Corrosion-Resistant

Teflon Control Valve

Model : HIT

User's Manual

OM2-8193-0200

NOTICEWhile the information in this manual is presented in good faith and believed to be accurate, Azbil Corporation disclaims any implied warranty of merchantability or fitness for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer.In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.

© 1993–2013 Azbil Corporation All Rights Reserved.

– 1 –

1. GENERAL

This manual comprises a general overview of the structure, operating procedures, and maintenance of Model HIT Corrosion-Resistant Teflon Control Valves.

1.1 Structure

A Corrosion-resistant Teflon Control valve consists of three major sections: valve body, actuator, and positioner as shown in Figure 1.1.

Figure 1.1. Basic Structure of Control Valve

Acturator

PositionerValve body

– 2 –

1.1.1 Valve BodyThere are two types of valve bodies: regular and bellows, classified by type of plug.

The parts in contact with fluid, such as valve body interior, valve plug, and guides, are made of highly corrosion-resistant PTFE. The outer frame of valve body, the bonnet, and the valve stem are made of stainless steel.

1.1.2 ActuatorThe model HIT valve employs the Model PSK1 actuator, a multi-spring diaphragm motor.

By its diaphragm and springs, it converts a pneumatic signal into a position signal with which to drive the valve plug via a valve stem.

For manual operation, a manual handwheel can be installed on top of the control valve.

1.1.3 Positioner (optional)Refer to the relevant operator's manual:

OM2-8310-0400: Single-acting Pneumatic Valve Positioner, Model VPE

OM2-8313-0100: Single-acting Electric/Pneumatic Valve Positioner, Model HEP

CM1-AVP300-2001: Smart Valve Positioner, Model AVP

1.2 ControlValveSpecifications

A nameplate as shown in Figure 1.2, is attached to each control valve. The nameplate indicates the model number, product number, date of manufacture, valve size, parts materials, and other major specifications. Before using the control valve, be sure its specifications conform with your intended use. When making any inquires on the control valve, such as for requesting information on modifications of the valve or ordering replacement parts, please mention the product number.

Figure 1.2. Control Valve Nameplate

– 3 –

2. STRUCTURE

2.1 Structure of Valve Body

2.1.1 RegularThe structure of the regular valve body is shown in Figure 2.1.

No. Parts Material No. Parts Material1 Valve stem SUS316 12 Bonnet SUS3042 O-ring(P10) FEPM 13 Guide holder PTFE

3-1 Packing compression nut SUS316 14 Screw(M6x10L) SUSXM73-2 Lock nut SUS304 15 Valve plug PTFE4 O-ring(P16) FEPM 16 Valve body SUS3045 Spring SUS316 17 Rubber seat FPM6 Packing ring SUS316 18-1 O-ring FEPM7 V PTFE retainer PTFE 18-2 PTFE ring PTFE8 V PTFE packing PTFE 18-3 O-ring FEPM9 V PTFE receiver PTFE 19 Flow direction indicator SUS30410 Retainer SUS304 20 Driving screw SUS30411 Screw SUS316 21 PTFE main body PTFE

Figure 2.1. Structure of the Regular Valve

1

12

13

14

15

16

17

19

20

21

2

3-1

18-118-218-3

3-2

4

5

6

2

4

7

8

9

10

11

– 4 –

2.1.2 Bellows TypeStructure of the bellows-type valve body is shown in Figure 2.2.

No. Parts Material No. Parts Material1 Valve stem SUS316 15 Bonnet SUS304

2-1 Packing compression nut SUS316 16 Tape liner PTFE(V-7980)2-2 Lock nut SUS304 17 Screw(M6x10L) SUSXM73 O-ring(P10) FEPM 18-1 O-ring FEPM4 O-ring(P16) FEPM 18-2 PTFE ring

(For upper guide spacer)PTFE

5 V PTFE retainer PTFE 18-3 O-ring FEPM6 V PTFE packing PTFE 19 Guide spacer PTFE7 V PTFE receiver PTFE 20 Valve plug PTFE8 Spring SUS316 21 Rubber seat FPM9 Packing ring SUS316 22-1 O-ring FEPM10 Vent plug SUS316 22-2 PTFE ring

(For lower guide spacer)PTFE

11 Vent bushing SUS316 22-3 O-ring FEPM12 Valve body SUS304 23 Flow direction indicator SUS30413 Retainer SUS304 24 Driving screw SUS30414 PTFE main body PTFE

1

23

24

12

13

14

15

16

17

20

19

21

32-1

18-1 18-2 18-3

22-1 22-2 22-3

2-24

5

6

7

8

9

10

11

Figure 2.2. Structure of Bellows-type Valve

– 10 –

6.3 DisassemblyofValveBody

6.3.1 Disassembly of Regular Valve Body

For disassembly of the regular valve body, refer to Figure 2.1 and proceed as follows:

(1) Loosen the packing compression nut -1.

(2) Loosen the four hex-socket-head setscrews (M6) around the bonnet by using a hex bar wrench (nominal size 3 mm). Loosen the bonnet from the valve body by using a wrench (nominal size 65 mm). Pull up the bonnet to remove it from the valve stem .

(3) Remove the guide holder . Remove the valve stem together with the valve plug .

(4) Remove the packing compression nut -1, spring , packing ring , V PTFE retainer , V PTFE packing and V PTFE receiver from the bonnet and guide holder .

(5) Remove the gland. O-ring and guide O-ring.

Never remove the seal retainer, PTFE main body, or rubber seat from thevalve body.

CAUTION

Figure 6.1. Parts for Removing the Actuator

3

4

2

Pneumaticactuator

Valve body

156

No. parts

1 Stem connector (pointer)

2 Bolt

3 Actuator stem

4 Valve stem

5 Yoke

6 Setscrew (hex socket head)

– 11 –

6.3.2 Disassembly of Bellows-type Valve BodyFor disassembly of the bellows-type valve body, refer to Figure 2.2 and proceed as follows:

(1) Loosen the packing compression nut -1.

(2) Loosen the four hex-socket-head setscrews (M6) around the bonnet by using a hex bar wrench (nominal size 3 mm). Loosen the bonnet from the valve body by using a wrench (nominal size 65 mm). Pull up the bonnet to remove it from the valve stem .

(3) Remove the valve stem together with the valve plug . Remove the guide spacer .

(4) Remove the packing compression nut -1, spring , packing ring , V PTFE re-tainer , V PTFE packing and V PTFE receiver from the bonnet .

(5) Remove the gland. O-ring and guide O-ring.

6.4 Disassembly of Actuator

6.4.1 Disassembly of Direct-acting ActuatorFor disassembly of the direct-acting actuator, refer to Figure 6.2 and proceed as follows:

(1) Disconnect the air piping and accessories from the actuator.

(2) Remove the stem connector.

(3) Remove the bolts (except the eyebolts) of the diaphragm case.

(4) Loosen the nuts of the two eyebolts gradually and evenly. [These two bolts determine the initial spring compression setting when assembling the actuator.]

(5) Remove the diaphragm case. Remove the rod and diaphragm unit upwards.

(6) Remove the springs.

6.4.2 Disassembly of Reverse-action ActuatorFor disassembly of the reverse-acting actuator, refer to Figure 6.3 and proceed as follows:

(1) Disconnect the air piping and accessories from the actuator.

(2) Remove the stem connector.

(3) Remove the bolts (except the eyebolts) of the diaphragm case.

(4) Loosen the nuts of the two eyebolts gradually and evenly. [These two bolts determine the initial setting of spring compression when assembling the actuator.]

(5) Remove the diaphragm case. Take out the springs.

(6) Remove the rod and diaphragm unit upwards.

Never remove the seal retainer, PTFE main body, or rubber seat from thevalve body.

CAUTION

– 13 –

7. ASSEMBLY OF CONTROL VALVE

7.1 Assembly of Valve BodyFor assembly of the valve body, as a general rule, follow the disassembly procedures in

the reverse order.

Thoroughly clean all parts before starting assembly. Be sure they do not carry dust, dirt or other foreign matter.

All sealing parts and mating surfaces should be covered with grease or another appro-priate sealing lubricant that will not be attacked by the process fluid. When control valves are shipped from the factory, silicone grease is applied as sealing lubricant (except for oil-free con-trol valves.)

7.1.1 Assembly of Regular Valve BodyFor assembly of the regular-type valve body, refer to Figure 2.1 and proceed as follows:

(1) Set the O-ring -1, 3 and PTFE ring -2 in the valve body .

(2) Set the valve plug with valve stem in the guide holder , and set them in the valve body .

(3) Setting so that the valve stem passes through the center of the bonnet , couple the bonnet to the valve body using the threads. Turn the bonnet with the specified torque until the threading shoulder of the bonnet is brought into contact with the top plane of the valve body cylinder. For the tightening torque of the bonnet, see Table 7.1.

(4) Apply Loctite to the four M6 hex-socket-head screws and drive them into the bon-net so that the bonnet is securely fixed and does not become loose. (When the valves are shipped from the factory, Loctite #602 is applied as the locking agent.) For the tightening torque of the setscrews, see Table 7.1.

(5) Set the gland parts , , , , , and in this order.

(6) Tighten the packing compression nut -1 until it is brought into contact with the bonnet . For the tightening torque of the nut, see Table 7.1.

7.1.2 Assembly of Bellows-type Valve BodyFor assembly of the bellows-type valve body, refer to Figure 2.2 and proceed as follows:

(1) Set the O-ring -1, 3 and PTFE ring -2 in the valve body .

(2) Set the guide spacer in the valve body .

Before starting assembly, fully inspect all parts. If you �nd any damagedparts, replace them with new ones.

Never re-use old gland packing. Be sure to use fresh gland packingwhenever assembling the control valve.

When ordering parts, please also mention the product number of thecontrol valve, which is indicated on the nameplate.

CAUTIONS

– 14 –

(3) Set the O-ring -1, 3 and PTFE ring -2 in the guide spacer . Set the valve plug with valve stem into a position that the brim section of the valve plug is aligned

with the centering location of the guide spacer .

(4) Apply the tape liner on the bore of the bonnet . (The tape liner acts as a guide for the valve stem.)

(5) Setting so that the valve stem passes through the center of the bonnet , couple the bonnet to the valve body by means of the threads. Turn the bonnet with the speci-fied torque until the threading shoulder of the bonnet is brought into contact with the top plane of the valve body cylinder. For the tightening torque of the bonnet, see Table 7.1.

(6) Apply Loctite to the four M6 hex-socket-head screws and drive them into the bon-net so that the bonnet is securely fixed and does not become loose. (When the valves are shipped from the factory, Loctite #602 is applied as the locking agent.) For the tightening torque of the setscrews, see Table 7.1.

(7) Set the gland parts , , , , , and in this order.

(8) Tighten the packing compression nut -1 until it is brought into contact with the bonnet . For the tightening torque of the nut, see Table 7.1.

Valve Size Bonnet Hex-socket-head Setscrews Packing Compression Nut

3/4" & 1"250 ± 37

{2500 ± 375}[M68 × 1.5]

8 ± 1.2{80 ± 12}

[M6 screw]

80 ± 12{800 ± 120}[M26 × 1.5]

1-1/2"300 ± 45

{3000 ± 450}[M90 × 2]

2"350 ± 51

{3500 ± 525}[M100 × 1.5]

7.2 Assembly of ActuatorBefore starting assembly, be sure the parts are perfect without any flaws, deformation,

peeling of paint, or other defects, To assemble the actuator, proceed as follows:

7.2.1 Assembly of Direct-acting ActuatorTo assembly the direct-acting actuator, proceed as follows:

(l) Set the bearing (together with the dust seal) to the yoke. Fix the bottom diaphragm case to the yoke with the four M10 bolts.

(2) Fix the spring plate (sec Figure 7.1) and set the springs on the spring plate.

(3) Insert in to the bearing the rod to which the diaphragm has been set. When doing this, be careful not to damage the bearing and dust seal with the threaded section of the rod. (For example, cover the threaded section with adhesive vinyl tape.)

Table 7.1. Tightening Torques (N·m {kgf·cm})

– 19 –

Valve size (inch) 3/4 1 1 1/2 2

A (mm) 140 140 200 240

H (mm)PSK1D 425 425 455 455

PSK1R 445 445 475 475

Weight (kg) 15 15 18 23

235

ø218

A

(28)

H

Figure 7.4. Overall Dimensions

Table 7.3. Overall Dimensions and Weights

– 20 –

8. DIRECT/REVERSE-ACTING CONVERSION AND SPRING RANGE MODIFICATION

8.1 ConversionToDirect-orReverse-actingTypeWhen you want to convert your control valve into a reverse-action type or a direct-action

type, it is recommended to change the whole actuators. However, if you want to convert your actuator by replacing required parts only, you need the parts shown in Table 8.1 or 8.2. In these tables, “+” denotes the new parts which you need to acquire for the conversion and “-” denotes the parts which you don't need for the conversion and which will become surplus parts.

For the conversion procedure, refer to Chapter 6 “DISASSEMBLY OF CONTROL VALVE” and Chapter 7 “ASSEMBLY OF CONTROL VALVE.”

8.2 SpringRangeModificationTo change spring ranges of Model PSK1 Actuator, refer to Table 8.3 which indicates the

color coding, dimensions and the required quantities of actuator springs.

Table 8.1. Parts for Direct to Reverse Conversion

Table 8.3. Actuator Springs

Table 8.2. Parts for Reverse to Direct Conversion

PSK1D → PSK1R

Parts Q'ty Parts No.

Seal washers +4 82521069-101

Rod packing +1 82521067-102

Rain cap +1 82553334-101

Spring rangekPa {kgf/cm2} Color coding Free length of springs

mm Q'ty

80 - 240{0.8 - 2.4} Yellow 89 4

120 - 290{1.2 - 3.0} Orange 73 4

PSK1R → PSK1D

Parts Q'ty Parts No.

Seal washers -4 82521069-101

Rod packing -1 82521067-102

Rain cap -1 82553334-101

– 24 –

10. OVERALL DIMENSIONS AND WEIGHTS

(1) Main Unit of Model PSK1

(2) Actuator with Top Handwheel

Strokemm

Overall dimensions mm Maximum handwheeloperating force

N {kgf}

Weight(kg)øB B øD H

20 218 235 140 390 160 {16} 9.5

235

240

M9 × 1

Stroke: 20 mm Effective diaphragm area: 160 cm2

Maximum capacity of diaphragm chamber: 700 cm2

Weight: 8 kg

ø218

ø34.9

Table 10.1. Overall Dimensions (Main Unit)

Table 10.2. Overall Dimensions (Actuator with Handwheel)

Date: 1st edition: Nov. 1993 2nd edition: Dec. 2013Issued/Edited by: Azbil Corporation

Document Number: OM2-8193-0200

Document Name: Corrosion-ResistantTeflonControlValve

Model : HIT User's Manual