Azbil HLS Series User Manual
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Azbil HLS Series User Manual

Azbil HLS Series User Manual

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OM2-8113-0201
Control Valve
Model HLS_ _ _/HTS_ _ _/HPS_ _ _/HLC_ _ _/HSC_ _ _/HAV_ _ _
User's Manual

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  • Page 1 OM2-8113-0201 Control Valve Model HLS_ _ _/HTS_ _ _/HPS_ _ _/HLC_ _ _/HSC_ _ _/HAV_ _ _ User's Manual...
  • Page 2 In no event is Azbil Corporation liable to anyone for any indirect, special orconsequential damages. The information and specifications in this documentare subject to change without notice.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1. General ............. .1-1 1-1.
  • Page 4 9-2-2. Disassembly and assembly ........... . . 9-5 Chapter 10. Azbil Low Emission standard-compliant gland packing ... . 10-1 10-1.

  • Page 5: Chapter 1. General

    Chapter 1. General 1-1. Scope This manual covers the instructions for the following Control Valves. ƒ Model HLS : Small-port single-seated control valves ƒ Model HLC : Small-port cage guide type single-single seated control valves ƒ Model HTS : Top-guide single-seated control valve ƒ...
  • Page 6 Figure 1-1A Small-Port Single Seated Figure 1-1B Model HLC Control Valve, Model HLS (Direct Action Type) Figure 1-2A Top-Guided Single Seated Figure 1-2B Model HSC Control Valve, Model HTS Figure 1-3A Top-Guided High-Pressure Figure 1-3B Venturi-Throat-Type Angle Single Seated Control Valve, Model HPS Control Valve, Model HAV...

  • Page 7: Nameplate

    The nameplate indicate also the product number (PROD.NO.) of the control valve. Please mention this number also when consulting an Azbil Corp. agent for replacement of parts or other modification of the control valve.

  • Page 9: Chapter 2. Installation

    Chapter 2. Installation 2-1. Maximum lifting loads of eyebolts The diaphragm case has a pair of lifting eyebolts. These eyebolts primarily are for lifting the actuator alone. When using the eyebolts for other purposes (such as lifting an actuator bed to its valve body or other components), note that the allowable maxi.mum lifting loads of the eyebolts are as shown in the following table.

  • Page 10: Item To Be Checked After Installation And Before Starting Operation

    2-1. Item to be checked after installation and before starting operation (1) Check that there is no leak from air piping. (2) Check that the bolts and nuts of the diaphragm case are not loose. Standard tight.ening torques are as follows: (3) Tighten the packing flange nuts to prevent leak from the gland packing chapter.
  • Page 11 Packing Flange V PTFE Lubricator Packing PTFE Yarn Bonnet Packing Blind Plug Graphite Graphite Yarn Packing Stem Packing V PTFE Packing PTFE Yarn Packing Graphite + Expanded graphite V PTFE + PTFE Yarn Packing Packing Figure 2-1 Gland Section (4) If the valve is provided with a lubricator as shown in Figure 2-2, check whether the bonnet section has been lubricated or not.
  • Page 12 Squeeze Lubricator Screw Handwheel G1/2 Figure 2-3 Lubricator for High Pressure Valve Figure 2-2 Lubricator (Class 600 or under) (Class 600 or higher) Lubricating procedure (a) prepare grease of the type indicated on the nameplate. (b) Tightly close the lubricator handwheel. (c) Remove the squeeze screw, apply grease, and set the squeeze screw.

  • Page 13: Chapter 3. Inspection And Maintenance

    Chapter 3. Inspection and Maintenance Inspect and service the actuator as follows: (1) Tightening the gland: Tighten the gland once in every 6 months or thereabout. The tightening procedure is as given in Section 2-3-(3). (2) Lubricating the gland: Lubricating the gland once in every 6 months or thereabout. The lubricating procedure is as given in Section 2-3-(4).

  • Page 15: Chapter 4. Disassembly And Assembly

    Chapter 4. Disassembly and Assembly This Chapter covers the disassembly and assembly procedures of the actuator for its overhaul or modification. 4-1. Detaching actuator from valve body See Figure 4-7. (1) Apply to the actuator an air pressure so that the valve position pointer is at a point of 10% - 20% above the fully closed point.
  • Page 16 (3) Check that the gasket-contacting surfaces of valve body, bonnet and guide ring are not damaged. Do not re-use the removed gasket. Use fresh gasket when assem.bling the valve. (4) Check that the plug guide section, the stem, and the internal guiding sections of guide bushing are not damaged..
  • Page 17 Table 4-1. Model HLS, HTS, HSC, HAV seated ring tightening torques Size (in.) Torque (N·m{kgf-cm}) 1-1/2 260 {2,600} 390 {3,900} 2-1/2 520 {5,200} 650 {6,500} 800 {8,000} 1200 {12,000} 1500 {15,000} 1, 3/4 180 {18,000} Table 4-2. Model HPS seated ring tightening torques Size (in.) ANSI Class Torque (N·m{kgf-cm})
  • Page 18 Table 4-4. Bonnet-body bolt size Models Size (in.) Rating ANSI, JPI 150# JIS 10K ANSI, JPI 300#,600# JIS16K, 20K, 30K, 40K 1/2 to 3 M12*4 M12*4 1-1/2 M16*6 M16*8 M16*6 M16*10 2-1/2 M16*6 M20*8 HTS, HCB M20*8 M22*10 M20*8 M22*12 M22*12 M30*3*12 M24*12...
  • Page 19 Hex Nut (2) Packing Flange Nut Lubricator Packing Flange Packing Follower Stud Bolt Gasket (2) Gland Packing Extension Hex Nut (1) Bonnet Bonnet Packing Guide Bushing Valve Stem Gasket (1) Valve Plug Seat Ring Stud Bolt Valve Body Figure 4-1-1 Normal Temperature Type Figure 4-1-2 High Temperature Type (Extended Bonnet Type) Figure 4-1 Model HLS Control Valves...
  • Page 20 Packing Flange Nut Packing Flange Packing Follower Stud Bolt Gland Packing Hex Nut (1) Bonnet Va lve Stem Gasket (1) Valve Plug Guide Bushing Seat Ring Stud Bolt Valve Body Figure 4-2 Model HLC Control Valves...
  • Page 21 Packing Flange Nut Packing Flange Packing Follower Gland Packing Hex Nut (1) Bonnet Extension Bonnet Gasket (1) Guide Ring Valve Stem Guide Bushing Gasket (2) Valve Plug Seat Ring Stud Bolt Valve Body Figure 4-3-1 Normal temperature type Figure 4-3-2 High temperature type (Extended bonnet type) Figure 4-3 Model HTS Control Valves...
  • Page 22 Packing Flange Nut Packing Flange Packing Follower Stud Bolt Gland Packing Hex Nut (1) Bonnet Gasket (1) Guide Ring Gasket (2) Valve Stem Valve Plug Stud Bolt Seat Ring Valve Body Figure 4-4 Model HSC Control Valves...
  • Page 23 Figure 4-5 Model HPS Control Valves...
  • Page 24 Paking Flange Nut Packing Flange Packing Follower Stud Bolt Gland Packing Hex Nut (1) Bonnet Gasket (1) Guide Ring Valve Stem Gasket (2) Valve Plug Seat Ring Stud Bolt Valve Body Figure 4-6 Model HAV Control Valves 4-10...

  • Page 25: Disassembly And Assembly Of Actuator

    4-3. Disassembly and assembly of actuator Normally the actuator requires no adjustment. However, it should be disassembled and assembled when installing it on a valve body, when modifying its specifications, or when replacing damaged parts. The disassembly and assembly procedure of the actuator for such purposes are covered in Sections 4-4 and 4-5.
  • Page 26 Notes for Disassembly (1) The nuts for the eyebolts are made of stainless steel. Discriminate these nuts from other nuts when assembling the diaphragm case. (2) It is recommendable to make locating marks on the top and bottom diaphragm cases before disassembly.

  • Page 27: Disassembly And Assembly Of Model Psa 1

    4-4. Disassembly and assembly of model PSA 1 Disassembly procedure A. Direct action model (see Figure 4-8) (1) Disconnect the air piping and detach the accessories from the actuator. (2) Remove the stem connector. (3) Remove the clamping bolts (except the pair of eyebolts) from the diaphragm case. (4) Alternatively and evenly loosen the pair of eyebolts.
  • Page 28 Rain Cap Eye Bolt Diaphragm Case (Top) Hex Bolt Diaphragm Case (Top) Hex Nut Eye Bolt Was her Hex Bolt Spring Plate Hex Nut Spring Was her Diaphragm Retainer Diaphragm Plate Diaphragm Diaphragm Diaphragm Plate Stopper Diaphragm Part Retainer Spring Hex Bolt Spring Plate Diaphragm...
  • Page 29 Assembly Before assembly, check the parts for scratches, damage, deformation, peeling paint or any other abnormalities. To assemble the actuator, proceed as follows: A. Direct action models • See Figure 4-8. (1) Secure the diaphragm case (bottom) with the four bolts to the yoke. At the same time, set the air vent hole as in Figure 4-10.
  • Page 30 B. Revers action models (1) Secure the bottom diaphragm case with the four bolts to the yoke. At the same time, set the air pipe connection port in the location shown in the Figure 4-11. (2) Insert the actuator rod (with diaphragm connected) into the bushing. Be careful to prevent the bushing 's inside surface or dust seal from being damaged by the threaded section of the rod.
  • Page 31 Direct Action Type (Model PSA1D) Reverse Action Type (Model PSA1R) Figure 4-12 Bolts and Nuts of Actuator Table 4-5. Tihtening Torques of Bolts and Nuts of Actuator Unit: (N.m{kgf-cm}) Materials Model PSA1 45-70 SK5 S45C {460-710} 35-50 S30C {360-510} 15-20 SUS304 {150-200} 10-15...
  • Page 32 Direct Action Type (Model PSA1D) Reverse Action type (Model PSA1R) Figure 4-13 Model PSA Actuator Parts Name Material Parts Name Material S45C, SUS301 Hex Bolt SUS304 Diaphragm Case (Top) SAPH400 Hex Nut SUS304 Diaphragm EPDM, Polyimide Spring Plate SUS304CP Eye Bolt SUS304 Hex Bolt S30C...

  • Page 33: Disassembly And Assembly Of Model Ha2, Ha3, Or Ha4 Actuator

    4-5. Disassembly and assembly of model HA2, HA3, or HA4 actuator Disassembly procedure (a) Direct action type (1) Disconnect the air piping and detach the accessories from the actuator. (2) Remove the stem connector, pointer and lock nut. (See Figure 4-21.) (3) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case.
  • Page 34 (b) Reverse action type (1) Disconnect the air piping and detach other external items from the actuator. (2) Remove the stem connector, pointer and lock nut. (See Figure 4-21.) (3) Remove the clamping-bolts (except the pair of eyebolts) of the diaphragm case. (4) Loosen evenly and alternately the pair of eyebolts.
  • Page 35 Assembly procedure Before assembly, check the parts for scrapes, damage, deformation, peeling off of paint, and other abnormality. To assemble the actuator, proceed as followes: (a) Direct action type (1) Fix the bottom diaphragm case and yoke with the bolts. (For models HA2D and HA3D, install the diaphragm case and spring plate together.) (2) Install the springs on the spring plate.
  • Page 36 (b) Reverse action type (1) Fix the bottom diaphragm case and yoke with the bolts. (2) Insert the actuator rod (to which the diaphragm is connected) into the hushing, exercising care not to damage the bushing inside surface or dust seal with the thread section of the rod.
  • Page 37 Reverse Action Type Direct Action Type Figure 4-20 Bolts and Nuts of Actuator Table 4-6. Tightening Torques of Bolts and Nuts of Actuator Unit:(N.m{kgf-cm}) Materials For Model HA2 For Model HA3 For Model HA4 S45C/SUS301 37 {370} 100 {1,000} 310 {3,170} S30C 42 {420} 100 {1,000}...
  • Page 38 Direct Action Type (Model HA3D) Reverse Action Type (Model HA3R) Parts Name Material Parts Name Material S45C, SUS301 Spring SWOSM-B Diaphragm Case (Top) SAPH370 Hex Bolt SUS304 Diaphragm EPDM+Nylon66 Hex Nut SUS304 Eye Bolt SUS304 Spring Plate SPCC Hex Nut SUS304 Hex Bolt S30C...

  • Page 39: Disassembly And Assembly Of Model Psa6 Actuator

    4-6. Disassembly and assembly of model PSA6 actuator Structure This actuator is comprised of a cylinder, spring unit, lift stopper, spring retainer, hex stay, yoke, manual handwheel and a single action positioner. For an external view of the a actuator, refer to "Figure 4-22 Exterior of Model PSA6R".
  • Page 40 CAUTION In operation and handling • When automatically operating an actuator with the manual handwheel, verify that the AUTO/MANUAL switchover pin is inserted into the pin holder, the chain is engaged with the handwheel and the indicator is in AUTO position starting operation.
  • Page 41 Procedure Step Procedure Pull AUTO/MANUAL switchover pin out of its holder and disengage the chain, that connects the handwheel with the wheel. Check the label on the handwheel and turn the handle in the shut direction and lower the slide screw. Align the round holes of the slide screw and the actuator rod, and then insert pin.

  • Page 42: Disassembly And Assembly Actuator

    4-7. Disassembly and assembly actuator Disassembly and assembly procedures are described herein. Refer to them for periodic maintenace or if a malfunction occurs which may call for the disassembly or assembly of the actuator. Before disassembly (1) Only the nuts for the eyebolts are made of stainless steel. Keep these nuts separate from other nuts when disassembling the diaphragm case.
  • Page 43 Disassembly of actuator <Disassembly procedure> Disassembly procedure of actuator is described herein. Refer to Figure 4-26 and Figure 4-27 or Table 4-4 for the information. 1. Marking and protection Step Procedure Match the mark of the spring retainer No.10 at the top of actuator, lift stopper No.13, cylinder No.14 and cylinder assembling yoke boss.
  • Page 44 5. Removing slide screw and cylinder Step Procedure Turn slide screw No.32 by hand and extract from the bottom. Loosen hex head bolts No.6 (four bolts) which fasten the cylinder and manual handwheel and remove. Lift cylinder straight up and remove. 6.
  • Page 45 Spring Unit Figure 4-26 Model PSA6R 4-31...
  • Page 46 Spring Unit Figure 4-27 Model PSA6R with Handwheel 4-32...
  • Page 47 Table 4-7. Parts reference list Parts description Parts description Parts description Eye Nut Slide Screw Hex Nut Bushing O-Ring Spring Washer Dust Seal Piston Hex Stay(Long) Tape Liner Spring Washer O-Ring Slide Screw Rotation Stopper Locking Nut Hex Bolt Hex Bolt Stopper Seal Washer Seal Washer...
  • Page 48 Disassembling spring unit <disassembly procedure> The disassembly procedure of spring unit is described herein. See Figure 4-28 for reference on part names. Disassembly is not required if only the piston's sealing parts (tape liner, O-ring) are to be replaced. 1. Removing spring unit Step Procedure Loosen hex nuts No.10 (four at the top) and remove.
  • Page 49 Assembling actuator <Cautions during assembly> ƒ Refer to the chapter of inspection items during disassembly and verify that no abnormality is found on the parts. If any are found, replace or repair as required. ƒ The O-ring of sliding parts should always be replaced at the time of periodic disassembly. Whenever the O-ring on the fixed part is deformed, damaged, or scarred during disassembly, replace it.
  • Page 50 2. Assembly of piston unit, lift stopper and spring retainer Step Procedure Install eyebolts into threaded holes (M12*2) at the top of spring retainer No.9 on the piston unit, suspend with crane and lift upward. While suspended, assemble lubricated O-ring No.15 and wear ring No.14 on piston No.3.
  • Page 51 Tightening torques of actuator assembly The table below lists the tightening torques for actuator assembly. Refer to Figure 4-30. Table 4-8. Tightening torque of bolt and nuts of actuator Key No. Size Tightening torque (N.m{kgf-cm}) 45-70 {450-700} 160-215 {1600-2200} 215-275 {2200-2800} 45-70 {450-700} 35-50 {350-500} Figure 4-30 Tightening torque of actuator thread...
  • Page 52 4-38...

  • Page 53: Chapter 5. Adjustment

    Chapter 5. Adjustment As a general rule the diaphragm type control Valves require no adjustment. However, when coupling an actuator to a valve body after removing the actuator for overhaul or other purposes, adjustment of travel (stroke) is necessary. For this adjustment, refer to Figure 4-7, Figure 5-1 and proceed as follows: (1) Fix the actuator to the valve body by securely tightening the yoke clamping-nut (use a chisel and a hammer).
  • Page 54 Actuator Stem Set at maximum or minimum value of spring range (for direct or reverse action) by moving actuator stem in this direction. Valve Yoke Stem Yoke-Clamping-Nut Figure 5-1...

  • Page 55: Direct/Reverse Action Change

    Chapter 6. Direct/Reverse Action Type Conversion and Spring Range Change of Actuator 6-1. Direct/Reverse action change As a general rule it is most recommendable to prepare separately the direct type and reverse type of actuators and not to convert actuators into different types. However, when it has become unavoidable to convert actuators into other types, conversions may be done by using the parts mentioned below (Table 6-1 and Table 6-2).
  • Page 56 Model HA3D -> Model HA3R For stroke For stroke For stroke Part name Q'ty 14.3mm 25mm, 38mm 38mm Seal washers 82521069-102 82521069-102 82521069-102 Rod packing 82521067-102 82521067-102 82521067-102 82521431-202 (25mm) Rod unit 82521431-201 82521431-204 82521431-203 (38mm) Rain cap 82553334-101 82553334-101 82553334-101 82521428-102 (25mm) (-1)
  • Page 57 Table 6-2. To Convert the Reverse Action Type into the Direct Action Type Model PSA1R -> Model PSA1D Parts neme Q'ty 82559229-102 14.3mm Rod unite 82559229-101 25mm 82559228-102 14.3mm 82559228-101 25mm Seal washer 82521069-101 Rod packing 82521067-102 Rain cap 82553334-101 "O"...
  • Page 58 Model HA3R -> Model HA3D For stroke Part name Q'ty For stroke 25mm, 38mm For stroke 50mm 14.3mm Seal washers (-2) 82521069-102 82521069-102 82521069-102 Rod packing (-1) 82521067-102 82521067-102 82521067-102 82521428-102 (25mm) Rod unit 82521428-101 82521428-104 82521428-103 (38mm) 82521431-202 (25mm) (-1) 82521431-201 82521431-204...

  • Page 59: Stroke And Range Spring Change

    6-2. Stroke and range spring change As a general rule it is most recommendable to prepare separate actuators for different strokes and spring ranges to avoid modifications. However, modifications can be done by using the parts mentioned below. Of Models HA2 and HA3, there are two different diameters of bonnet connection sections. For these models, note the following: Of Model HA2, modification for change between read stroke of 14.3 or 25mm and that of 38mm cannot be done.
  • Page 60 Actuator model Part name Q'ty For Stroke 25mm For Stroke 38mm Scale plate 80225032-464 82554022-103 20-98{0.2-0.1} 82521206-101 82521206-103 Spring 80-240{0.8-2.4} 82521206-102 82521209-101 R (Reverse action) 82521431-202 82521431-203 unit D (Direct action) 82521428-102 82521428-103 Actuator model For Stroke For Stroke For Stroke For Stroke Part name Q'ty...
  • Page 61 Color Codes and Dimensions of the Springs of Model HA Actuators The color codes and dimensions of the springs of Model HA Actuators are as shown in the following table. The color codes may help you confirm springs when disassem.bling and assembling actuators for modification or other purpose.

  • Page 63: Chapter 7. Instructions For Top Handwheel Of Actuator

    Chapter 7. Instructions for Top Handwheel of Actuator 7-1. Model PSA1 actuator 7-1-1. Operating instructions To manually operate the actuator, refer to Figure 7-1 and Figure 7-2 and proceed as follows: (1) Loosen the lock nut of the handwheel and turn the handwheel in the direction indicated by the corresponding arrowhead mark.
  • Page 64 Direct Action Type Reverse Action Type Parts Name Parts Name Parts Name Hex Nut Hex Bolt Spring Washer Bushing Truss Screw Washer Dust Seal Scale Plate Handwheel Stem Connector Name Plate Lock Nut Screw Shaft Drive Screw Washer Housing Yoke O-Ring Spring Pin Rain Cap...

  • Page 65: Disassembly And Assembly Of Top Handwheel

    7-1-2. Disassembly and Assembly of Top Handwheel To disassemble or assemble the top handwheel, refer to Figure 7-1 through Figure 7-3 and proceed as described in this section. For disassembly work, keep the actuator in the vertical attitude. (a) Direct action type (1) Disconnect the air piping.
  • Page 66 Figure 7-2 Figure 7-3 Model PSA1D (Direct Action Type) Model PSA1R (Reverse Action Type)

  • Page 67: Model Ha2, Ha3, Or Ha4 Actuator

    (4) Sufficiently insert the handle shaft by turning it and then remove the handwheel and the lock nut. Insert the shaft further and then remove the screw shaft from the housing. (5) Remove the O-ring. To assemble the top handwheel, follow the disassembly procedure in the reverse order. Azbil Corporation Safety...
  • Page 68 Parts Name Hex Nut Washer Handwheel Screw Shaft Lock Nut O-Ring C type Retaining Ring Diaphragm Case (Top) Eye Bolt Hex Nut Diaphragm Diaphragm Case (Bottom) Bushing Bearing Dust Seal Pointer Yoke Stem Connector Hex Bolt Housing Bearing Spring Retainer O-Ring Seal Washer Hex Bolt...
  • Page 69 Parts Name Washer Handwheel Lock Nut Screw Shaft Bearing Case Diaphragm Case (Top) Eyebolt Through Bolt Diaphragm Connector Diaphragm Case (Bottom) Stopper Diaphragm Retainer Bearing Bushing Yoke Lock Nut Pointer Stem Connector Stem Connector Bolt Housing Bearing Washer Bearing Cotter Pin Castle Nut Seal Washer Bolt...
  • Page 70 Parts Name Washer Handwheel Screw Shaft Lock Nut Bearing Bearing Case Cotter Connector Eyebolt Through Bolt Diaphragm Case (Bottom) Coil Spring Bearing Bushing Pointer Lock Nut Yoke Stem Connector Stem Connector Bolt Housing Piston Plate O-Ring Bolt Bearing Retainer Seal Washer Bolt Diaphragm Case (Top) Diaphragm...
  • Page 71 Parts Name Washer Handwheel Lock Nut Screw Shaft Bearing Case Diaphragm Case (Top) Eyebolt Through Bolt Diaphragm Diaphragm Case (Bottom) Stopper Connector Diaphragm Retainer Bearing Bushing Yoke Pointer Stem Connector Stem Connector Bolt Housing Washer Bearing Bearing Cotter Pin Seal Washer Bolt Coil Spring Setscrew...
  • Page 72 (b) Reverse Action Type (1) Disconnect the air piping. (2) Set the handwheel shaft in the automatic operation position (fully lower the handwheel shaft). (3) Remove the handwheel and the lock nut. Insert the shaft into the housing by means of the threading until the threading sections are disengaged.
  • Page 73 Figure 7-8 Model HA3 Actuator with Figure 7-9 Model HA3 Actuator with Top Handwheel (Direct Action Type) Top Handwheel (Reverse Action Type) 7-11...
  • Page 74 7-12...

  • Page 75: Chapter 8. Instructions For Side Handwheel Of Actuator

    Chapter 8. Instructions for Side Handwheel of Actuator As you turn the handwheel clockwise, the actuator stem moves downward regardless of whether the actuator is of the direct action type or reverse action type. The handwheel bears the ''SHUT' mark to indicate that the valve is closed as the handwheel is tuned clockwise and the "OPEN'' mark to indicate that the valve is made open as the handwheel is tuned counterclockwise.

  • Page 76: Disassembly Of Side Assembly Of Side Handwheel

    8-3. Disassembly of side assembly of side handwheel Before starting disassembly, check that the pointer is set at the AUTO position. (Refer to Figure 8-1) (1) Loosen the bolt 6 which connects the levers 2 and then disengage the levers from the pointer.
  • Page 77 Parts Name Housing Lever Shaft Bushing Bearing Screw Pointer A–A Collar Hex Bolt Hex Bolt Bushing Spring Washer Handwheel Washer Hex Nut Handle Lock Hex Nut Spring Washer Bushing Bearing Holder Bearing B–B Bush Hex Nut Spring Washer Hex Bolt Washer HA4 only Hex Bolt...

  • Page 79: Chapter 9. Instructlons For Bellows Sealed Type Of Control Valves

    Chapter 9. Instructlons for Bellows Sealed Type of Control Valves The bellows sealed type of control valves differ from other control valves in that the former employ a bellows for seal. This chapter covers primarily the particular items related to the bellows sealed type of control valves. Note: The bellows seal assembly should be replaced periodically.
  • Page 80 Packing Flange Nut Packing Flange Nut Packing Flange Packing Flange Hex Nut (1) Hex Nut (1) Bonnet Bonnet Gasket (2) Gasket (2) Valve Stem Valve Stem Bellows Flange Bellows Flange Bellows Assembly Bellows Assembly Gasket (3) Gasket (3) Valve Plug Extension Bonnet Hex Nut (2) Extension...

  • Page 81: Disassembly And Assembly

    9-1-2. Disassembly and assembly (1) Detach the actuator from the valve as described in Section 4.1. (2) Loosen the packing flange nut. (3) Loosen the hex nut (1) of the bonnet, using the wrench. (4) Raise the bonnet and remove the gasket (2). Note: When raising the bonnet, press down the stem so that it will not come up together with the bonnet.

  • Page 82: Model Hts Control Valves

    9-2. Model HTS control valves 9-2-1. Structures The structure of model HTS Control Valve is shown in Figure 9-3. Hex Nut (2) Bellows Flange Packing Flange Nut Backup Ring Packing Flange Seal Ring Nut (1) Stem Bellows Seat Bellows Assembly Gasket (3) Gasket (4) Extension Bonnet...

  • Page 83: Disassembly And Assembly

    9-2-2. Disassembly and assembly (1) Detach the actuator from the valve as described in Section 4.1. (2) Loosen the packing flange nut. (3) Loosen the hex nut (1) of the bonnet, using the wrench. (4) Raise the bonnet and remove the gasket (3). Note: When raising the bonnet, Press down the stem so that it will not come up together with the bonnet.

  • Page 85: Chapter 10. Azbil Low Emission Standard-Compliant Gland Packing

    Fig. 10-1. Structural drawing of Azbil low emission gland packing 10-2. Structure The gland packing P4519 for use in Azbil low emission gland packing is woven PTFE yarn with carbon fiber core. This gland packing provides asbestos-free properties in addition to low sliding friction and adaptability to heat cycles, and is adaptable to a wide range of fluids.

  • Page 86: Installation Into The Gland

    10-3. Installation into the gland 10-3-1. Preparation for installation 1. Checking for the surface conditions of parts If there is any flaw or the like on the surface of a part, the total amount of gland leakage may exceed a specified value because of fluid leakage from the periphery. For this reason, check the surface conditions of the following parts: Table 10-1.

  • Page 87: Start Of Installation

    3. Preparation of lubricating grease and anti-seize compound Prepare proper amounts of lubricating grease and anti-seize compound indicated in the following table. (Equivalents also can be used.) Table 10-3. Lubricating grease and anti-seize compound Product name Area to be coated Silicone grease G40M made by Shin-Etsu Entire surface of the gland packing Chemical Co., Ltd.
  • Page 88 Step 2: Being careful not to damage the surface of the stem, install the spacer first. Step 3: Next, install one piece of the gland packing. Be sure to note how to open indicated in Fig.10-3. Insert it tightly with a pipe or the like. Finally, press it lightly. Insert the second and subsequent pieces, with the gap position shifted by 180 degrees.
  • Page 89 Step 7: Being careful not to damage the surface of the stem, install the packing flange. Step 8: After applying the anti-seize compound indicated in Table 10-3 [Never-Seez made by Bostik, Inc., in the U.S.] to the surface of the threads of the stud bolts and the bearing surface of the nuts, tighten them by hand.

  • Page 90: Retightening

    10-3-3. Retightening In the following cases, retighten the gland nuts with the specified torque: a) At the time of an inspection before the installation of the control valve b) At the time of a test operation or start-up operation of the equipment c) In case the leakage amount of the gland exceeds the specified value during operation of the equipment.
  • Page 91 Part name Actuator model Stem size Material Part No. Qty. Main packing P4519 80255385-111 Belleville spring SUS304 82559308-101 O-ring (small) Viton 82592221-497 O-ring (large) Viton 82592222-297 Stem connector S20C/S25C 82571706-011 Gland stud SUS304 82571706-011 φ13 mm Gland nut SUS304 82592448-173 Spring case SUS304 82559309-101...
  • Page 92 10-8...

  • Page 93: Chapter 11. Certified Iso 15848-1 Compliant Low Emission Gland Packing

    Chapter 11. Certified ISO 15848-1 compliant low emission gland packing 11-1. Overview Certified ISO 15848-1 low emission gland packing employs a live-loaded packing system to maintain valve seal performance for a long period of time. The gland packing system has acquired third-party certification for compliance with ISO15848-1, which is the international standard for low-emission performance of valves.

  • Page 94: Structure

    11-2. Structure The main packing (No. P4519) is PTFE yarn with a carbon fiber core. It features low friction and can be used for various types of fluids. The main packing (No. P6617CL) is an expanded graphite packing. The part of it that slides is aligned with an expanded graphite sheet that was specially modified and lubricated.

  • Page 95: Assembling The Parts Of The Gland

    11-4. Assembling the parts of the gland 11-4-1. Preparation for assembly (1) Checking the surface condition of the parts Any flaw or the like on the surface of the parts may cause leakage from that area, resulting in a total amount of leakage from the gland that exceeds the specified value. Therefore, check the surface of the following parts.
  • Page 96 (2) New parts When assembling or reassembling, for the parts indicated in the table below, be sure to use new parts. Table 11-2. Parts requiring treatment Part name Checkpoints Possible problems Gland packing (main Fluid leaks from flawed areas can cause packing and adapter the total amount of leakage from the packing)

  • Page 97: Assembly

    11-4-2. Assembly (1) Applying lubricating grease Step 1 For Certified ISO 15848-1 low emission gland packing for PTFE yarn, apply a thin film of grease Krytox GPL207 indicated in Table 11-3 to the surface of all gland packings (main packing and adapter packing). For Certified ISO 15848-1 low emission gland packing for expanded graphite, greasing is not necessary.
  • Page 98 (2/3) Step Procedure [Certified ISO 15848-1 low emission gland packing for PTFE yarn] Insert one adapter packing ring, without opening the gap, all the way to the bottom with a pipe, etc., and push it lightly. Open the gap of the main packing rings as illustrated in Fig. 11-4 and insert one of them all the way to the bottom with a pipe, etc., and push it lightly.
  • Page 99 (3/3) Step Procedure Stack the Belleville spring washers as shown in Fig. 11-5, and insert them into the packing follower. 2 same-direction washers × 3 3 same-direction washers × 2 [For PTFE yarn] [For expanded graphite] Fig. 11-5. Place the packing flange onto the packing follower. Apply anti-seizing agent Never-Seez made by Bostik Inc.
  • Page 100 (2/2) Step Procedure By tightening the gland nuts to the torque indicated in Table 11-4 or Table 11-5, the top of the packing flange and packing follower will be at almost the same level, as illustrated in Fig. 11-6 below (the level may not be exactly the same due to the tolerance of the Belleville springs and friction on the gland studs or gland nuts).

  • Page 101: Parts List

    11-5. Parts List Table 11-6. Parts list for PTFE yarn Part name Actuator model Material Part No. Qty. Main packing P4519 80255384- 111 Adapter packing P6720 82573475- 101 Carbon ring P6210C2FS 82573484- 001 Belleville spring SUS304 82573462- 101 O-ring (small) Viton 82592220- 897 O-ring (large)
  • Page 102 Part name Actuator model Material Part No. Qty. Main packing P4519 80255387- 111 Adapter packing P6720 82573475- 104 Carbon ring P6210C2FS 82573484- 004 Belleville spring SUS304 82573462- 104 O-ring (small) Viton 82592221- 997 O-ring (large) Viton 82592223- 397 Gland stud A193 GrB8CL2 82571707- 012 Gland nut...
  • Page 103 Table 11-7. Parts list for expanded graphite Part name Actuator model Material Part No. Qty. Main packing P6617CL 82573489- 001 Adapter packing P6720 82573475- 101 Carbon ring P6210C2FS 82573488- 001 Belleville spring SUS304 82571710- 101 O-ring (small) Viton 82592220- 897 O-ring (large) Viton 82592221- 897...
  • Page 104 Part name Actuator model Material Part No. Qty. Main packing P6617CL 82573489- 004 Adapter packing P6720 82573475- 104 Carbon ring P6210C2FS 82573488- 004 Belleville spring SUS304 82573462- 108 O-ring (small) Viton 82592221- 997 O-ring (large) Viton 82592223- 397 Gland stud A193 GrB8CL2 82571707- 012 Gland nut...

  • Page 105: Application To Existing Control Valves

    11-6. Application to existing control valves If Certified ISO 15848-1 low emission gland packing is used for an existing control valve, please note the following: „ If there are scratches on the inner surface of the stuffing box or the surface of the stem of the current valve, the specified seal performance of Certified ISO 15848-1 low emission gland packing may not be achieved.
  • Page 106 11-14...

  • Page 107: Chapter 12. Troubleshooting

    This chapter covers the symptoms, causes and remedies of most probable types of troubles. Parts may be required to be replaced depending on the type of trouble. For further troubles, please ask an Azbil Corp. agent for repair. Table 1-1. Troubleshooting...
  • Page 108 Symptom Cause and Remedy Even when valve plug • Air leak at actuator section. is in closed position, • For trial, apply the air supply pressure or atmospheric large flow leaks to pressure to the actuator. (Check the air supply source and downstream side.

  • Page 109: Chapter 13. Recommended Spare Parts

    Chapter 13. Recommended Spare Parts It is most recommendable to replace the following parts when servicing the control valve. Valve body Be sure to replace the following parts with fresh ones whenever the valve body is disassembled: ƒ Gland packing ƒ...
  • Page 110 13-2...
  • Page 112 1. Warranty period and warranty scope 1.1 Warranty period Azbil Corporation's products shall be warranted for one (1) year from the date of your purchase of the said products or the delivery of the said products to a place designated by you.
  • Page 113 Although acceleration of the above situation varies depending on the conditions or environment of use of the products, you are required not to use any Azbil Corporation's products for a period exceeding ten (10) years unless otherwise stated in specifications or instruction manuals.
  • Page 115 Model HLS_ _ _/HTS_ _ _/HPS_ _ _/ HLC_ _ _/HSC_ _ _/HAV_ _ _ User's Manual Date: 11th Edition: Apr. 2012 14th Edition: Nov. 2018 Issued/Edited by: Advanced Automation Company Address: 1-12-2 Kawana, Fujisawa kanagawa 251-8522 Japan URL: https://www.azbil.com/global/...

This manual is also suitable for:

Hlc seriesHsc seriesHts seriesHav seriesHps series

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