CONTROL VALVES 2WAY & 3WAY CYLIN DER VALVE

INSTRUCTION MANUAL FOR

2WAY & 3WAY CYLINDER VALVE

CONTENTS

SECTION TITLE Page

1. 2 WAY CYLINDER VALVE 02

A. INSTALLATION 02

B. OPERATION 02

C. MAINTENANCE 03

2. 3 WAY CYLINDER VALVE 06

A. INSTALLATION 06

B. OPERATION 06

C. MAINTENANCE 07

3. CYLINDER ACTUATOR 08

A. DIRECT ACTING ACTUATOR 08

B. DIRECT ACTING ACTUATOR

BY
CONTROLS,INC.

February 2008 Edition

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

SECTION Ⅰ: 2-WAY CYLNDER VALVE

A. INSTALLATION

1. Valve Body: Set cylinder valve in the horizontal line of piping in an accessible location with the arrow on the
side of the valve body in the direction of fluid flow. Upright positioning of control valve is preferable for ease of
maintenance.

<Fig. 1> Typical installation

Work spaces around the cylinder valve body are to be provided sufficiently for easy removal or reinstall of parts
during maintenance.

Caution: Piping systems are to be flushed thoroughly with sufficient amount of water or air prior to installation of
cylinder valve body and strainer to prevent possible damage on the internals by foreign materials after
commissioning.

2. Strainer: To be installed between the inlet block valve and cylinder valve. In case other strainer is installed
upstream line, this strainer may be deleted.

3. Isolation valves: Stop valves (and gauges if necessary) in inlet and outlet lines are able to be installed to provide
means for checking, adjustment or emergency maintenance during operation.

4. Bypass valve: Set a bypass around the cylinder valve for emergency use when the cylinder valve needs to be
isolated.

5. Air tubing: Connect air tubing between the controller and cylinder actuator or the valve positioner (if one is in
use). Maximum allowable operating pressure for cylinder actuators is 4 kg/cm² (60 psig).

B. OPERATION

1. Isolation: Close inlet and outlet stop valves.

2. Movement check: Check if control valve responds properly through rated travel in relation to the changes in
operating pressure in the cylinder Rated travel is shown by the position of the indicator on the valve stem relative to
the indicator plate scale on the yoke.

3. Manual operation: Manually operate cylinder valve fitted with manual operating devices through the rated
travel range to check freedom of movement. Return manual operating devices to its stand-by position.

4. Commissioning: Place cylinder valve in operation in accordance with the operating instructions provided with

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

controller or other operating device.

C. MAINTENANCE

To reduce maintenance time, please refer to proper drawing and follow the steps shown below for applicable
maintenance.

1. Renewing packing set (See Fig. 2 ):

(1). Replacement: Renew the valve stem packing if cylinder valve has been in service beyond normal maintenance
interval with packings showing signs of wear. Wear will be indicated by leakage which can not be corrected by
minor tightening of packing gland.

Caution: Over-tightening of the packing gland can cause erratic operation of the valve.

Note: Where V- packing is used, additional packing can be installed to overcome minor leakage without
dismantling the cylinder valve. Close the inlet and outlet stop valves and check that valve body is not under
pressure. Remove nuts and lift gland nut and packing gland in sufficient height on the valve stem to apply the
split packing around diameter of valve stem. (See Figure 2)

<Fig. 2> Packing set

(2). Adjustment: During start-up some leakage may be observed. Do not readjust packing - allow at least 15
minutes for pressure/temperature stabilization to occur. If leakage continues adjust a maximum of 1/6 turn at a time.
If pressure is raised considerably, the packing may leak slightly. Do not readjust - leakage will stop when new
pressure/temperature stabilization is reached.

(3). Break-in: For best results, it is recommended that after packing installation and adjustment the valve be fully
stroked approximately 20 times to break-in the packing and reduce stem friction.

2. Disassembly of cylinder actuator from valve body (See Figure 3 ~ 6)

(1). Preparation: Close inlet and outlet stop valve and relieve all pressure from piping involved.

(2). Disengagement of disc from the seat:

Relieve air pressure from cylinder of actuator. Remove tubing from the cover.

(3). Separation of stems: Loosen (42)nut. Use wrench on stem flats and turn (6)stem out of actuator (upper) stem
until both stems are separated.

(4). Remove yoke from bonnet: Remove the (44)set Screw, (17)gland nut & (13)ring nut holding the actuator to

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

the bonnet and lift off the actuator.

3. Disassembly of valve body assembly ( See Fig. 3~6 )

(1). Removal of actuator: Remove actuator from valve body assembly as previously described in disassembly of
cylinder actuator from valve body assembly.

(2). Removal of bonnet: Remove (2)bonnet turn(anti clock wise) Lift off bonnet assembly including stem & disc
from the body.[15A~40A] or Remove (15)bolt. Lift off cover & bonnet assembly. Remove (7)bolt. Lift off
(33)seat fixing plate and including (5)seat, stem & disc from the body. [50A~150A]

(3). Disassembly of bonnet and valve body: Remove (4)disc rubber, packing gland and old (8)V-packing set.

4. Cleaning

(1). Cleaning of component parts: Clean all parts thoroughly. Polish stem with crocus cloth. It should be
smooth and free of scratches especially in the packing area. Use approved and non-residue forming solvent for
cleaning. Wipe dry with clean cloth.

(2). Inspection: Inspect all parts and replace any excessively worn out or damaged part.

(3). Replacement of parts: Install a new (8)V-packing set as shown on packing installation sketch Fig. 2. See
previous section on renewing packing set. The packing gland has a long wearing life which under normal usage
should not require replacement. However, if damaged or worn out, the packing gland and/or the bonnet must be
replaced. The bonnet O-ring and seat O-ring should be replaced each time the valve body assembly is disassembled
for cleaning.

5. Reassembly of Valve Body & Actuator

(1). Valve body: Insert seat, be correctly seated in place.

(2). Bonnet assembly: Applying light pressure and turning motion, assemble disc stem into the bonnet assembly.

(3). Bonnet & cover on valve body: Place bonnet O-ring in the body recess and install the bonnet assembly on top
of the valve body, and turn it clockwise, Apply (15)bolt and tighten firmly and evenly until the bonnet and valve
body flanges almost touch each other.

(4). Indicator ring: Place the (18)indicator ring and (42)nut on to the (6)stem.

(5). Cylinder actuator on bonnet: Place the yoke and actuator assembly on top of the bonnet, and (13)ring nut
turn it clockwise, watching the valve (6)stem, to connect the (6)stem to the actuator piston rod. During this time the
(6)stem must be kept standstill to prevent the disc from being scratched or damaged. And then, Tightly fasten the
yoke by turning the lock nut clockwise using tightening tools.

(6). Gland nut: Fasten the gland nut turning the lock nut clockwise. Excessive tightening could prevent the
movement of valve stem.

(7). Stem length adjustment for “Open” or “Close” position:

With wrench on flats of valve stem turn the stem clockwise until it does not move upward. Tighten nut for firmly
fixing (18)indicator ring to (24)piston rod. The position of indicator at this point is "0pen" or “Close” position, and
this must match with marking on the (19)indicator scale.
Caution: Avoid to turn the stem when disc is on seat to prevent the disc from being damaged.

Note: The 1/4 turn toward the seat provides the positive closing force required to obtain tight valve closure in
single ported valves. In all cases be sure to make this final adjustment.

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

6. Setting valve travel

(1). “Close” position: Supply 3.0 kg/cm² (45psig) of operating pressure to actuator cylinder. Check and confirm if
the valve fully closes at this pressure.

(2). Connection of tubings: Reduce air pressure from actuator cylinder and reconnect operating medium tubing
from control pilot, instrument, or loading device to the cylinder cover.

<Fig. 3> 2WAY CYLINDER VALVE 15A~40A <Fig. 4> 2WAY CYLINDER VALVE 15A~40A

<Fig. 5> 2WAY CYLINDER VALVE 50A~150A <Fig. 6> 2WAY CYLINDER VALVE 50A~150A

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

SECTION Ⅱ: 3 WAY CYLINDER VALVE

A. INSTALLATION

1. Valve location

Install 3way cylinder valve in an accessible location. Connect supply and outlet pipe lines to the valve as described
below. 3way cylinder valve may be placed in any position but upright posture is preferable for ease of maintenance.
Connect operating medium tubing from control pilot, instrument or loading device to cylinder chamber connection
of 3way cylinder valve or to valve positioner. If one is in use.
In converging (mixing) service two fluids are mixed to produce a third fluid. The valve has two inlet connections
(marked “B” and “C”) and one outlet connection (marked “A”). Connect supply lines to “C” and “B” connections
and outlet to “A” connection. See figure 7.
In diverging (dividing) service the valve has one inlet supply connection (marked “A”) and two outlet connections
(marked “B” and “C”).
Connect supply line to “A” connection and outlet lines to “B” and “C” connections. See figure 8.

<Fig.7> Converging (Mixing) <Fig.8> Diverging (Dividing)

2. Considerations for preventing possible troubles

(1). Provide removal space around the 3way cylinder valve for easy removal of parts during maintenance.

(2). Blow or flush out pipe line thoroughly before installing cylinder valve.

(3). Protect cylinder valve and following equipment with a Self-Cleaning Strainer.

(4). Install stop valves and gages in inlet and outlet lines to provide means for checking process condition or
equipment.

B. OPERATION

(1). Close inlet and outlet stop valve.

(2). Check that 3way cylinder valve responds properly through rated travel in changes in operating pressure on the
piston. Rated travel is shown by position of travel indicator on the valve stem relative to travel indicator scale on
the yoke.
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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

(3). Manually operate 3way cylinder valves fitted with manual operating devices through rated travel to check
freedom of movement.

(4). Place 3way cylinder valve in operation in accordance with instructions furnished with controller or other
operating device.

<Fig. 9> Valve body with internal parts, 25A (1”) <Fig. 10> Valve body with internal parts,
32A (11/4”) thru 150A (6”) size

C. MAINTENANCE

1. Disassembly

(1). Loosen (42)stem nut. Unscrew the valve (6)disc stem from the actuator (24)piston rod. Loosen and Remove the
(44)set screw from the yoke, Loosen and (13)ring nut and remove the (17)gland nut. Lift the actuator from the
bonnet.

(2). Remove the (22)packing gland, (8)V-packing set.

(4). Loosen the (9)bolt and remove the (3)bottom flange and (7)gasket from the (1)body. Loosen the (10)bolt and
remove the (34)seat fixing plate from the (1)body. Remove the (14)”C”seat, & (6)stem including (5)disc come
out of the main (1)body Remove the (4)seat out of the main (1)body.

2. Cleaning & replacement of parts

Clean all parts thoroughly, including the packing set. Use an approved and non-residue forming solvent. To remove
encrusted materials use crocus or a very mild aluminum oxide cloth. Examine all parts. Replace any badly worn or
damaged part.

3. Reassembly
(1). Install the (4) seat into the (1) Body. Insert the (6) stem including (5)disc & (14)”C”seat. Install the (3) bottom
flange and the (7)gasket below the (1)body. Insert (9)bolt through the flange and tighten. Replace (7)gasket.
[For 15A(1/2”) thru 25A(1”)]

(2). Insert the (4)seat into the (1)Body. Insert the (6) stem including (5) disc & (14)”C”seat in the (34)seat fixing
plate. Insert (10)bolt through the seat fixing plate and tighten. Install the (3)bottom flange and the (7)gasket below
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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

the (1)body. Insert (9)bolt through the flange and tighten. Replace (7)gasket. [For 32A(11/4”) thru 150A(6”)]

(3). Insert packing set<13>, packing follower<14> Install packing flange<15>. Insert stud bolt<16> through the
packing flange<15> and hand tighten.

(4). Position actuator on bonnet<2>. Insert the lock nut<18> and tighten firmly.

(5). Lift the valve (6)stem and engage its threads with those of the actuator piston rod. Screw into actuator stem
one to two diameters. Then adjust the cylinder valve for rated travel.

4. Adjustment of valve travel range

In all cases full valve travel is mechanically predetermined by the distance between seats. Valves must be adjusted
to make full contact with seat in either direction.

(1). Connection of tubings: Reduce air pressure from actuator cylinder and reconnect operating medium tubing
from control pilot, instrument, or loading device to the cylinder cover.

(2). Indicator position: Supply 3.0 kg/cm² (45psig) of operating pressure to actuator cylinder. Check and confirm
if the valve fully stork at this pressure.

[Direct type]
(1). Screw (6)stem upward into (24)piston rod until valve (5)disc contacts upper seat.

(2). Connect air line to actuator. Supply sufficient air pressure to move (5)disc slightly away from seat.

(3). Then turn (6)stem one full turn further into (24)piston rod to make positive compression contact of (5)disc with
upper seat at rated travel.

(4). Tighten (42) nut and travel (18) indicator ring against (24) piston rod. Tighten (17) gland nut.

[Reverse Type]
(1). Screw (6) stem upward into (24) piston rod approximately one diameter (thickness of stem.)

(2). Connect air line to actuator. Supply 3.0kgf/cm² (45 psig) air pressure to actuator to move actuator through full
travel.

(3). Turn (6) stem upward into actuator (24) piston rod until (5) disc contacts upper seat.

(4). Reduce air pressure on cylinder to permit (5) disc to move slightly off seat.

(5). Then turn (6)stem one full turn further into (24)piston rod to make positive compression contact with upper
seat at rated travel.

(6). Tighten (42) nut and travel (18) indicator ring against (24) piston rod. Tighten (17) gland nut.

SECTION Ⅲ: CYLINDER ACTUATOR

A. Direct Acting Actuator

Direct acting actuators are normally used where opening of valves is required on loss of air pressure.
The actuator spring preload required to seat valve plug varies according to the valve size and maximum pressure
drop.

1. Disassembly

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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

(1). Remove (36) nuts from upper (23) cover.

(2). Remove (23) cover, (21) piston include (24) piston rod and (16)o-ring, (20)cylinder. To examine, clean or
replace parts other than piston (16) O-ring from (12)yoke.

(3). Clean all metal parts. Remove any rust, dirt or sharp edges that might damage stem seal.

2. Reassembly
(1). Clean and lubricate piston & O-ring.
(2). Replace parts and install new O-ring.
(3). Tighten (36)nuts and bolts evenly.

3. Installation of the actuator

Refer to “Reassembly” of 2-way cylinder valves”

Note: maximum allowable actuator air pressure is 3 kg.cm2 (45 psig) for all sizes.

4. Adjustment of the valve travel

Refer to “Setting valve travel” of 2-way cylinder valve.

<Fig. 11 > Direct acting actuator

B. Reverse Acting Actuator

Reverse acting actuators are normally used where closing of valves is required on loss of air pressure.
The actuator spring preload required to seat valve plug varies according to the valve size and maximum pressure
drop.

1. Disassembly
(1). Remove (36)nuts from upper (23)cover.

(2). Remove (23)cover & (9)spring from the (20)cylinder.

(3). Remove (21)piston and (16)o-ring, (20)cylinder. To examine, clean or replace parts other than piston (16)O-
ring from (12)yoke.

(4). Clean all metal parts. Remove any rust, dirt or sharp edges that might damage stem seal.

2. Reassembly
Install parts in reverse order.
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 CONTROL VALVES 2WAY & 3WAY CYLINDER VALVE

When reassembling, place a block under the

actuator stem to hold the stem high enough.

3. Installation of actuator
Refer to “Reassembly” of 2-way control valves”

4. Adjustment of the valve travel

Refer to “Setting valve travel” of 2-way control valve.

5. Installation of the actuator

Refer to “Reassembly” of 2-way cylinder valves”

6. Adjustment of the valve travel

Refer to “Setting valve travel” of 2-way cylinder valve.

<Fig. 10 > Reverse acting actuator

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