Azbil CV3000 Alphaplus Series User Manual
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Azbil CV3000 Alphaplus Series User Manual

Top-bottom guided double seated control valve
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CM2-ADV100-2001
CV3000 Alphaplus series
Top-Bottom Guided Double Seated
Control Valve
Model ADVB, ADVM
User's Manual

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Summary of Contents for Azbil CV3000 Alphaplus Series

  • Page 1 CM2-ADV100-2001 CV3000 Alphaplus series Top-Bottom Guided Double Seated Control Valve Model ADVB, ADVM User's Manual...
  • Page 2 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.
  • Page 3 The location of the product's nameplate is shown in the figure below. Position of the nameplate Inquiries For inquiries concerning this device, contact the azbil Group. When making an inquiry, have your model number and product number ready. Compliance with Regulations This product complies with the directive below.
  • Page 4 Precautions for Storage Observe the following precautions in order to store the purchased valve properly. • If the valve is packed in a cardboard box, store it indoors at room temperature and humidity. • A valve packed in a wooden crate should also generally be stored indoors at room temperature and humidity.

  • Page 5: Table Of Contents

    Table of Contents Chapter 1. General Description ........... .1-1 1-1.
  • Page 6 Appendix-A. Parts List ............A-1 1.

  • Page 7: Chapter 1. General Description

    Chapter 1. General Description 1-1. Scope This manual contains the instructions on the use and safe handling of top and bottom guided double seated control valves (model ADVB/ADVM). For instructions on the valve positioner, refer to the following Operator’s Manuals: „...

  • Page 8: Structures

    1-3. Structures A typical CV3000 Alphaplus series control valve is shown in Fig. 1-1. The valve body is connected to the bonnet by stud bolts and nuts. Gaskets mounted between body and bonnet act as a seal for the internal fluid, making the valve body a pressure vessel.

  • Page 9: Chapter 2. Installation

    Chapter 2. Installation 2-1. Installing the valve on a process pipe (1) Before installing the valve, remove scaling, welding chips or any other contaminants from both the upstream and downstream sides of the process pipe. (2) Confirm that the direction of process fluid flow conforms to the arrowhead mark on the valve body.
  • Page 10 PTFE yarn packing PTFE chevron PTFE chevron Graphite packing (for regular service) packing (Direct + reverse) (for high temperature (for oil-proof service) (for vacuum service) service) Fig. 2-1. Gland section...

  • Page 11: Chapter 3. Inspection And Maintenance

    Chapter 3. Inspection and Maintenance 3-1. Inspection Inspect and service the control valve as follows: (1) Tightening the gland: Tighten the gland approximately every 6 months. Follow the tightening procedures given in “2-2. Check after installation and before starting operation”. (2) Check for valve position hunting.

  • Page 13: Chapter 4. Disassembly And Assembly

    Chapter 4. Disassembly and Assembly This section covers the disassembly and assembly procedures for its overhaul or modification. 4-1. Detaching actuator from valve body (refer to Fig. 4-1.) (1) Apply air pressure to the actuator so that the valve positioner is 10% to 20% open. (2) Loosen the clamping bolts on of the stem connector and remove it.

  • Page 14: Disassembly And Assembly Of Valve Body

    4-2. Disassembly and assembly of valve body To disassemble or assemble the valve body, refer to figures and proceed as described below. 4-2-1. Disassembly procedure (1) Loosen the hex nuts on the packing flange. (2) Remove the hex nuts from the bonnets. (3) Lift and detach the bonnet from the valve body.
  • Page 15 Table 4-1. Seat ring tightening torques Body size (inches) Torque N·m {kgf/cm} 1230 to 1400 {12100 to 13800} 1870 to 2140 {18400 to 21000} 2250 to 2570 {22100 to 25200} 3930 to 4490 {38500 to 44000} Table 4-2. Tightening torques of bonnet stud bolts Body size (inches) Bolt size Torque N·m {kgf/cm}...
  • Page 16 Fig. 4-1. Model ADVB/ADVM control valve...

  • Page 17: Disassembly And Assembly Of Actuator

    4-3. Disassembly and assembly of actuator Normally, the actuator should require no adjustment. However, at certain times the actuator should be disassembled and reassembled. Reassembly is recommended when installing it on a valve body, when modifying its specifications, or when replacing damaged parts. The disassembly and reassembly procedures for the actuator in such cases are covered in subsections “4-4.

  • Page 18: Disassembly And Assembly Of Model Psa3, 4

    4-4. Disassembly and assembly of model PSA3, 4 4-4-1. Disassembly procedure A. Direct action model (see Fig. 4-2.) (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) Alternately and evenly loosen the pair of eyebolts.
  • Page 19 Fig. 4-2. Direct action mode (PSA3D, 4D) Fig. 4-3. Reverse action model (PSA3R, 4R)

  • Page 20: Assembly Procedure

    4-4-2. Assembly procedure 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 Fig. 4-4. and Fig. 4-5.) (1) Secure the diaphragm case (bottom) with the four bolts to the yoke. At the same time, set air vent hole as shown in Fig.
  • Page 21 Fig. 4-4. Direct action model: PSA3D actuator Fig. 4-5. Direct action model: PSA4D actuator...
  • Page 22 B. Reverse action models (see Fig. 4-6. and Fig. 4-7.) (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 Fig. 4-6. and Fig. 4-7. (2) Insert the actuator rod (with diaphragm connected) into the bushing.
  • Page 23 Fig. 4-6. Reverse action model: PSA3R actuator Fig. 4-7. Reverse action model: PSA4R actuator 4-11...
  • Page 24 Direct action model Reverse action model Fig. 4-8. Bolts and nuts of actuator Table 4-4. Tightening torques of bolts and nuts of actuator Key no. Material PSA3 PSA4 S45C 160 to 215 265 to 358 {1,600 to 2,200} {2,700 to 3,650} 90 to 120 90 to 120 S30C...
  • Page 25 (29)(1) (12) (2) (3) (28)(29)(1) (18) (15) (14) (16) (16) (17) (17) (15) (14) (18) (19) (13) (19) (22) (20) (21) (26) (26) (23) (23) (27) (27) (12) (25) (12) (11) (25) (24) (11) (10) (10) Direct action model Reverse action model Fig.
  • Page 26 4-14...

  • Page 27: Chapter 5. Adjustment

    Chapter 5. Adjustment As a general rule, diaphragm control valves do not require adjustment. However, adjustment of travel (stroke) is necessary when coupling an actuator to a valve body, after removing the actuator for overhaul, or for other purposes. For this adjustment, refer to Fig. 4-1. and Fig. 5-1. and proceed as follows: (1) Connect the actuator to the valve body by securely tightening the yoke clamping nut using a chisel and hammer.
  • Page 28 Fig. 5-1. Adjustment for direct or reverse action models...

  • Page 29: Chapter 6. Secure-Seal Certified Iso 15848-1 Compliant Low-Emission Gland Packing System

    Chapter 6. SECURE-SEAL Certified ISO 15848-1 Compliant – Low-Emission Gland Packing System 6-1. Overview SECURE-SEAL 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 30: Structure

    6-2. 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 31: Assembling The Parts Of The Gland

    6-4. Assembling the parts of the gland 6-4-1. 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 32 (2) New parts When assembling or reassembling, for the parts indicated in the table below, be sure to use new parts. Table 6-2. 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 33: Assembly

    6-4-2. Assembly (1) Applying lubricating grease Step 1 For SECURE-SEAL for PTFE yarn, apply a thin film of grease Krytox GPL207 indicated in Table 6-3 to the surface of all gland packings (main packing and adapter packing). For SECURE-SEAL for expanded graphite, greasing is not necessary. Step 2 For SECURE-SEAL with two O-rings, which are placed inner and outer sides of the packing follower, apply grease Plastilube No.3 made by Sulflo Inc.
  • Page 34 (2/3) Step Procedure [SECURE-SEAL 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. 6-4 and insert one of them all the way to the bottom with a pipe, etc., and push it lightly.
  • Page 35 (3/3) Step Procedure Stack the Belleville spring washers as shown in Fig. 6-5, and insert them into the packing follower. 2 same-direction washers × 3 3 same-direction washers × 2 [For PTFE yarn] [For expanded graphite] Fig. 6-5. . Place the packing flange onto the packing follower. Apply anti-seizing agent Never-Seez made by Bostik Inc.
  • Page 36 (2/2) Step Procedure By tightening the gland nuts to the torque indicated in Table 6-4 or Table 6-5, the top of the packing flange and packing follower will be at almost the same level, as illustrated in Fig. 6-6 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 37: Application To Existing Control Valves

    6-5. Application to existing control valves If SECURE-SEAL 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 SECURE-SEAL may not be achieved. If scratches are found, replace the affected parts with new ones.
  • Page 38 6-10...

  • Page 39: Chapter 7. Troubleshooting

    Chapter 7. Troubleshooting This section covers the symptoms, causes, and remedies of problems that may occur. Parts may need to be replaced. For further assistance, please contact your an Azbil Corp. representative. Table 7-1. Troubleshooting Symptom Cause and remedy • Cv value is too large.
  • Page 40 Table 7-1. Troubleshooting Symptom Cause and remedy Sluggish valve operation or • Air leak from piping. inoperative valve. • Air leak from actuator. • Foreign matter trapped in guide section of valve plug. • Aged and hardened gland packing, causing increased hysteresis.

  • Page 41: Chapter 8. Recommended Spare Parts

    Chapter 8. Recommended Spare Parts It is recommended to replace the following parts when servicing the control valve. Valve body Replace the following parts whenever the valve body is disassembled: „ Gland packing „ Gaskets Actuator Replace the following parts approximately every 5 years: „...

  • Page 43: Appendix-A. Parts List

    Appendix-A. Parts List 1. Bonnet 1-1. Valve size: 6 inches Parts Name Body material Guide bushing material Remark Parts name Qty. Note Bonnet SCPH2/WCB SUS440C 82554662-111 Actuator type PSA3, 4 Bonnet SCPH2/WCB SUS316 stellite all over 82554662-131 Actuator type PSA3, 4 Bonnet SCPH2/WCB SUS316 UOP stellite...

  • Page 44: Valve Size: 10 Inches

    1-3. Valve size: 10 inches Parts Name Body material Guide bushing material Remark Parts name Qty. Note Bonnet SCPH2/WCB SUS440C 82554665-111 Actuator type HA4 Bonnet SCPH2/WCB SUS316 stellite all over 82554665-131 Actuator type HA4 Bonnet SCPH2/WCB SUS316 UOP stellite 82554665-181 Actuator type HA4 Bonnet SCS13A/CF8...

  • Page 45: Extension Bonnet

    2. Extension bonnet 2-1. Valve size: 6 inches Body Parts Name Guide bushing material Remark Parts name Qty. Note material Extension bonnet SCPH2 SUS440C 82554663-111 Actuator type PSA3, 4 Extension bonnet SCPH2 SUS316 stellite all over 82554663-131 Actuator type PSA3, 4 Extension bonnet SCPH2 SUS316 UOP stellite...

  • Page 46: Valve Size: 8 Inches

    2-2. Valve size: 8 inches Body Parts Name Guide bushing material Remark Parts name Qty. Note material Extension bonnet SCPH2 SUS440C 82554663-311 Actuator type HA4 Extension bonnet SCPH2 SUS316 stellite all over 82554663-331 Actuator type HA4 Extension bonnet SCPH2 SUS316 UOP stellite 82554663-381 Actuator type HA4 Extension bonnet...

  • Page 47: Valve Size: 10 Inches

    2-3. Valve size: 10 inches Body Parts Name Guide bushing material Remark Parts name Qty. Note material Extension bonnet SCPH2 SUS440C 82554666-111 Actuator type HA4 Extension bonnet SCPH2 SUS316 stellite all over 82554666-131 Actuator type HA4 Extension bonnet SCPH2 SUS316 UOP stellite 82554666-181 Actuator type HA4 Extension bonnet...

  • Page 48: Valve Size: 12 Inches

    2-4. Valve size: 12 inches Body Parts Name Guide bushing material Remark Parts name Qty. Note material Extension bonnet SCPH2 SUS440C 82554666-511 Actuator type HA4 Extension bonnet SCPH2 SUS316 stellite all over 82554666-531 Actuator type HA4 Extension bonnet SCPH2 SUS316 UOP stellite 82554666-581 Actuator type HA4 Extension bonnet...

  • Page 49: Valve Plug (With Valve Stem

    3. Valve plug (with valve stem) 3-1. Valve size: 6 inches plain bonnet Parts Name CV value Trim material Parts name Qty. Note Valve size (inches) Valve plug SUS316 82554658-111 Actuator type PSA3, 4 Valve plug SUS316 stellite all over 82554658-112 Actuator type PSA3, 4 Valve plug...

  • Page 50: Valve Size: 10 Inches Plain Bonnet

    3-5. Valve size: 10 inches plain bonnet Parts Name CV value Trim material Parts name Qty. Note Valve size (inches) Valve plug 1100 SUS316 82554660-111 Actuator type HA4 Valve plug 1100 SUS316 stellite 82554660-112 Actuator type HA4 Valve plug 1100 SUS316 stellite all over 82554660-113 Actuator type HA4...

  • Page 51: Valve Size: 12 Inches Extension Bonnet

    3-8. Valve size: 12 inches extension bonnet Parts Name CV value Trim material Parts name Qty. Note Valve size (inches) Valve plug 1580 SUS316 82554661-121 Actuator type HA4 Valve plug 1580 SUS316 stellite 82554661-122 Actuator type HA4 Valve plug 1580 SUS316 stellite all over 82554661-123 Actuator type HA4...

  • Page 52: Seat Ring

    4. Seat ring 4-1. Valve size: 6 inches Parts Name CV value Trim material Parts name Qty. Note Valve size (inches) Seat ring 450, 215 SUS316 82554357-101 Seat ring 450, 215 SUS316 stellite 82554357-102 Seat ring 450, 215 SUS316 stellite all over 82554357-103 Seat ring 450, 215...

  • Page 53: Gasket

    5. Gasket 5-1. Gasket for bonnet Parts Name Material Remark Parts name Qty. Note Valve size (inches) Gasket V543 PTFE For bonnet 82554484-101 Plain Gasket V543 PTFE For bonnet 82554484-201 Plain Gasket V543 PTFE For bonnet 82554484-301 Plain Gasket V543 PTFE For bonnet 82554484-401 Plain...

  • Page 54: Bottom Plate

    6. Bottom plate Parts Name Body material Material Parts name Qty. Note Valve size (inches) Bottom plate SCPH2, SCS13A, SCS14A SUS304 82554258-201 Bottom plate SCPH2, SCS13A, SCS14A SUS304 82554258-202 Bottom plate 10, 12 SCPH2, SCS13A, SCS14A SUS304 82554258-203 7. Plug guide Parts Name Body material Parts name...

  • Page 55: Grand Packing

    8. Grand packing 8-1. PTFE yarn (for regular service) Parts Name Packing Remark Stem dia Parts name Qty. Note Valve size (inches) Grand packing P4519 82553328-101 Actuator type PSA3, 4 Grand packing 8-12 P4519 82553944-101 Actuator type HA4 8-2. V type PTFE (for regular and oil free service) Parts Name Packing Remark...

  • Page 56: Grand Parts

    9. Grand parts 9-1. PTFE yarn (for regular service), Valve stem dia. 16 mm Parts Name Packing Remark Stem dia Parts name Qty. Note Valve size (inches) Packing follower SUS316 82553027-101 Actuator type PSA3, 4 O-ring (P22.4) Fluorine rubber 82592222-401 Actuator type PSA3, 4 O-ring (P16) Fluorine rubber...

  • Page 57: Type Ptfe Direct+Reverse (For Vacuum Service), Valve Stem Dia. 16 Mm

    9-5. V type PTFE direct+reverse (for vacuum service), Valve stem dia. 16 mm Valve size Parts Name Packing Remark Stem dia Parts name Qty. Note (inches) Packing follower SUS316 82553027-101 Actuator type PSA3, 4 O-ring (P22.4) Fluorine rubber 82592222-401 Actuator type PSA3, 4 O-ring (P16) Fluorine rubber 82592221-701...

  • Page 58: Other Parts

    10. Other parts 10-1. Packing flange Parts Name Packing Remark Stem dia Parts name Qty. Note Valve size (inches) Packing flange SCS13 82509513-264 Actuator type PSA3, 4 Packing flange 8-12 SCS13 82509514-201 Actuator type HA4 10-2. Stud bolt, nut (for grand parts) Parts Name Packing Remark Stem dia Parts name...

  • Page 59: Secure-Seal Certified Iso 15848-1 - Compliant Low Emission Gland Packing System

    11. SECURE-SEAL certified ISO 15848-1 – Compliant low emission gland packing system 11-1. For PTFE yarn (actuator: PSA3 or PAS4) Part name Actuator Material Part No. Qty. Main packing P4519 82553328- 101 Adapter packing P6720 82573475- 202 Carbon ring P6210C2FS 82573484- 007 Belleville spring SUS304...

  • Page 60: For Expanded Graphite (Actuator: Psa3 Or Psa4

    11-3. For expanded graphite (actuator: PSA3 or PSA4) Part name Actuator Material Part No. Qty. Main packing P6617CL 82573489- 007 Adapter packing P6720 82573475- 202 Carbon ring P6210 82573488- 007 Belleville spring SUS304 82559308- 102 O-ring (small) Viton 82592221- 797 O-ring (large) Viton 82592222- 497...
  • Page 62 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 63 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 65 Document Number: CM2-ADV100-2001 Document Name: CV3000 Alphaplus series Top-Bottom Guided Double Seated Model ADVB/ADVM User's Manual Date: 1st edition: Mar. 2001 6th edition: Apr. 2023 Issued/Edited by: Advanced Automation Company Address: 1-12-2 Kawana, Fujisawa kanagawa 251-8522 Japan URL: http://www.azbil.com/global/...

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