GE Oil & Gas Masoneilan* 35002 Series Camflex*| Rotary Control Valve Instruction ManualTHESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT- SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR'S NORMAL. OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS. AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED. ‘THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING. OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS. APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE. ‘THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE. THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS. THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT ‘THE WRITTEN APPROVAL OF GE. (©2018 General cecvieCompeny lights reservesTable Of Contents Safety Information... About this Manual. Warranty. 1 Introduction 2. General 3. Principle Of Operation. 4, Unpacking S. Installation ooo 6. Air Supply Piping... 7. Placing In Service. 8, Disassembly. BL Actuct 8.2 Actuator Complete Disassembly Removal from Body S/A 83 Volve Body 9. Maintenance. 9.1 Spring Diaphragm Replacement. 9.2 Body S/A Internal Parts. 9.3 Voke Assembly. 10. Reassembly Procedures. 10.2 Spring Diaphragm Actuator 102 Spring Diaphragm Actuator on Body S/A. 103 Handwheel Reassembly. 10 10.4 Limit Stop Reassembiy 10 105 Valve Body Reassembly. 10 106 Seat Ring Alignment. a 107 DVO Plate Reassembly 2 11. Actuator Stem Adjustment, 12. Changing Body Positior 13. Changing Actuator Action.. 14 14, Manual Actuator Option 35 14.1 Disassembly Procedure 18 142 Maintenance. 18 143 Reassembly Procedure. 18 gh reserved Mosaneion 35002 Seres Cans Irstructon Manuel | €Safety Information Important - Please Read Before Installation re 35002 Series contra) valve instructions canton OANGER, WARNING, ond CAUTION labels. where necessary, to elert you to safely elated or other important information, Reed the instructions carefully before instaling and maintaining your cortrol valve DANGER and WARNING hazards are related to personal injury, ‘CAUTION hazards involve equipment or property damage. Operation (of damaged equiemen: can, under certain operational result in degraded pracess system performance that can lead to inury or death Total complisnce with all ANGER, WARNING, and CAUTION notices 's veauited fr sate operation A This isthe safety alert symbol It alerts you to potential personal injury hazerds. Obey al safety messages that fallow this symeol to ‘void possible injury or death ADANGER Indicotes « potentilly hazerdous stuation which, f not avoided, could resultin| nor sens injury AWARNING lly hazerdous stuation which, f not avoided, us inury tes @ poten could result in se ACAUTION tes a potentilly hazardous stuation which, if not avoided, ‘could result in minor oF moderate injury, CAUTION When used without the safety olert symbol indicates a potentially hazardous situation when, if not avoided, could result in propery damage. ‘Note: Indicates important facts and conditions. About this Manual ‘+ The information in ths manual is subject to change without, ‘or neice + Theinformation contained inthis monual.inwhole or ear shall 1 be ronscrived or copied without Ge's written permission, + Please report any errors or questions about the inform: this manuel to your local supple. + These instructions are writen soecfcaly for the 35002 Series control valve ond do not apply for other valves outside ofthis product line Useful Life Period he current estimated useful life period for the Masonelan 35002, Seres Carex! 25-years, lemeximizethe useful eof the product Its essential to conduct annvalinspections, routine maintenance and censure prose 1 any unintended slresses on the roduct. The specfc operating conditons wil oso imeact the useful (ory for guide nsf required prior tanstaition, pict Warranty Items sold by General lecvic are warranted tobe free from defects in rmaterio's and workmanship for « periad of one yea” from the date of shipment provided saditemsareused according GE recommenced sages. GE reserves the right to discontinue manufacture of any product or change product materials, design or szecifications without notice. Note: Prior to installation + Thevalve must be installed. out int service end maintained by quolified and competent professionals who have Lndergone sutabie waining. + Al surrounding pipe lines must be thoroughly flushed to ensure al entrarned debr's has been removes from the syste + Under certsin operating conditions, the use of damaged ‘equipment could couse a degradation ofthe performance of the system which may lead to personal inury or death + Changes to specifications, stucture, and components used may not lead to the revision of this menusl unless such ‘anges affect tne function and perfarmance of the product.1. Introduction Tae folowing instructions are designed to essist maintenonc personnel in performing most of the maintenence required on the Camflex I valve ond i fllowed carefully wil reduce maintena GE hos highly skilled Service Engineers availaole for maintenance ond repair of our valves and co ‘addition. regulary scheduled traning programs are strumentation person rain customer serviee and tand instruments. Arrangements for these services ca hrough ducts representative or district office. When performing maintenance use only Masoneilan replacement parts. Ports are obtainable throug” your lacol representative district office, When ordering parts always include MODEL and SERIAL NUMBER oF the unit being repaired. 2. General These installation and maint nance instructions apply to 1 igh $00 sizes), 2 avalabie ratings, ‘actuators, The model number, se and rating ff the vaive are shawn an the serial plate, Refer to Figure 1 ta identify the valve made! 35002 Series Body Numbering System etn 3. Principle of Operation The concept of the Camflex Il valve is based on an ec: tating spherical plug contained in a free flow body d plugse ed by flexible arms to a hub whicn sides ‘onto a rotating shatt. The plug free to centr ise along the axis cof the shaft A positive seol between plug and seat is achieved by i¢ deformation of the plug arms. The chamfered seat ring Is lug and shal are rotated through an angle ef $0" by a lever linked to a powerful spring-opposed raling daphragm actus he solid disktype handwiee! ond lacking hex nut, optional, ore mounted on the yoxe, oppasite the actustor and may be used to manually operate the valve or as limit stop. A threaded hole in the oppeste side of the yoke s plugged but can be equipped with an optional cap screw a te inserted (a lnrt stop in the other oirecton, Note: The handwheel on Camflex I! is designed to be used for emergency action only, ss wc Cesar Acwetor ype we, Actwtor Mounting seatowion | | 8880 | [ oesen Seay = [naa [Dewemeca| (lina 2 ¥ eee ome eee 2 Soe fined tren 2 ruck pesoevareepen | |S ecto ee ieee 3 Perpendicuor to podine, valve ‘cores on sem extension 4 Perpendcu at opine, valve ‘person stem extension 5 orale! to pipeline valve closes ‘on stem extension 6 Paral! to pipeline, vove opens lon stem extension 7 Perpendicuar'o poeine, valve | Perpendcuar‘opipeine, valve opens on stem extension 5 Cerome in [a optional, Comtex with separable bonnet Figure 1 15 Genera lectre Company. alls eseve,Handwheel Figure 2 ne actuator is generally mounted with ait-loading to counter the dynamic torque on the plug. In Figure 2 the flow direction tends ta open the plug and the actuator is oriented to close it with increasing a pressure, The actuator spring force ass'sts lug oft bbolance forces to open the valve on airfalure the valve is to close (on air failure, the body would be turned around in the line so that flow tends to close the plug and the actuator position would be ‘The Comex valvehos 6 madifed liner flow choracterstic, which is the some in ether flow drectian. It con be easly tansformad to {an equel percentage when equigping the valve with a paskioner {4700 series, 8000 series or SVI Smart Valve interface. Reduced TRIM factors 04 and 06 ore avaiable on al szes, The ow copacty fof 2 04 factor s 40% of the rominal eapecty ofthe valve and i is 60% for the 06 factor 01 ond 02 are avaiable on the (ON 25)voive, “Te sbiity ofthe Camfex I valve to handle 6 wide range of process fic temperctures is due to the long integrally cost bonnet Tis affords emple radiation surface to normalze the packing temperature. Therefore. with set-iubricating TFE Aroma fiber packing, the vaive handles temperotures ‘rom -196°C to + 400°C [21°F to +752°0, When insulating the valve, do not insulate the valve bonnetisee Figure 3 +. Figure 3 4, Unpacking Actuator \ Guide Bushing Flexible Arms Guide Bushing ‘Air Cate must be exercised when unpacking the valve to prevent damage to the accessories and component parts. Should any problems arise, contect your representative a istic office, Note: For ease of shipment and to prevent damage, valves equipped with the spring diaphragm actuator are shipped With the handwheel unassembled, Refer to Section 10.3 for handwhee! assembly procedures. 5. Installation The Comflex Il valve has eeen assembled at the fectory in teccordance with specific instructions concerning flow direction tend actuator made. The valve must be installed sa that the contralled substance wil fow through the waive in the direction indicated by the flow arrow (25), which ' Iocazed on the upper port of the valve bonnet. The uaive actuator should be installed 0 the actuator s abave the centerline of the shat. To instal tre valve in the line, proceed as follows: CAUTION ‘Any change in flow direction or actuator mode must be ‘sccomplshed cs outined in Sections 7 and 10 of this instruction, ‘manual. Failure to fallow these cou resut in personal injury and rent matfunction |A. Check the model number on the serial plate (56) against the numbering System described in Figure 1 o determine the wave 8, Clean piping ane valve of al foreign material such as welding chips. scale, oi, grease or dirt. Gasket surfaces should be ‘thoroughly cleaned to ensure leak proof connections. C. Te allow for in-line inspection, maintenance or removal of ition, provide 9 manuclly «de of the Comex i valve with 2 manually operated throtting valve mounted in che by-Note: If a flanged Camflex 1! is being installed and the distance between flanges is established by ANSI or IN, spool pieces (spacers) are inserted between the line flange ‘and the valve body flange, Gaskets and valve bolting are then installed and torqued using standard flange and line bolting criteria ©. For flangeless vaives, refer to Figure 23 and determine the correct size and quantly of bolts to be used forthe valve and flange rating , I the yalve isto be installed in @ horizontal poston, install the lower flange batting o provide a cradle, which will help support the valve while instaling tne remaining batts . Place the valve in the line G. Select ond instal correct gask Note: Spiral wound gaskets, suitable for service conditions are recommended. H, Insert remaining flange bolting ensuring that the baits align with the special bosses on the body, which assure the vave is centered inthe ine and aso prevent rota Note: For certain flange standards, through bolting is not possible because of the valve body neck or bonnet. To ‘accommodate flange bolting, guide arms with threaded holes or slots are provided on the valve body to receive ange bolts refer to Figure 22 |. Tighten flange bolts evenly and fry. CAUTION If che values to be insulated, do not insulate the valve bonne Note: if the valve is equipped with manual handwheel, it ‘may now be placed in service. 6. Air Supply Piping Airis supaleg tothe actuator through the 3/4” NET topped anrecton in the doptvagm cose. Refer to Figure 14 determine the correct suppy pressure and tubing ze, then conrect or supp} pip CAUTION Do not exceed maximum air pressure indicated. Personal injury land equipment matfunction could result Note: When the valve is equipped with regulators or other ‘accessories supplied by GE, only connections to those accesso- ries are required since the piping to the actuator is connected ‘at the factory. Some valves equipped with electrical acces~ sories will require appropriate wiring. Refer to manufacturer's instructions fer correct wiring information gh reserved 7. Placing in Service With the velve properly installed in the ine and oll irr electrical service connected, tis recommended (nat the valve be run through one cycle to ensure proper functioning. Proceed as follows: ‘A. Back off the hanchvhee! (53 so that twill nat interfere with the ‘operation of the valve ond tighten the handwheelock(52 Note: ifthe valve is equipped with the optional limit stop (77, it should also be backed off to prevent interference withthe ‘operation ofthe valve. 8. Aaply correct air pressure the actuator Note: Valve should function smoothly and with maximum pressure, the valve indicator (6) should show full open or full close depending on valve mode. . Relieve air pressure and return valve to normal made. ©. Gradualy open process ines to place the valve in service, E, Check for leaks. Repair as required CAUTION ‘Always ensure process pressure, air pressure end electrcel service are off ond the value ssolated andrel eved of press before performing maintenance on the valve F. If desire, the handwheel may be used as a limit stop. Set in desired position and lock 6. ith ional mit stop (771s used, set and tighten lacknut, 8. Disassembly 8.1 Actuator Removal From Body S/A (Refer to Figures 16 and 17) Maintenance required onthe internal components af the valve oF reorientation of the actustor and vady, cequtes that the actuator and yoke be remaved fram the valve, On the sze 6, 7 and 9 actuators, for ease af handling and reassembly, itis recommended that the spring Barrel be removed from the yoke onc then the yoke separated from the vaive body. CAUTION Prior to performing maintenance on the vale, isolate the valve, vert the process pressure and shutoff supply and sigrcl airlines to the actuator Note: If the valve will be reassembled in the same ‘orientation, it is recommended that the body to yoke ‘orientation and the actuator to yoke orientation be marked inrelation to each other. This will simplify reassembly. A. tf required remave the valve from theline, 8. Remove rear cover [29) end front cover [32] by removing the two cover screws (30), . Remove bottom cover 11} and spring barre! bass cover (58) D. Remave the adjustable in screws (8), +188] by removing the two. Loosen handwhee! lock (52) and turn handwhee! (53 soit dees not interfere withthe movement ef the ever 84 Note: On valves supplied with the optional limit stop, (Figure 17) loosen nut (78) and back off the limit stop ‘screw (771 soit will nt interfere with the movement of the lever (34, F. Connect an air line to the actuatar supely port and using 2 manual loading panel or reguated av supply, apply enough arr pressure tothe actuator so the lever wil move toon intermediate posi CAUTION Do not exceed pressure liste in Figure 24 for actustor Used D9 not use handwnee! io move the lever Note: Ifthe valve is to be reassembled using the same ‘orientation, it is recommended that the yoke (33) and ever (34) alignment, in the closed position, be marked to simplify reassembly and alignment ofthe lever and shaft to ensure proper valve functioning. See Figure 17. 6. Remove spin clips (Sh Remove clevis pin (7 |. Relieve ar pressure from ectuator enabling clevs 351 to disengage from lever (54), Note: Ifthe valve is equipped with a positioner, refer to the appropriate positioner instruction for procedures on ‘cam or lever removal. Then proceed to step K. J. Remove sh CAUTION Depending on the size and weight of the actuator It is recommended that proper lift and sue utlized when removing the spring barrel or yoke. cover (9) by removing cover screw (10, K, Ensure spring berrlis properly supported L. Loosen and remove cap screws [371 then remove spring barrel (38) | and lock washers M, Loosen lever capserew 9) NN. Loosen the stud nuts 134) and disengage the packing flange, 0. Loosen the stud nuts (271 to separate the actuator from the body S/n Note: With body secure, grasp lever and yoke and separate. Yoke, lever and packing flange are removed ‘at the same time. The yoke may have to be struck with ‘a soft face mallet to break it loose 8.2 Actuator Complete Disassembly he spring diaphragm actuator used on the Camfex il valve was designed boscally as a low cost nan-replaceable item tang therefore disassembly is not recommended. However. in some instances and for emergency purposes, disassembly may be required. Procead as fol ows [A Ifthe actuator is not removed from phOTA 13 he boxy proceed to sen locknut 46) then remove the clevis 13 nut 5) ‘ond the sen and remove copscrew [tl and remove dio: shragm case (62) and ciaphragm [40 D. Using a deep socket, loosen and remave lack nut ert E, Remove piston (43) and spring (39) and inspect all components F, Proceed to section 102 for reassembly 8.3 Valve Body (Refer to Figures 4 and 16) Maintenance to the internal components required on the Camfex Valve can normally be easily determined since the seat ring and plug can be seen once the valve is removed from the line, Although it may be determined that the seat ring does not need replacement, it must be noted that the new plug and seat ring must be lopped, thus requiring the disossembiy of the body. Its recommended that both seat ring and plug be replaced if one othe ather is demmaged due to service a ator has been removed from the body, dis assemble the vave using the folowing procedure CAUTION nthe uae, solatethe valve ang vent the process pressure A 35002 SB [Seporable Bonnet! versions, remove bonnet nuts {104} and it aff eannet (102) complete with packing {171 snd packing follower (151 rom the body os fan assembly, Praceed to step 0. 8. Remove packing follower 25] C. Remove safety pin (18) CAUTION ‘The purpose of the safety pin isto prevent the shaft from being pushed out if the yoke is removed while the valve 5 stil pressurized, The internal components of the valve ‘cannot be removed without frst removing the safety pin. D. Pullonthe shaft (19) ta remove ‘Note: Difficulty is sometimes encountered when removing the shaft from the plug mainly due to an excessive ‘accumulation of deposits between the plug splines and the shaft. Application of heat to the plug shaft bore while "using one ofthe following methods wil facilitate removalCAUTION When using heating devices, ensure that proper safety Such tems as the fammatilityend ‘of the controlled substance rm and proper precautions token Ifthe shafts not removed easly, repace the lever [2] on the splined end ofthe shat 1), tighten the lever c (49) ard using a male, cop the lever (34) os close to shaft as poss ble and remove the sha II Note: Ifthe shaft cannot be removed by tapping the tightenedIever, Figure 20illustrates an alternative method ‘of removal. Using a pipe nipple of suitable size and length ‘and reversing the packing lange and stud nuts as shown, the shaft may be jacked out ofthe body. Fer larger valves, the use of an additional washer and nipple to assist in holding the tightened lever is recommended. The lever should be tightened at a point where the hub on the lever, is flush with the end ofthe spline. . The components which should come out with the shaft {19) are: the packing (17), packing box ring [23 or 106}, spacer tube (20] and upper guide Busting I21) Note: The spacer tube (20) and upper guide bushing (21) may remain in the body. They should be removed. The ‘spacer tube [20] can only be removed by pulling it out the bonnet end of the body. The upper guide bushing (2 may be pushed through the body after removing the plug or pulled through the bonnet end of the body. On valves designed for use on slurry or viscous service, ‘the upper guide bushing has an inner “O" ring (82) and ‘an outer "0" ring (93) and the lower guide bushing has inner "0" ring (95) and outer “0” ring (96 Refer to Figure 4 soon Rn 6 os cal) Figure 4 - Optional “0” ring arrangement F. Remove the plug through the end oft the seat ring 6G. Remove the loner guid shing 122) Note: A groove is provided in the bushing for prying ‘out the bushing using a screwdriver. If the bushing will be pried out it should be pried from two sides to prevent jamming the bushing during removal. if the bushing does not come out easily, fill the bushing with ‘grease, insert the shaft (19) nto the valve insuring that the machined portion of the shaft starts into the lower guide bushing. Using @ soft faced mallet, strike the ‘end of the shaft lightly until the bushing is pushed out partially. Remove the shaft and complete removal of the bushing by prying out using the groove provided. gh reserved CAUTION Do not pry the bushing using the seat for leverage. Ifthe ishing cannot be easiy removed, proceed to section 83, ‘and remave the seatringretciner and sectring then re bushing. Place a piece of sot stock brass, etc) between theinner seat shoulder ond prying device to prevent damage ‘tothe seat sealing area of the bony 83.1 Seat Ring Removal (Refer to Figure 16) The following procedures outline the recommended method for removing the seat ring retainer {3} with use of retainer wrencnes, GE menufectures ond hes avaiable, for a nominel pice, seat ring retainer wrenches for the Camflexl, I" through &" [ON 25 through 109) sizes, is highly recommended that wrenches be purchased or fabricated to facilitate removal and reassemaly of the ‘eat ring [2] since SPECIFIC TORQUES MUST BE ACHIEVED to obtan tight shuto‘? and ensure proper functioning of the valve, Figure 5 shows the recommended maoterias, thickness fang method ef construction along with specific dimensions to faclitete construction, pusre ines (ae & 1-00 Seat Ring Retainer With of ct Retainer Figure s AA. Secure the vaive body in a vise or appropriate holding device with the seat ring facing up, CAUTION Care must be token to avoid domage to the gasket face on the valve body, 8. Place etainer wrench so engages retainer lugs C. Engoge the retoiner wrench with an impact wrench or suitable wrench andllaosen, then remove retainer turning counterclockwise D. Litout seat ring, ‘Note: In an emergency, drifts may be used to remove the seat ring retainer. However, two drifts should be Used and placed in the slots 180° apart and struck simultaneously.83.2 DVD Removal IRefer to Figure 16) 20 Carflexwith the DVD option madel number 38x tx.the DVD isinstalledin the body, tis recommended to use the DVD wrenches to remove this device (105). GE monufactures and has ovale, for © nominal srce, OVD wrenches for the Camflex I, 1" through 12" ses [DN 75 ‘through 300 sizes, is highly recommended that wrenches be purchased of fabricated to facitate removal and reassembly of the DVD 105) since SPECIFIC TORQUES MUST BE ACHIEVED to ensure proer clamping ofthis OVD plat Figure 6 shows the recommended thickness and method 8. Place DVD plate wrench soit engages retainer lugs . Engage the retainer wrench with an impact wrench o/ suitable wrench and loosen, then remove DVD |105) by turning counter-clockwise 9. Maintenance 9.1 Diaphragm Replacement. {Refer to Figures 16 and 17) The recommended maintenance to be performed an the Comex Il Spring Diaphragm Actuator is limited to the replacement ofthe diaphragm {40 Removal of the actuator afeanstructon along wilhspecte dimension (ofaciate constructon from the valve is nt requted. To reloce te dphragm, proceed a ‘allows The vale must be footed and free rom any sevice pressure / Al eecical or ar pressure to component pars must be of [/ Pn eee ere S Handwheel (53 andlimit tap 77 ust be backed off to alow free travel ofthe ever ‘A. 8yposs the vave, shutoff stop vaves and isolate valve in nea compliance win CAUTION note sted above 8. Shutoff end dsconnec ir suply tubing to the actuator i ro ohn C. Remove the four copscrws {tt fom dachrogrn case eo om (e2hond remove dophregm case 7 one tas boon | es 0. Remove aphragr 40 onas)| en | eo [ors | @ | 0 Note: Diaphragm is glued tothe top ofthe piston ve [ra06 | 0187 | 177 fare | os eons eeeeeeneey onaoy| os a | as | | om the ton of the piston and clean a [1220 |a1s7 | 2208 fare | a7 a onso)| as |w | es | | co 3 142) ond spring bare! 181 ot te ee ee dophrogm beadin preparation fr conaso)| ‘oo | vas) [ees |e | 2, : Note: To hold the diaphragm in place on te piston, an a [asse[oxe7 | azre |oz7s | o8 on‘r00)| “ae | ae” | fate | O25 | oe atthesive csc ladhesive both sides or rubber cement woof ooh 8 | or | | oh acer cet ue ahald be apo 0 oth the piston and the daphragm or n accordance HON 150)| (150) | (6) _| (159) | (9) | (25) wth the manufacturer's directions for the adhesive [7213 | 226 | e268 foaoe | 10 Used, For recommended adhesives see Figure 15 pn 200)| 201) |e) | wre) | eta) | ee lewe{ase| or For the diaphragm replacement, use one of the two (on 250) (250) | ce) | zea) | a0) | 0) following methods: sa=_[it7a2| 0276 [iaa08 poem | 12 Method 1: Points G-1//H-1 1 /J-1/K-1 [(ON 300)] (298) | 7) | (310) | (12) | (80) G-1, Apply adhesive t ‘cement to the top of the piston. Figure 6 HL, Thelnscrpion “itn Side" located onthe phragm 1) used, ply cement sie of he slap A, Secure the vave body na se of appropriate hong enter ad adhere Sgphyoge (0) to the top of the device vith he plug sid facing up eter to Figure 26 oc here caphragm I) to te top of the piston [63 (se Figure 7-Method 1, Step Jet, Rell the diaphragm 0 inside the spring bore! (38 unt the diaphragm is partially engaged in the spring barrel Isee Figure 7 Method 1, Step 8) CAUTION Core must be token t fon the waive body, avoid damageto the gasket face) Se CAUTION Ensure that the capscrew holes in the diaphragm case and spring barrel are aligned to prevent twisting of the diaphragm in aligning the holes. The diaphragm case [42] 's normally assembled withthe air inlet port placed an the fom sie of the actuator Depending on the desired ication, con be placed in any desired position around the ig barrel which allows the capscrew holes to line Up "the drain hole in the spring barrel must always low for draining of ny moisture whien may enter the spring barrel cyiinder (38. f the valve is equipsed with the optional purge line, that line s inserted into the drain hole K-1. Place the bead ofthe diaphragm lA0 over the diaphragm cease lp t2} and carefully slide the diaphragrn cose (i down aver the aiston 13) unt it seats on spring earel [s@) s0e Figure Method 1 Step For next step, go to Point L Method 2: Points 6-2 /H-2 /1-2/ J-2/K-2 6-2, Avply coating of Neoprene glue for sila fang on the inner face af the dechragm {40 on the piston (43} and in the spring barrel ip (38) Figure 7-Method 1 Note: The inner face ofthe diaphragm in contact with the piston is marked with the inscription "piston side’ be careful to keep coating of the Neoprene with limits corresponding to the flat part of the piston (Figure 7- Method 2, Step Al H-2. Center ond adhere the diophragm 40! onthe piston 143), [Figure ?- Metnad 2, Step A 1-2, Rothe diaphragm 0} careful inside the spring barrel [Bal ntl the bead engages the spring barrel groove [8 Press lighty and evenly the bead so as to get with the lwo Neeprene-coated part stuck tegether. Check there is no twisting of diophrogm inside the spring borrel Figure 7- Methad 2, Step 8) 4-2, Adjust diophragm case 2 tothe spring bare (38) ater necking that air connection is on the correct side and the teadedholes of diaphragm case 42] and the holes ofthe spring barrel 38 line up Note: Tapped air connection should be inline withthe vent hole in spring barrel (38, K-2._ Clamp the bead of the diaphragm {40} between lips of siaphrogm case|42land saring arte Figure 7- Method 2,Step CL Fornext step, go to point LL. Ensue thatthe digphragm case 2 is evenly seated on the spring barrel (38), insert the four copscrews lal} and tighten evenly, gh reserved stenc Figure 7- Method 2M. Connect air supp line to diaphragm cose NN. Turn on ar supaly and check for leaks, (0. If necessary, repostion handivhee! (53) ond limit stop (77, ‘optional to dese location and place vave backin sevice 9.2 Body S/A Internal Parts During amaintenance of Camfexl vavetisnecessaryteinseec! alte internal parts ta determine Ff they are worn, corroded ond damaged, especially the following seating ores = body and seat ring contact area, = the seating su the plug and seat ring ‘the guide surface ofthe shott and the guide eushing Allparts wach spare pars ore damaged must be replaced by original 9.2.1 Hard Seat Lapping ace'ng is the pracess of working the valve seaing parts against each other with an abrasive, to produce cise f To perform 'g operation, proceed as follows, ‘A. Clean the seat ing sedling surface inthe vave body and the seat rng shoulder 8. Apply a small amount of fine grinding compound tothe seat ing shoulder, FABRIC Mano TYPICAL LAB BOTTLE STOPPER Figures the seat ring inte the bedy ond lap lightly by rotating the seat ning in the body, ensuring that the fentie seat ring seging surface in the valve body is lapped. Do net rotate in one place Note: Figure 8 illustrates 0 simple tool which may be fabricated to facilitate this lapping operation on smaller valves. . Remove seat rng and clean thoroughly E, Place seat rng on a fat surface withthe seating area facing up. F. Apply a small amount of fine grinding compound tothe seat ing seating surface, 6. Lop the plug lightly against the seat ring while turning ‘and ascilating the 21ug ina! directions H. Clean seat ring, plug ond valve body thoroughly in pe aration for reassemaly 9.2.2 Soft Seat 29 net lap the sft seat ring to the plug: however the seat ring must be lonped ta the valve bady. The procedure for ing the to the body is the sar tems Athrough D of Section 9.21 on Hard Seats 9.3 Yoke Assembly [Refer to Figures 16 and 17) Maintenance required on the yoke (33) is limited to replacement of the grommet {121 and the shaft bearing (8) To replace either, the actuatar must be seperated from the body. (Cepending on the type of actuator used, refer to appropriate section|. Insert the grommet into the yoke with the recessed part of the grommet towsrds the shoft bearing, The shaft bearing [is sip tino the yoke ond is removed by pushing it out towards the grommet. CAUTION Ensure the be side in easy. De ingseotin the yokes clean, The bearing should jt use excessive force to push bearing in 10. Reassembly Procedures 10.1 Spring Diaphragm Actuator \When the actuator has been disassembled using Section 8.2 to reassemble the actuator, proceed as follows: 'A. Replace spring 38 in ps:on 4 8. Replace wosher lad and lacks), ‘Note: Locknut (45) must be threaded the full length of the threads. C. To reassemble the dachtagm and upper diaphragm case, refer to Section 1 steps E.through L , Replace locknut 46) and cevis (35. E, Determine correct arientation and realace act ke ond replace lackwasners (37, c tighten firly F. Refer to Section 11 for ctuato 10.2 Spring Diaphragm Actuator on Body S/A (Refer to Figures 16 and 17) ‘After completing the required maintenance or changing vaive, a ‘and yoke assembly, reassemble using the fallowing procedure: A, Determine correct valve tustor ore 8. If required, reposition body studs (28) and packing Tange studs ‘Note: Depending on the actuator position, ensure that the body studs (short studs] when placed through the ‘yoke holes will be positioned in the front of the yoke ‘opening for ease of accessibility sure that grommet {12) and shaft bearing 8) are in the yoke. Turn shaft so the piug inthe closed position, . Slide the valve shaft party into the lower yoke opening, ‘lowing enough room ta place packing flange 34) aver the shoft 119,Note: Packing flange (14)is placed on the shaft i191 with the concave side toward the valve packing (17 E. Ensure slots in pa flange studs 15) ing fonge 114) line up with packing With packing flange on the shaft continue sing the vaive shaft toward the yoke [23] and trough the grommet {121i ‘the yoke 23. 6G. Pace the ever [st inthe yoke andin ine withthe shaft so the bass on one side af the lever shatt hoe is toward the shatt ‘Bearing i) ond engage the sha tothe ever spines Note: Shaft must engage lever so the indicator dot on the clevis pin, when placed in the ever hole, shows the valve closed. Temporarily place clevis pin into lever (34) ‘and check indicator dot alignment. Dot should just start touching the closed indicator line on the front cover (32) (Refer to Figure 18). Ifthe orientation is not changed, ‘align lever and mark on yoke then check alignment. {Refer to Figure 171 CAUTION Do nat use a'r pressure ta check alignment, since during normal operation and with full air pressure, the indicator ‘may overshoot the closed Indicator mark on the cover This is acceptable H. Sie shaft completely through lever to engage shaft vesting (8), Yoke should now be fully seated on the valve bonnet flange Replace and tighten body stud nuts (27 J. Replac ony. K, Side the lever 134) on the shaft (191 toward t tighten lever copscrew (9) LL Pulthe lever and shaft toward the bearing fin the yoke 2 iL, my ji) Lust toe sro Figures gh reserved CAUTION ensure the shaft 129s shouldered on lensure free operation of the -apscrew (09) and side lever 134) so it wil shoulder against the shaft bearing i] and tighten capscrow as Note: if the actuator cylinder (38) has been removed proceed to step N. Ifit has not, proceed to Section 11, Actuator Stem Adjustment. NN. Determine the dested actuator action and replace actuator ylince’ [8l on the yoke [83) ang secure i place with feur ccopscrews (36 and lockwosners (37). 0. Pro ‘Section 11, Actuator Stem Adjustment 10.3 Handwheel Reassembly [A Place the vaive so the position cover (11}is up 8. Remove Trvac ring 501 andhondwhee! washer handwheel powerscrew C. Insert handwee powerscrew with lock52)in place into the ‘appropriate hole inthe yoke and screw in clockwise, . Replace the washer [51] and Truac ring {50 , Back lf handwheelightlyagcinst pasion with ack 52, erandlockin the off F. Replace bottom cover (11 by snapping in place. ‘Note: To use the handwheel, loosen the lock (52) and turn. The handwheel can be used as a limit stop on the valve by locking it in any position. 10.4 Limit Stop Reassembly ‘Two diferent types of assembly for tne limit stop in function of the ectuater se see Figure 9, 10.5 Valve Body Reassembly (Refer to Figure 16) Prior to reassembly, the valve body should be thoroughly cleaned and the seat ring and plug may be loppedas indicated in Section 92. Upon completion of the above, proceed as follows CAUTION Lubricants and sealers ore required during reassembly. Figure 15 identifies recommended products for certain service conditions. Ensure that any lubricant used is compatible with service conditions A, Aply 2 small emaunt of thread lubricant to the seat ring CAUTION ttn8. Picce volve body (1! on flat surface so that the seat is (C. Cost lower guide bushing 22) wth recommended lubricant and inset into the body, Note: Groove in the guide bushing (22) must be towards the body center, Refer to Figure 10 for correct assembly. ‘sequence. Ifthe shaft (9) isthe previous design it may have a circular grove ifso, instal the retaining ring (1 Figure 10 1. Coot the upper guide bushing [21) spacer tube (20) ans the shaft spines lug sdel with recommended lubricant E. Insert the spacer tube (20) ove shaft CAUTION When @ recessed groove exists in the spacer tube (20), this spacer tube [20) must be placed on the shatt [19] that the shaft shoulder or re:sining ring fits into the recessed groove on one end of the spacer tube [20 e lubricated part ofthe F, Place upger guide bushing (2 onthe shaft (19, G. Pace plug thin be ody sitrestson the seat H. Insert the shaft sub-assembly into the body Ii] ang engage plug 41 ond lower guide bushing (22) Note: The shaft (19) should be inserted into the plug so ‘that when the plug is seated, the slot atthe outer end of the shaft is perpendicular to the flow through the valve. In case of 35002 $8, separable bonnet version follow the operations described from N to U 3 the pecking box ring (23), bevel side out, over the shaft nto the valve tonnet being sure the fing i gned with te tieaded prin tre bonne! J. Apply a suitable lubricantto the threads ofthe safety an (16) and screwinto the bay neck ane ughten, CAUTION The Safety Pin is a safety device which must not be replaced by a plug. Use only genuine supplied safety pins, Pin must engage ho! king bax ring |23) Test by manually pling on the shaft to verify engagement. K. Install packing [271 insuring af packing is offset apprexim piece of packing, nat the skive cut of each piece ly 120° from that ef the ‘Note: Sizes 1” thru 3° (ON 25 through 80) use 7 pieces ‘of packing; sizes 4" thru 12" ION 100 through 300) use 6 pieces of packing. LL Install packing follower {15} rounded, bevel side out M. Proceed to Section 1 1 on seat ring ligament 1 through U apply te separable bonnet design only IN. ifnecessory, install the studs [103}in the bonnet (102 ©. Install the stop ring 100) P. Place the gasket (1011 in the groove of the bonnet, The old gasket [101] must note re-used @. Place the bonnet withthe studs an the body end screw the nts {104 R. Tighten the ruts 4) according the table of Figure L. 1" (ON25) 1" (ON AO) 22 30 2° (N50) 3 (ON 80) 35 a 4” (DN 100) 55 75 (ON 150)| 107 145 Figure 11 ‘Note: It is important to tighten the nuts step by step, during the tightening the bonnet flange must keep the shaft axis aligned. 5. Instll packing 7) insuring thot the skive cu piece ‘of packing is offset aparoxmately 120° from that of the ‘adjacent piece of packing ‘Note: Sizes 1" through 3"(ON 25 through 80) use 7 pieces ‘of packing: sizes 4" through 12"IDN 100 through 300) use pieces of packing. T. install packing follower {15} rounded, bevel side out U. Proceed to Section 106 on seat ring alignment 10.6 Seat Ring Alignment Aligning the seot rng (2) ond plug (t's required whenever the seat ing or plug have been replaced or disossembled Proceed as follows A, Place focing up. fe on flat surface with etzine seat ring 12 Note: The casting marks (lindicate the seat ring end of the body, 8. Remove the retainer ring 3} andthe seat rng 2) C. Apply a thin coat of sealant to the seat ring shoulder that lengoges the body and replace sect ring (2) . Apely 2 small amount of thread lubricant to the seat ring reiciner threads and install sect ring retainer (3) and hand tighten ony,CAUTION Bo not tighten the seat ring retainer to tion at this time, rave speci . Replace lover (24) on vaive shatt (19) ‘ond tighten lever 2 [a] manuolly close the plug with sufficient ow seat ring and slug to align. er tothe G. Using the seat ring wrenen, tighten seat rin minimum torque value specifed n Figure 12 Note: In some cases, forthe valves from 3"to 12"ION 80 to 300) with metal seat, the alignment can be improved by placing a piece of paper 0.10mm (0.0041 thick and ‘approximately 6mm (1/4 wide at a point where the leading edge and the trailing edge ofthe plug contacts the seat ring and close the plug. With a slight pressure ‘on the lever, the paper strips should both be clamped in place. For the valve 8" to 12" |ON 200 to 300), the piece ‘of paper shall be 0.20mm (0.008 thick and 12mm (1/4°) wide. Se 11. Actuator Stem Adjustment (Refer to Figures 16 and 17) CAUTION acedures must be edhered to in order to ensure The following correct valve operation. Falure to do so could result in valve damage and equipment malfunct'on functioning, With the actua desired location and or ental ‘actuator stem adjustments imperative for sroper valve assembled to the vave in the Note: If any of the following steps were completed during ‘maintenance or reorientation of actuator to valve, proceed to the next step |A. Remove front cover (821 and rear cover (281 by removing the two-cover screws (30, 8. Bock off handwheel (531 so it does not inte ration of the aver [34 C. Hfopplicable, backo'foptionalir stop (77}s0itwillno with the operation ofthe lever [24 ©. Apply oir pressure to the actuator and move lever [4 to an ons) | 89 a emesis peston T_(ON ao) | 8 720 away) [ao | a CAUTION 3"_ (ON 80) 290 395 4" (ON 100) 363, 430 OP (ote) 825, 1120 used. Do not use handwheel (53! to move lever (34). #(oNa00)| «75 | —t200 __atenmocenaesis ore . om tenon esl nso by roving the to a?(ON00)] 2050 | —s080 W Pocettosenn ona 6. Reeve or presse the ecatr alo he ces 8 and i. lever (34) to seperate. 10.7 OVO Plate Reassembly Using the some methos tighten the Lo-8 plate a tadle of Figure 13. Toke 2 tooling as described in 82.2 Note: Ifthe units air-to-open, separate clevis(35land lever (34) then loosen clevislocknut 46) and remove clevs. H. Insert clevis pin (7 back in lever (34 L Man sh the lever [54) so the valve is in the closed position J. Temporary replace front cover 182] and check the location of 1" (ON 25) 74 100 the clevis pin (?)n relation tothe clased position indicator mark (ON 40) at 10 an front cover (521 2" (N50) 00 135 3"_ (ON 80) 220 295 CAUTION (ON 100)[—_363 490 oes) 70 1050 ‘The relationship must be as shown in Figure 18. If ts not (ON 200)[ "975 1320 the yoke m ‘nd the lever [34 {ON250)| 1820 1830 repos (ON 300)[ 2250 3050 to comply stroking and could damage the vove Figure 15 15 Genera lectre Company. alls eseve, Note: Ifthe unitis air-to-open, replace clevs locknut 46) and levis 85.. Proceed to one of the folowing sections for final adjustment. ‘Airto-Open, Section {k-1) Ali-to-Close Section K-2) K-1. Air-to-Open ‘ter come fallows: sing step A through J ofS jon 11, proce A. Scribe a ine on the clevs (35) Ine with the inside of the yoke. 8. Connect o regulated air supaly direct to the actustor ond gradually opsly 8 psig [SS bargl for size 9 actuotors and 7 sig L 48 boral for the other. C. The cevis should move approximately 1/4 ©. With the lever and valve plug in the fully CLOSED position, the holes nthe clevis [35] and lever Ld) shoul be inline, Note: holes are in line proceed to Step J. fnot in line, continue to next step E. Move lever [40 fullogen poston, F. Gradually apply sufficient air pressure to extend clevs lecknut to an accessible poston. CAUTION Donot exceed pressurelisted in Figure 14 forthe used G. Loosen clevs lcknut 6) orto 7 psig, vs [35)in or outon actuator stem so thatthe holes rd ever (36) are algned withthe lever and plugin the fully closed postion. cevis pin (7 s0 indicator det is vsile through front cover (32) and secure with clevs in clips Note: On the size 6 and 7 actuators, without the ‘adjustable indicator (88), the clevis pin (7) must be installed so it protrudes toward the front cover (32. Ifthe indicator det is damaged, paint may be applied to the ‘end facing the front cover (32 to make it more visible. K. Gradually apply sulfcient air pressure to extend clevs iocknut 46) t0 an accessible postion an ghten firmly CAUTION Do not exceed pressurelisted in Figure 14 for the actustor used L. Relieve ar pressure, M. If used, replace adlustable indicator {88} to lever (34) with (83) Note: If required, adjust indicator to front cover indicator marks. IN. Replace front cover 132) and reer caver [28] and secure in place with cover screws (30, (©. Replace spring barrel bass cover (S8| and bottom caver (111 (Snop ft ‘Note: Prior to placing the valve in service, operate the valve actuator through one complete cycle to ensure proper functioning. P. If desied, set handwhee! [58 or optional limit stop (771 to desired position K-1.Airto-Close ‘Ater completing step A through Jo Section 11, proceed as follows ‘A. Manualy push lever (34 to the full CLOSED positon. 8. Connect regulated air supply to the actuator . Gradually apply the final air press closed postion See value on the eral pace. . With the lever holes in the clevs (2 nd vaive plugin the CLOSED positon the ‘ond lever 24 shouldbe in lne Note: If holes are inline proceed to Step Hi not inline, Continue to the next step. E, Release air pressure so clevs (35) will separate from lever 64) F. Loosen clevs locknut 46) sv (85) inf out so that when the oir pressure ding to che closed gostion mentioned in above ' applied, clevs holes and lever wil be mine H. Insortclevs gin 71 s0 indicat cover [82}and secure otis visible through font fh levis pin clips 5 Note: On the size 6 and 7 actuators, without the ‘adjustable indicator (88), the clevis pin (7) must be installed so it protrudes toward the front cover (32). If the indicator dot is damaged, paint may be applied to the end of the levis pin (7 facing the front cover (32) to ‘make it more visible. 1. Tighten clevislocknut fs J. Relieve ar pressure K. If used, replace adjustable in screws (89. for (88) to lever (24) with Note: f required, adjust indicator (88 to front cover (321 indicator marks with the valve in the closed position LL. Replace font cover {82} and rear cover |28) and secure in piace with cover screws (30, M. Replace spring aarre! bass caver (58) and bottom caver [1 (Snap ft ‘Note: Prior to placing the valve in service, operate the valve actuator through one complete cycle to ensure proper functioning. NN. if desired, set hanawheel{53) or optional limit stop (771 to desired position 12. Changing Body Position CAUTION re ony chan in flow r mode is made, the valve ond actuatar must be resized using curtent process r mode ions, Any chenge in the flow direction or actuat pony Alghts rsen, otherwise ‘must be accomplished as outlined in this ins equipment malfunction could result Changing service requirements or service conditions may require 1 change in fow direction through the Carex I valve. Figure 19, ilustrares the various positans and flow directions in which the valve may be placed te accommodate require CAUTION Changing the body position and fow direction could aso require recaling the actuator. Ensure that the actuator lecstion end) fection are in accordance wth the recommended postions and es ilustrated in F gute 19 lustrations are shown looking che body through the bonnet with the actuator in front of the vave, the glug shafts always rotated in a clockwse direction by the actuator to open the valve oceed os follows |. Refer ta Figure 19 ond etermine whichis the desea vaive position, fow drection ond which actuator poston is 8. Proceed to the appropriate section of this instruction for the di jembly and assemialy procedures, 13. Changing Actuator Action CAUTION Before any change inflow direction or actuator mode is made, uotor must be resized using current concitions. Any change in the flow direction or actu ‘must be accomplished as outlined in ths instru equipment malfunction could result peters fe . Using arranual loading panel. cooly sufficient air pressure Remove frant cover {32} and rear cover 29) by removing the two cover serews (30, Remove spring barrel boss caver 158)|Snap ft Remove bottom cover (11}8nap fi ‘ove the lever [24)t0 an intermediate postion CAUTION Do nat exceed aressure ited in Figure 14 for actu Do not use handwheel to move lever used. Remove cevs gin clips} remove clevs in ( Position lever soit assembly. 5 not contact handihee! powe Remove Truore ring 150) and washer (Sil from handwheel randwnee! powerscrew assembly fom Remove hondiee! tread aug Note: If the actuator is equipped with the optional limit ‘stop (77), in place of the handwheel thread plug, it must be removed, CAUTION Devending the size ond weight of the proper lift and suppor utlized wher removing the spring bare or yoke Coan)