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Type 2000 / 2002 Replacement of Valve Kits and Seal Kits Wechseln von Ventil- und Dichtungssätzen Maintenance and Repair Instructions Wartungs- und Reparaturanleitung Pneutrol International Limited Unit 173 Argyle Industrial Estate, Argyle Street, Nechells, Birmingham B7 5TE www.pneutrolfluidcontrol.com sales@pneutrol.com Tel: +44 (0) 1213287288...
3 DesCription of parts ......................4 4 replaCe ValVe kit ........................6 4.1 Replace valve kit of actuator in Control Functions A, B and I (CFA/B/I) ....................6 5 replaCe seal kit.........................8 5.1 Replace seal kit of actuator Control Function A (CFA) ........8 5.2 Replace seal kit of actuator in Control Functions B and I (CFB / CFI) ........................12 6 tool kits ............................16 6.1 Assembly key ......................16 6.2 Mandrells ........................17 7 reCoMMenDeD aDjuVants ....................18 7.1 Product designations and manufacturers: ............18 2000/2002 - 1...
1 this Manual The maintenance and repair manual describes the procedure for changing valve kits and seal kits of process valve Models 2000 and 2002. Keep this manual where it will be available for every user and provided to every new owner of the control cabinet for chamber pressure regulation. Caution! The manual must be read and understood before work begins on changing valve kits and seal kits. Read the operating instructions carefully. In particular, follow the chapter “General safety information” 1.1 symbols The following symbols are used in these operating instructions: marks a work step that must be carried out. DanGer! means an immediate risk. If it is not avoided, serious injury or death will result. WarninG! means a possibly dangerous situation. If it is not avoided, death or serious injury may result. Caution! means a possibly dangerous situation. If it is not avoided, • light injury may result.
DanGer! • Hazard due to high pressure! Access of the facility will result in acute risk of injury. Disconnect the pressure before loosening lines and valves! • Power is applied to the system. Access will result in acute risk of injury. Always switch off the power before starting work! Observe all applicable accident protection and safety guidelines for electrical equipment. WarninG! • Unintended operation or impermissible damage can lead to dangerous situations including bodily harm. Take suitable measures to prevent unintentional operation or inadmissible damage. • Dangerous situations may occur during installation and maintenance work. These tasks may be performed only by authorized, trained personnel using suitable tools! • Use only original replacement parts when exchanging worn or defective parts. • Following a disruption to the electrical or pneumatic power supply, ensure that the process is re-started in a defined and controlled manner! Caution! The general rules of technology apply to the planning and operation of the Process valve! If you fail to observe these rules, injuries may result and/or the equipment or its surroundings may be damaged. Observe the general rules of technology! 2000/2002 - 3...
3 DesCription of parts Control function A (CFA) Control function B (CFB) 4 - 2000/2002...
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Control function I (SFI) Detail drawing: Packing gland pos. Designation Valve body Spindle Articulate plug graphite seal Nipple Wipper (part of packing gland) Pipe Reinforcement ring O-ring Actuator housing Packing gland including Pos. 7 und Pos. 39 Plugsprings Screw Volume filler Intermediate disc O-ring Piston Piston seal Support disc Position indicator Pressure spring Pressure spring O-ring Cover O-ring Pressure spring Part of packing gland Disc 2000/2002 - 5...
Caution! Open piston actuator care- fully – risk of accident from tensioned springs. • Unscrew actuator on the nipple (Pos. 6) from valve body (Pos. 1). • Insert articulate plug (Pos. 3) into V-block and punch out the seal pin (Pos. 4). • Remove articulate plug. • Put on new articulate plug (Pos. 3), align and lock with new seal pin (Pos. 4). • Permanently press bolt bore holes into the articulate plug to both sides with chisel or center punch. • Carefully remove old graphite seal (Pos. 5) from valve body (Pos. 1). Caution! Do not damage seat! • Insert new graphite seal (Pos. 5). • stainless steel body only: Grease over nipple thread (Pos. 6) with "Klüberpaste UH1 96-402". • type 2002 only: Use sealing tape. • Thightly fasten actuator with nipple in body 6 - 2000/2002...
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Caution! Observe torques (see table). • Cfa only: Refasten cover (Pos. 31) with special key • Examine valve on reliable operation and tightness. Table: Valve kits stainless steel body Gunmetal body type 2000 / 2002 type 2000 / 2002 ptfe- fkM- ptfe- fkM- seal seal seal seal order no. order no. order no. order no. 011 134 011 234 010 984...
1 Bürkert-mandrell (see Cap. "Tool kits") Caution! Do not use any pointed or sharp auxiliary means! notiCe! The actuator must be completely dismounted in order to allow to replace all the seals. The installation of the packing gland requires a special BÜRKERT-mandrell. Disassembly: • Hold valve on the body (Pos. 1) • Unscrew cover with special key (Pos. 31), while counter holding on hex nut of the actuator housing (Pos. 12). Detail drawing: Caution! Packing gland Open piston actuator care- fully – risk of accident from tensioned springs. • actuator sizes G-100 / h-125 mm only: remove disc (Pos 40). • Remove pressure springs (Pos. 28, 29). • Dismount position indicator (Pos. 26) with Allan key. • Unscrew actuator on the nipple (Pos. 6) from valve body (Pos. 1). 8 - 2000/2002...
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Old reinforcement ring (Pos. 10) remains on the pipe notiCe! (Pos. 8). • Take blunt tool and carefully slide packing gland kit (Pos. 7, 13-16 and 39) out of pipe (Pos. 8). • Thoroughly clean all individual parts after disassembly. installation: • Restructure packing gland kit according to drawing: - Grease over new wiper „OKS 1110-3“ and insert into pipe. - Thoroughly grease over every individual stern seal with “OKS 110-3” (spare grease of packing gland). - Place packing gland kit (Pos. 7, 13, 14, 15, 16 and 39) into pipe (Pos. 8) in correct order according to detail drawing. • Push packing gland kit into pipe (Pos. 8) until it stops, while holding on nipple (Pos. 6) and screwing in packing gland kit with screw (Pos. 18), then immediately remove screw (pos. 18). • Place actuator housing (Pos. 12), plug springs (Pos. 17) and screw (Pos. 18) onto pipe (Pos.8). • Firmly tighten screw (Pos. 18) with wrench, thus observing the centric position of the plug springs (Pos. 17). • Slightly grease over spindle (Pos. 2) with OKS 1110-3 and plug appropri- ate mandrell on spindle thread. 2000/2002 - 9...
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• Tighten nut (Pos. 25) with wrench and mount position indicator (Pos. 26). • Hold valve body (Pos. 1). • Replace graphite seal (Pos. 5) Caution! Do not damage the seal edges when removing the seal! • stainless steel body only: Grease over nipple thread (Pos. 6) with “Klü- berpaste UH1 96-402”. • Screw nipple (Pos. 6) and actuator into valve body (Pos. 1), observe torque according to table 9. • type 2002 only: use seal tape. • Insert spring (Pos. 28/29). • actuator sizes G-100 / h-125 mm only: Insert disc (Pos. 40). • Replace O-ring (Pos. 32), thus unscrewing transparent cap. • Slightly grease over cover thread (same grease as for actuator housing). • Put on cover (Pos. 31) and refasten with special key. • Examine valve on reliable operation and tightness. 10 - 2000/2002...
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007 768 Tabelle: Seal kits of PA-actuator type 2000 / 2002 actuator Ø Gunmetal body stainless steel body [mm] order no. order no. C-40 13/20/25 643 438 D-50 13/20/25 011 308 011 369 E-63 25 - 50 011 334 011 372 F-80 25 - 65 011 366 001 902 G-100 32 - 65 007 763 011 386 H-125 40 - 65 011 368 011 387 2000/2002 - 11...
The actuator must be completely dis- mounted in order to allow to replace all the seals. The installation of the packing gland requires a special BÜR- KERT-mandrell. Disassembly: • Hold valve on the body (Pos. 1). • Unscrew cover with special key (Pos. 31), while counter holding on hex nut of the actuator housing (Pos. 12). Caution! Open piston actuator care- Detail drawing: fully – risk of accident from Packing gland tensioned springs. • actuator sizes 100/125mm only: remove disc (Pos. 40). • Dismount position indicator (Pos. 26) with Allan key. • Unscrew actuator on the nipple (Pos. 6) from valve body (Pos. 1). • Carefully hold actuator on the articu- late plug (Pos. 3) between the bore holes(thus only putting pressure on the upper part of the articulate plug). • Unfasten nut (Pos. 25). 12 - 2000/2002...
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Old reinforcement ring (Pos. 10) remains on the pipe notiCe! (Pos. 8). • Take blunt tool and carefully slide packing gland kit (Pos. 7, 13-16 and 39) out of pipe (Pos. 8). • Thoroughly clean all individual parts after disassembly. installation: • Restructure packing gland kit according to drawing. • Grease over new wiper with “OKS 1110-3” and insert into pipe. • Thoroughly grease over every single stem seal with “OKS 1110-3” (spare grease of packing gland). • Place packing gland kit (Pos. 7, 13-16 and 39) in the pipe (Pos. 8) in correct order according to detail drawing. • Push packing gland kit into pipe (Pos. 8) until it stops, while holding on nipple (Pos. 6) and screwing in packing gland kit with screw (Pos. 18), then immediately remove screw (pos. 18) • Place actuator housing (Pos. 12), plug springs (Pos. 17) and screw (Pos. 18) onto pipe (Pos.8). • Firmly tighten screw (Pos. 18) with wrench, thus observing the centric position of the plug springs (Pos. 17). • Slightly grease over spindle (Pos. 2) with “OKS 1110-3” and plug appro- priate mandrell on spindle thread. 2000/2002 - 13...
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• Hold body (Pos. 1). • Replace o-ring (Pos. 32), thus removing transparency cap. • Replace o-ring (Pos. 30). • Slightly grease over cover thread (same grease as for actuator housing) • Replace graphite seal (Pos. 5). Caution! Do not damage the seal edges when removing the seal! • stainless steel body only: Grease over nipple thread (Pos. 6) with “Klü- berpaste UH1 96-402”. • Screw nipple (Pos. 6) and actuator into valve body (Pos. 1), observe torque according to table 12. • type 2002 only: Use seal tape. • Insert springs (Pos. 28/29). • actuator sizes G-100 / h-125 mm only: Insert disc (Pos. 40). • Put-on cover (Pos. 31) and refasten with special key. • Examine valve on reliable operation and tightness. 14 - 2000/2002...
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H-125 40 -65 007 764 007 768 Table: Seal kit of PA-actuator type 2000 / 2002 actuator Ø Gunmetal body stainless steel body [mm] order no. order no. D-50 13/20/25 011 308 011 369 E-63 25 - 50 011 334 011 372 F-80 25 - 65 011 366 001 902 G-100 32 - 65 007 763 011 386 H-125 40 - 65 011 368 011 387 2000/2002 - 15...
7.1 product designations and manufacturers: These instructions recommend the following adjuvants for the impeccable maintenance and repair of the device: type of product Manufacturer and internet adjuvant designation address Sealing and Multi-Silikonfett OKS OKS Schmierstoffe GMBH anti-blocking 1110 www.oks-germany.com agent Lubricant Lagermeister SL FUCHS LUBRITECH GmbH www.fuchs-lubritech.de Lubricant AMBLYGON TA 30-1 Klüber Lubrication München KG www.klueber.de Klüberpaste UH1 Lubricant Klüber Lubrication München KG 96-402 paste www.klueber.de Liquid glue LOCTITE 274 Henkel Loctite Deutschland GmbH www.loctite.de 18 - 2000/2002...
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Steuerfunktion A (SFA) ..................26 5.2 Wechsel des Dichtungssatzes bei Antrieb mit Steuerfunktion B und I (SFB / SFI) ..............30 6 werkzeugsätze........................34 6.1 Montageschlüssel ......................34 6.2 Montagehülsen ......................35 7 empfohlene hIlfsstoffe ....................36 7.1 Produktbezeichnungen und Hersteller: ..............36 2000/2002 - 19...
1 DIese anleItung Die Umbauanleitung beschreibt die Vorgehensweise für den Wechsel von Ventil- und Dichtungssätzen der Prozessventile Typ 2000 und 2002. Bewahren Sie diese Anleitung so auf, dass sie für jeden Benutzer gut zu- gänglich ist und jedem neuen Eigentümer des Gerätes wieder zur Verfügung steht.
2. allgemeIne sIcherheItshInweIse hInweIs! Die Prozessventile der Typen 2000 und 2002 wurden unter Einbeziehung der anerkannten sicherheitstechnischen Re- geln entwickelt und entsprechen dem Stand der Technik. Trotzdem können Gefahren entstehen. Betreiben Sie die Ventile nur in einwandfreiem Zustand und unter Beachtung der Betriebsanleitung.
• Neue Graphit-Dichtung (Pos. 5) einle- gen. • nur bei Va-gehäuse: Nippelgewinde (Pos. 6) mit "Klüberpaste UH1 96-402" einfetten. • nur bei typ 2002: Dichtungsband verwenden. • Ventilantrieb mit Nippel fest in das Gehäuse einschrauben. VorsIcht! Beachten Sie das Drehmoment (siehe Tabelle) 24 - 2000/2002...
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• Nur bei SFA: Deckel (Pos. 31) mit Spezialschlüssel wieder fest verschrauben. • Ventil auf Funktion und Dichtheit prüfen. Tabelle: Ventilsätze Va-gehäuse rg-gehäuse typ 2000 / 2002 typ 2000 / 2002 ptfe- fkm- ptfe- fkm- Dichtung Dichtung Dichtung Dichtung best.- nr.
• nur bei antriebsgröße g-100 und h-125 mm: Scheibe (Pos. 40) entnehmen. • Druckfedern (Pos. 28, 29) entnehmen. • Stellungsanzeige (Pos.26) mit Innen- sechkantschlüssel demontieren. • Antrieb am Nippel (Pos. 6) aus Ventil- gehäuse (Pos. 1) schrauben. 26 - 2000/2002...
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(pos. 18) sofort wieder entfernen. • Laufbuchse (Pos. 12), Tellerfedern (Pos. 17) und Schraube (Pos. 18) auf Rohr (Pos. 8) aufsetzen. • Schraube (Pos. 18) mit Steckschlüssel fest verschrauben; dabei auf zen- trische Lage der Tellerfedern (Pos. 17) achten. 2000/2002 - 27...
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• nur bei antriebsgröße g-100 / h-125: Scheibe (Pos. 40) einsetzen. • O-Ring (Pos. 32) wechseln, dazu Klarsichthaube abschrauben. • Deckelgewinde leicht einfetten (Fett wie bei Laufbuchse). • Deckel (Pos. 31) aufsetzen und mit Spezialschlüssel festschrauben. • Ventil auf Funktion und Dichtheit prüfen. 28 - 2000/2002...
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Tabelle: Drehmomente werkstoff Drehmoment nippelgewinde [mm] (Richtwerte) [Nm] Messing oder Edelstahl Tabelle: Dichtungssatz PPS-Antrieb Typ 2000 / 2002 antrieb Ø [mm] rg-gehäuse Va-gehäuse best.- nr. best.- nr. D-50 13/20/25 011 373 011 388 E-63 25 - 50 007 765 007 766...
• Stellungsanzeige (Pos.26) mit In- nensechkantschlüssel demontieren. • Antrieb am Nippel (Pos. 6) aus Ventil- gehäuse (Pos. 1) schrauben. • Antrieb am Pendelteller (Pos.3) zwi- schen den Bohrungen vorsichtig ein- spannen (dabei nur den oberen Bereich des Pendeltellers belasten). 30 - 2000/2002...
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, schraube (pos. 18) sofort wieder entfernen. • Laufbuchse (Pos. 12), Tellerfedern (Pos. 17) und Schraube (Pos. 18) auf Rohr (Pos. 8) aufsetzen. • Schraube (Pos. 18) mit Steckschlüssel fest verschrauben; dabei auf zentrische Lage der Tellerfedern (Pos. 17) achten. 2000/2002 - 31...
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• nur bei typ 2002: Dichtungsband verwenden. • Federn (Pos. 28/29) einsetzen. • nur bei antriebsgröße g-100 / h-125: Scheibe (Pos. 40) einsetzen. • Deckel (Pos. 31) aufsetzen und mit Spezialschlüssel festschrauben. • Ventil auf Funktion und Dichtheit prüfen. 32 - 2000/2002...
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Tabelle: Drehmomente werkstoff Drehmoment nippelgewinde [mm] (Richtwerte) [Nm] Messing oder Edelstahl Tabelle: Dichtungssatz PPS-Antrieb Typ 2000 / 2002 antrieb Ø [mm] rg-gehäuse Va-gehäuse best.- nr. best.- nr. D-50 13/20/25 011 373 011 388 E-63 25 - 50 007 765 007 766...