WATTS BALL VALVES

OPERATING AND MAINTENANCE

INSTRUCTIONS

B/C SERIES PIPE END CONTROMATICS BALL VALVES

PREFACE

The Contromatics’ Ball Valve contains many improvements and

simplifications not found in other Ball Valves. These improvements serve to

insure a long and trouble -free life, as well as making maintenance much simpler

and less expensive when it is finally required.

BASIC DESIGN

BALL AND SEAT DESIGN

The Contromatics’ Ball Valve employs the “Floating Ball, Fixed Seat”

design to affect a completely pressure-tight shutoff. When the end pieces are

bolted tightly against the body, both the upstream and downstream seats are

squeezed against the ball for initial sealing pressure. Upstream pressure forces

the floating ball against the downstream seat to further increase sealing

pressure.

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BODY DESIGN

The standard Contromatics’ Ball Valve employs a three (3) piece design

which is made up of the body (Pc. 12) and two (2) end caps (Pc. 14A and 14B),

(see attached exploded assembly drawing). Note that, when the assembled

valve is installed in a line, any one (1) body bolt can be removed, the remaining

three (3) loosened with the ball in the open position, and the entire body capsule

can then be removed from the line to perform maintenance.

STEM DESIGN

The Contromatics’ Ball Valve employs a back seated stem design

whereby, as pressure within the valve is increased, the sealing ability of the

inside tem seal (Pc. 3A) is increased. Conversely, in vacuum service, the sealing

ability of the outside stem seal (Pc. 3B) is increased by the pressure decrease

within the valve.

TRAVEL STOP DESIGN

Contromatics' Ball Valves utilize the existing finished surfaces of the end

caps (Pc. 14A and 14B) and separate travel stop (pc. 7) to insure 90% travel.

This rugged feature eliminates troublesome and fragile pressed-in pins, cast

lugs, etc., as travel stop devices. When the handle is parallel to the pipeline, the

valve is open.

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GENERAL

INSTALLATION AND WELDING INSTRUCITONS

Installation of Contromatics’ Valves is straight forward, simple, and self-

explanatory; however, a few considerations or checks can prevent possible

future problems. Although the valve has great structural integrity, severe

misalignment and/or pulling part of the adjoining pipe has a detrimental effect on

the valve and should be avoided. Standard industrial practices should be

followed on screwed end valves. Over tightening as with all pipe fittings can

result in stripped threads and/or misaligned or defective end caps.

Weld end valves are shipped with permanent and replacement seat

depending on size. Welding procedure tags are attached to all weld end valves.

The procedures are on of the following three:

1. ¼ to 2 inch size with buna seats installed and permanent seats

attached to the body. These seats will be destroyed during welding

and must be replaced after installation. The ball port should be in

the open position during welding to protect the sealing surfaces.

2. 3 to 4 inch valves are shipped complete and must be disassembled

before welding to remove ball, seats and O-rings if applicable.

3. Pipe extension valves are shipped complete and can be welded in

line as such. The ball should be kept in full open position during

welding. All weld end valves have tags attached to explain

procedures to be followed.

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MAINTENANCE INSTRUCTIONS

GENERAL

Contromatics’ Ball Valves require negligible maintenance through

the first 75,000 to 100,000 cycles. In the unlikely event that leakage is

encountered in the stem area tightening the stem nut (Pc. 4) may be

required. This tightening should be done as soon as evidence of leakage

appears around the gland ring. Prompt tightening of stem packing can

avoid early stem failure.

PREVENTITIVE MAINTENANCE

If the Contromatics’ Ball Valve is being utilized in a service where

leakage through the valve or to the outside of the valve could be

detrimental to the process in which the valve is used, replacement and/or

adjustment of certain parts on a periodic basis should be employed as

follows.

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 NUMBER OF CYCLES

PART NAME ADJUST REPLACE

Stem Seals _ _ _ 75,000

Seats _ _ _ 75,000

Stem _ _ _ *200,000

Ball _ _ _ *200,000

* Only if required

TROUBLE SHOOTING

Following is a list of some of the more common malfunctions of Ball

Valves and suggested corrective actions.

1. MALFUCTION: Stem Seal Leak

CORRECTIVE ACTION: A. Tighten stem nut (Pc. 4)

B. Replace stem seals (Pc. 3A and 3B).

2. MALFUNCTION: Leak between body (Pc. 12) and end caps

(Pc. 14A and 14B).

CORRECTIVE ACTION: A. Tighten body bolts (Pc. 11A, B, C, and

D).

B. Replace seats (Pc. 2A and 2B)

3. MALFUCTION: Leak through valve seats

CORRECTIVE ACTION: A. Replace seats (Pc. 2A and 2B).

B. Replace Ball (Pc. 13).

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4. MALFUNCTION: Excessive operating torque

CORRECTIVE ACTION: A. Slightly loosen stem nut (Pc. 4).

B. Replace stem (Pc. 5) if slight galling has

occurred.

C. Replace body (Pc. 12) if galling in stem

hole is excessive.

ASSEMBLY INSTRUCTIONS

1. Place stem seal (Pc. 3A) over stem (Pc. 5) until seal rests on lower

stem shoulder.

2. Insert stem into body (Pc. 12) form the inside with the flats on the

bottom of the stem parallel with the low path through the body.

3. Insert ball (Pc. 12) into body bore with ball slot engaging stem.

4. Insert seats (Pc. 2A and 2B) into body counter bores (Note: small

diameter of seat should be towards the ball).

5. Insert body bolts (Pc. 11A, B, C, and D), through holes in end cap

(Pc. 14).

6. Place body capsule (containing stem, ball and seats) into the end

cap assembly defined in #5 above being certain that the stem is

located in the same plane as the flat on the end cap (Pc. 14).

7. After inserting body (Pc. 12) make certain body bolts (Pc. 11)

engage grooves in body or strattle lobes on body.

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 Place end cap (Pc. 14) on top of the open end of the body

assembly again being sure that the flat on the end cap (Pc. 14A) is

in the same plane with the stem which protrudes from the body

assembly.

8. Pull the body bolts up through the holes in the upper end cap (Pc.

14A) and install star lock washers (Pc. 15A, B, C and D) and the

nuts (Pc. 1A, B, C, and D).

9. Tighten nuts (Pc. 1) uniformly such that the gap between the end

caps (Pc. 14A and 14B) and the body (Pc. 12) is reduced to zero

on an equal basis (nuts should be tightened until both end caps

bottom out metal-to-metal on the body).

10. Insert the following parts over the stem extension in the order

shown: stem seal (Pc. 3B), bland ring (Pc. 10) grounding spring

(Pc. 17), spring washer (Pc. 8A and 8B), stem nut (Pc. 4). Tighten

stem nut (Pc. 4) until spring washers (Pc. 8A and 8B) are

completely flattened. After tightening the stem nut insert the travel

stop (Pc. 7), hand (Pc. 9), washer (Pc. 6), and hex nut (Pc. 16).

Tighten hex nut (Pc. 16) until travel stop (Pc. 7), handle (Pc. 9), and

star washer (Pc. 6) are tightly compressed, then back off on the

stem nut (Pc. 4) approximately ¼ turn.

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DISASSEMBLY PROCEDURES

After a Contromatics’ Ball Valve has been installed in a pipe line,

the entire body capsule can be removed from the line in the following

manner:

1. Turn valve handle (Pc. 9) to the open position, i.e. parallel with the

pipe line.

2. Remove one (1) body bolt (Pc. 11A).

3. Loosen the three (3) remaining bolts (Pc. 11B, 11C, 11D).

4. Lift entire body assembly from the line (it may be necessary to

apply a slight separating force to the two (2) end caps to allow

clearance for body removal).

5. To perform disassembly to any of the body components, reverse

assembly procedures as defined above. Note: Seats are

removable by placing ball in the closed position and pushing the

free floating ball. Caution should be taken not to mar the ball

surface.

6. It is important that, when the body assembly is reinserted into the

pipe line, the ball is in the open position.

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STANDARD MODIFICATIONS TO OUR VALVE

Some modifications commonly used in our product line are listed

below with the appropriate comments:

1. Steam Design Valves

O-rings are included in the end caps and in some cases in

the stem. These are easily installed and removed. Caution is

recommended upon assembly and disassembly not to shear the O-

ring in the stem. O-ring in end caps must be in grooves upon

assembly.

2. Fasteners

Shown on our drawing are hex cap screws and hex nuts.

Fasteners may vary with size and material. Standard nuts, studs,

and bolts may also be used.

3. Stem Nuts

Jam nuts with star washers are usually used on manual

valves.

4. Handles

Vary with size and include cast handles.