch yoke(142)and thrust bearing(47)from the housing(1) BsW-6 20, Remove the snap ring(48A)and thrust bearing(47)and push out the shaft downwards, A\ CAUTION eo @ An anchor key(60)is provided to fix the scotch yoke( 142)to the shaft. Be careful not to lose it. 21, Remove the hexagonal bolts(36)and pull the housing cover(144)upwards to remove. 22. Remove the scotch yoke 142)from the housing( I>. IKiITZ CORPORATIONDocument No:iKE~4025-06 44/50 Assembly A\ CAUTION Before attaching the piston nut(13a), degrease the threaded portion of the piston rod <103> and the nut(13a)and apply some locking liquid (KITZ standard: LOCTITE No. 263) to prevent loosening. A\ CAUTION eo Lubricate the threaded portions of spindle(123)with grease (KITZ standard: Shell ‘Alvaria EP2) to prevent fixing withthe stopper(49). 2 It is recommended to replace piston O ring 45A)because it contacts with sliding parts repeatedly 3. Aoply some lubricant (KITZ standard: Shell Alvania EP2) to O ring grooves. cylinder internal surface and sliding parts. 4, Anply some liquid gasket (KITZ standard: Three Bond 1206E) to the contact faces of the housing (1>, rod guide A <196A>, rod guide B <196B>, spring case <100>, spring cover <158>, housing cover(144) and cevlinder(2). 5. After assembly of the actuator, check the valve opening and closing positions and with position indicator and mount the actuator to the bracket 93). Position Adjustment 1. Adjust the valve opening and closing positions by adjusting the bolt <132> on the cylinder side and the stopper <49> on the spring cover side 2. See Chapter 15 of this operation manual for details of adjustment. IKiITZ CORPORATIONDocument No:iKE~4025-06 45/50 ‘Assembly Diagram of Type BSW — 1 to BSW 6 Fie, 30 Wo. [Parts Wa | Parts 1 x 1 [Housing [69 [aot | 2 | Gxinder [92 | Connector a] shat wa [Bracket @ | Handaneet [94 [aot iO [Cop seren [87 | tneator a [Wt 9a [deator pte a6 | wt 100 | Spine cose aa | Plate 102_| Piston rod 66 | Washer | 108 [Guide [Pn 108 | Spine 25] Bo Tit Caution pate 36_[ bat 123_[ Spine 3¢_| Sere 152 [ Aaiust sero Hand aa [Fende Yona |e Tam | rine aaa [Na —————— t 458 [Oring 136A [Rodan —] Le 450_| Oring 1366 | Red euide 47_| Trust Bearing 1408 [ap sero ——————— S oe it 2 48 | snap ine | 10° | an sew 70_| Soap rng | 142 Seateh woke 48_[ Stopper [144 | Housing over ss [wa 148A | Spring washer 56 Te roa 1658 [Washer f i 0 | key (os | Bachan re 670] Bearing | 153 Roter 670] Bearing | 155 | Seal washer — 76_| Trust Bear] 10s | Spring cover a: 76 [ous cap [177 [Piston mo @ Some parts are ferent depending #1 ony Bsw-s onthe ‘ype 52 BSW5 or higher a a 1 ¢ 3 [shaft | 36 | Bok [Trt ore “48 | Shap ing 142 | Scotch yore 144 | Housing cover a BSWH6 Actustor Shaft Porton IKiITZ CORPORATIONDocument No:KE~4025-06 46/50 15 Adjustment of Valve Operating Positions Adjust the valve fully opening and fully closing positions by adjusting the adjustment bolts on the both sides of the actuator. ‘Adjustment for KITZ Butterfly Valves (#1) (1) Set the difference, [A minus Bl, to 2er0 for KITZ UB Series and SHB Series butterfly valves. (2) Contact KITZ for information on Size DN250 and DN3OO, (3) Contact KITZ for information on $2 DNS. Valve size | Arminue 8 [mm Nes | ON | tony | 16DJ v2] 40 OtoZ 2 [50 tos z72[_ 65 3to4 3 [80 3to4 4 [| 100 to 5 5 | 125 ato § 6 | 150 5to6 @ | 200 Bto7, 10 | 250 | fete20] *2 12 | 300 | tat020[ +2 14 [350 3 ‘Adjustment for KITZ Class 150/300 Full-Bored Floating Ball Valves (#4) L L ryan Valve size (ful-bore) NPS DN Linn t 378 to 3/4 10 to 20 50 iS 1 to 1-1/2 25 to 40 55 2 50 60 Half open from the Fuly closed m4 65 70 fully closed postion pay 20 80 4 100 95 5,6 125, 150 125 8 200 210 10 250 265 (4) Applicable to KITZ JIS 10K/20K ASME Class 150/300 full bore floating ball valves. Fig, 31 Adjustment bott ‘Type BS Actuator Adjustment bolt IKiITZ CORPORATION