J) metso automation IMO - 11 INSTALLATION, MAINTENANCE, AND [-———— OPERATING INSTRUCTIONS Issue Date: 11/01 CLINCHER’ VALVES 1/4” - 2” (DN 15 --50) SERIES 2000 Read ene inswucton careful before instalation servicing 1 GENERAL This instruction manual contains important information regarding the installation, operation and maintenance of the Jamesbury CLINCHER Valves 1/4" - 2" (DN 15 - 50) Series 2000, Please read these instructions carefully and save them for future reference. 1.1. WARNING SAFETY FIRST FOR OUR SAFETY, TAKE THE FOLLOWING PRE- CAUTIONS BEFORE REMOVING THE VALVE ASSEMBLY FROM ‘THE LINE, OR BEFORE ANY DISASSEMBLY. 1. WHAT'S INTHE LINE? BE SURE YOU KNOW WHAT FLUID IS INTHE LINE. IF THERE |S ANY DOUBT, DOUBLE CHECK WITH THE PROPER SUPER- VISOR, 2. ARE YOU PROTECTED? WEAR ANY PROTECTIVE CLOTHING AND EQUIPMENT NORMALLY REQUIRED TO AVOID INJURY FROM THE PAR- TICULAR FLUID IN THE LINE, 3. ISTHE LINE DEPRESSURIZED? [DEPRESSURIZE THE LINE AND DRAIN THE SYSTEM FLUID. CYCLE THE VALVE SEVERAL TIMES TO RELIEVE ANY PRES- ‘SURE STILL INSIDE THE VALVE, 4. CYCLE THE VALVE SEVERAL TIMES AGAIN AFTER REMOVAL FROM THE LINE, 2 INSTALLATION ‘The CLINCHER may be installed for flow in either direction, Screwed end valves have NPT threads.To insure leaktight joint, iberal use of a compatible pipe joint compound is necessary. To ensure that a good installation is achieved, follow standard piping practices. When tightening valve to pipe, apply wrench to end nearest pipe being worked. ‘After valve is in line, or before testing, tighten stem nuts (16) according to the MAINTENANCE Section. 3 MAINTENANCE 1. General Maintenance consists of periodically tighten- ing the lower stem nut (16) to the values shown in (Table 1). Ths is to compensate for the wear caused by the stem turning against the stem seals and may be done as follow: ‘A. Manual Valves - Loosen the handle nut (16) and tighten the lower stem nut (16) to the value shown in (Table 1). Retighten the handle nut (16) to the same value. B. Actuated Valves - When valves are connected to {an actuator, refer to the applicable actuator mounting instructions (AMI) prior to adjusting the stem nut. 2. Overhaul maintenance consists of replacing seats and seals, A standard service kit consisting of these parts ‘may be obtained from your Jamesbury Inc. Distributor. Refer to the REPAIR KITS/SPARE PARTS Section.TABLET ‘Stem Nut (Item 16) Assembly Torque ‘Valve Size — Inches (mm) ‘Torque — tin (Nm) 4 — 3/4 (ONG 20) 3004) 1 = 1-1/4 (0N25 -30) 7018) 15172 = 2 (ON 40-50) 160 (18) 3.1 Disassembly - (Refer to Figure 1) |. Read the instructions in the WARNING Section. Place the valve in the open position. Remove the stem nut (16),shakeproof washer (19),and_ handle (17). 4, Remove the lower stem nut (16) and remove and dis- ‘card the old disc spring washers (31) if present. 5. Remove the top ground springs (70) (brass valves only). Remove the compression ring (21). = Unfasten the four body bolts (52) and remove the body cap (2). 8 Turn the stem (4) so that the valve is fully closed. 9. Remove the ball (3). 10, Remove and discard the body seal (6) and seats (5). 11, Press the stem (4) from the top into the valve body and remove it through the end of the body. 12. Using a pointed instrument, pry out and discard the old stem seals (8) and (24), and the secondary seal (7) in fire-tested valves, BEING CAREFUL NOT TO SCRATCH ANY SEALING SURFACES IN THE VALVE BODY. 2. Assembly - (Refer to Figure 1) 1. Clamping the body (1) securely in a vise, drop in one seat (5) with the fiat surface on the bottom. 2. a) STANDARD: Insert the lower stem seal (7) from the inside, Insert the upper stem seal (8) from the out- side of the valve. NOTE: In standard valves these two seats are identical. bb) FIRE-TESTED: From the insert secondary stem seal (7) fist and then red-tinted lower stem. seal (24). Insert the upper stem seal (8) from the outside of the valve. 3. Insert the stem (4) through the flanged end of the body (1), and, being careful not to scratch the seals, press it gently up into the stem hole. DO NOT attempt to push the stem all the way up into place. Push it up only until you encounter resistance from the lower seal. 4, Holding the stem in place from the bottom, drop on the compression ring (21),top ground spring for brass CLINCHER, and the two disc spring washers (31) and screw on one stem nut (16). NOTE: Disc Spring washers have been eliminated on 1/4"- 3/4" ON 6 - 20) sizes, and should only be used if present on existing valves. For all sizes with Monet” trim or for chlorine service, these washers are not used. 5, Tighten down the nut (16) to the value shown in (Table 1). 6. Insert the ball (3), rotating it onto the stem (4) in the. closed position, If necessary, turn the stem blade to align with the ball slot. 7. Insert the body seal (6) and gently press it into the ‘groove in the body. ‘As shown in Figure 2, there is a substantial size difference between the brass and steel CLINCHER standard body seals. They are not interchangeable. ‘8. Insert the second seat (5) in the body cap (2) so that the sealing surface of the seat is towards the ball (see detailed diagram in Figure 1). 9. NOTE: The handle stop is part of the body cap (2). When assembling the valve, be sure the handle stop that projects from the body cap is in the upper right hand corner as the body cap faces you (see Figure 1). Join the body (1) and body cap (2) by inserting the four body bolts (52).Bolt heads should be on the body cap. 10. Screw on the four hex nuts (53) with the four lock- washers (55) until they are snug. NOTE: 4449 carbon steel body bolts do not use lockwash- ers. Be careful to see that the body and cap are properly aligned. Using 2-Ib-ft increments, tighten the bolts alter- nately in a diagonal pattern until the torques shown on page 3 are met. DO NOT TIGHTEN ONE NUT COMPLETELY, THEN PROCEED ‘TOTHE NEXT. 11. Install the handle (17), the shakeproof washer (19),and, the second stem nut (16) and tighten. IMPORTANT NOTE: With the valve in the closed position, the handle curves up and to the left as the body cap (2) faces you (refer to Figure 1). The extended edge of the handle should just touch the handle stop on the cap. 12. Cycle the valve slowly twice to insure permanent posi- tioning of the ball between the two seats.PARTS RECOMMENDED TORQUES FOR BODY BOLTS Tm BESCRINON Cad Valve Size Torq fo hm) 1 | eoay 1 inchesimm) _|ESealoy eons | 30055 Bakr 2 | Sade can : ve=rione-29 | 206 795) t | Sem ' N20 00 1500 5 | Se Fl fie —7onwo-so] ssn 7707) ™ ‘Secondary Seal 1 “identified by (2) bolt head marks at 90°.ie: @) © | ieee ' te | stmt 2 | pane ; 1 | Shkeproot washer : 2, | Conprenion ig ' ie | nerstemsea ' Si | Dac Spina Washer 2 32 | Boop bor i 5 | techn ‘ . St | Ucwanen ‘ Jot_| Topcon Sing ' > Upper and ower stem sa ae enc in Serdar rete ahs nt ‘* Nateguredon aves wth MONEL timo ‘aves roe svc + Setpewin ast ot E btsswhes oo Ione vier raderakcf NCO, EXPLODED VIEW ; pay auc ea Seat shout be NO tbe png wanes a os in this position ° ‘shown. Tighten g ® ‘upper ight when Figure 14 SERVICE KITS Service kits contain one pair of seats, a body seal,a pair of stem seals, and a pair of dise spring washers." Kits for fire- tested valves also include a secondary stem seal Kits for standard valves include both A and B body seals (Figure 2). The body gasket is suitable for valves with carbon steel or stainless steel trim. Consult the factory for replacement Parts of valves with trim other than carbon or stainless steel, and for seat materials not listed or for special services ‘When ordering service kits, seat and seal material must be specified. For example, a kit for a 1” (ON 25) standard CUNCHER valve with filled PTFE seats and PTFE seals, should be ordered as: RKC23MT.* NOTE: Disc spring washers have been eliminated on 1/4" - 3/4" (DN 6 - 20) sizes, and should only be used if present on existing valves. 5 REPAIR KITS/SPARE PARTS For further information on spare parts and service or assistance vist our web-site at www.jamesbury.com Valvesize | 14"(0N6) | 3/@°(ON10) | 1/2"(0N15) | 3/4"(0N20) | 1°(DN25) |1-114"(0N30)|1-1/2"(0N-40)| 2°(0N SO) Standard raczi ret] xc ert mca, Pace xcs raC26 Fire-Tested xcs acs Pacis rac. xc rxc18. rac rxc20 ‘Add To Kit Number: TT = PTFE Seats and Seas or MT = Filed PTFE Seats and PTFE Seals BODY SEALS a 8 c Bras Standard Stee standard Steel Fre Tested Figure 2 Metso Automation Field Systems Division Europe, Levi 6 PO.B0x:310, 00811 Helsinki Finland Tl int +358 20 483 150, Faxint. +358 20-483 151 (UK). 8 Pipers Wood Industrial Park Waterloovile, Hampshire PO7 7XU UX. Tel nt +44 (0)23 9223 8500. Faxint. +4 0)23 9223-8510 North America, 44 Bowditch Drive, PO.Box 804, Shrewsbury Massachusetts, 01545-8044 USA, TeL.int.+1 S08 8520200. Faxint+1 508 852 8172 "North America, 3100 Medioc Bridge Road, Suite 250, Norross,GA 30071, USA. TeLnt+1 70446 7818 Fx int +1 770 242 6386 Latin Americ, Av Central, 181-Chéracas Reunidas, 12238430, S30 Jose dos Campos, Te.int. +55 12335 3500. Faxint. 455 12.335 3535. ‘Asa Pacific 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel int. +65 7355200. Fax int. 65735 2955 wow jamesbury.com metso automation mosaye (©2001 Mets Automation Pitedin USA