USER`S MANUAL
Contents
1. Model 01 05 83A 83 89 CIS GU A 8 2 Operating Disassembling and Re assembling of Top Mounted Handwheel 8 2 1 Operating 1 Don t operate Handwheel under perssure loading to Actuator 2 To operate Actuator manually release Handle Lock that restrains Handle grasp the grip tightly and then turn Handle Turning Handle clockwise to lower Top Stem in either case Actuator is direct or reverse acting type 3 To return to automatic operation turn Handle counterclokwise on direct acting Actuator until the Spindle is raised fully up to its thread limit so that Pointer points to OPEN on Indicator Scale and then lock Handle Lock On reverse acting Actator turn Handle clockwise until screw Shaft is depressed fully down to the thread limit so that Pointer points SHUT on Indicator Scale and then lock Handle Lock D Be sure to operate Handle manually and do not give any excessive force CAUTION by tools such as Handle turning device etc In any case such a further turning may cause deformation or damage of related parts 8 2 2 Disassembling and Re assembling 8 2 2 1 Direct Acting Actators See Fig 8 4 1 Disconnect air piping 2 Trun Handle to move Spindle up fully and put the position in automatic operation 3 Remove Diaphragm Cover Hadle Handle Lock and Spindle in order This completes disassembling of Top mounted Handwheel 4 When re assembling reverse the order of the disassembl2. Stopper Union Washer Union Nut Diethread Lock Nut 2 Union Hexagon Nut 3 Union Nut 3 Washer Lock Nut Seat Bearing Hexagon Socket amp Set Screw Oil Seal No Part Name D Spring Case Seat No Part Name D Bonnet Spindle Adjuster pinala amp Bush Grease Head Screw Diaphragm Cover Limiter Diaphragm Union Nut Diaphragm Plate Lock Nut Stem Lock Nut 2 Washer Washer 5 3 Seat Bearing Diethread Hexagon Socket 2 O Ring Set Screw 3 Lock Nut Oil Seal 33 34 Model 01 05 83A 83 89 IMOTOYAMAN m Bellows Seal Type Valve Two types of metal bellows formed bellows and welded bellows are used in MOTOYAMA Control Valves Bellows should be replaced in proper intervals according to the status of Control Valves operations When replacement of bellows required please contact MOTOYAM sales office At this time kindly inform us valve serial number to choose correct bellows To change bellows kindly reffer following procedure together with chapter 5 and 6 Never rotate Valve Stem Bellows would be twisted and damaged A CAUTION 2 When disassembling replace Gaskets on top and bottom of Bellows Washer and Gland Packing with new ones 10 1 Split of Actuator from Valve Body See Fig 10 1 1 Place fitting mark on each connecting parts before disassembling 2 On
3. This catalog is supplied for information purpose only and should not be considered certified marketability and conformability of this product MOTOYAMA is continuously improving and upgrading its product design specifications and or dimensions Information included herein is subject to change without notice A KURIMOTO LID Company 3 MOTOYAMA ENG WORKS LTD http www motoyama cp co jp lll Head Office and Factory 5 2 Ohira Aza Kameoka Ohira mura Kurokawa gun Miyagi ken 981 3697 Japan TEL 81 22 344 4511 FAX 81 22 344 4522 H Overseas Marketing amp Sales Dept 5 2 Ohira Aza Kameoka Ohira mura Kurokawa gun Miyagi ken 981 3697 Japan TEL 81 22 344 4546 FAX 81 22 208 5020 2015 08 MSP
4. Lift Stopper Lift Stopper 2 3 og Diestat ley Ring Diethread Somby Spring Washer Flat Washer O Ring Hexagon Nut Spring Washer 9 Bolt Spring Guide Hexagon Nut 9 Besta O Ring Holder K P C I Spring Guide W i Stem Connection N33 N40 No Part Name Top Stem O Stuffing Box Locking Plate Guide Seal Packing Dust Seal Model 01 05 83A 83 89 CIS GU A Fig 5 8 Model 3800 Direct Acting Actuator Cover Hexagon Bolt Eye Bolt c Air pipe connector f Top Stem Lift stopper Spring Hexagon Nut Case Assembly Fig 5 9 Model 3800 Reverse Acting Actuator Exh cap Cover Hexagon Bolt Exh hole Lift stopper Top Stem Hexagon Nut Case Assembly Model 01 05 83A 83 89 IMOTOYAMAN 5 4 Disassembling and Re assembling Model 2800 Actuator This Single Spring Type Diaphragm Actuator requires no site adjustment To modify Actuator or parts replacement disassemble or re assemble as follows See Fig 5 10 to 5 11 for reference Actuator should be placed vertically to disassemble or re assemble WARN NG Before disassembling be sure Actuator operating pressure to be zero 0 to prevent accident 5 4 1 Disassembling 5 4 1 1 Direct Acting Actuator Put matching mark on Cover and Diaphragm Case
5. Remove air pipes and accessories w Loosen Adjust Screw to completely free springs Loosen and remove Diaphragm Clamping Bolt and Nut O1 Remove Cover O Pull out Diaphragm Assembly upward Take out Springs pr Dp a as P 8 Inspect disassembled parts for damage deformation corrosion or paint flaking 5 4 1 2 Reverse Acting Actuator 1 2 3 4 Put matching mark on Cover and Diaphragm Case Remove air pipes and accessories Remove Cap and loosen Adjust Screw to completely free springs Loosen and remove Diaphragm Clamping Bolt and Nut Remove Cover attached Spring Case Pull out Springs Seat Bearing Ball and springs 7 8 Pull out Diaphragm Assembly upward 1 2 3 4 5 6 7 8 Inspect disassembled parts for damage deformation corrosion or paint flaking 5 4 2 Re assembling 5 4 2 1 Direct Acting Actuator 1 2 3 4 Place Springs on Spring Seat Insert Top Stem of Diaphragm Assembly into Bush of Adjust Screw Place Cover over the Case and tighten Bolts evenly Lo Yer E Connect air piping to Air Connector on Cover Model 01 05 83A 83 89 CIS GU A 5 4 2 2 Reverse Acting Actuator 1 Insert Top Stem of Diaphragm Assembly into Stuffing Box of Case Assembly Pay attention to avoid damage to seal When inserting Top Stem into Stuffing Box pay attention to Guide or Seal A
6. 2 years Actuator Once in every 5 years Disassemble Valves and check internal parts See Chapter 5 WARNING When leakage is found from the Valve or piping Do Not Touch or Access to the fluid until the safety is confirmed by proper responsible person Model 01 05 83A 83 89 CIS GU TA 5 Disassembly amp Assembly Following is recommended procedure to disassemble or re assemble valves D Please prepare following spare parts available before disassembly Gland Packing Gasket Packing Do not reuse the used Gland Packing Gasket Packing 2 Prepare required Tools in advance CAUTION 3 Never disassemble Valves on system under existing inside pressure or A before cooling down of Valves completely 4 Do not turn Valve Stem when Valve is closed 5 On Model 2800 spring diaphragm Actuator Do Not Turn Spring Adjuster Turning of Spring Adjuster makes change of Spring Range limit upper and lower 5 1 Split of Actuator from Valve Body See Fig 5 1 WARNING To disassemble Valves on system line Close the line and Release all the system pressure in advance 1 Place fitting mark on each connecting parts before disassembling 2 Hold Valve Plug at full open position depressurizing supply pressure to zero on direct action Actuator or supplying Air pressure on reverse action Actuator 3 Loosen Stem Nut and Pointer together and go downward then lock On Actuator size N33 and larger
7. 89 IMOTOYAMAY Table 7 2 Identification and quantity of spring used for Model 3800 Actuator Actuator Size N24 N28 N33 N40 Paint Color Black Blue Green Black Item Quantity of Quantity of Quantity of Quantity of Springs ID Color Springs ID Color Springs ID Color Springs ID Color Type Type Type Type Spring Range 15 4 A None 4 B None 4 D Yellow two band 4 F Red two band 20 100kPaG 20 4 A Red one band 4 B Black one band 4 D Brown two band 4 F Green two band 25 4 A Puple one band 4 B Purple one band 4 D Blue two band 4 F Silver two band s 1 0 38 6 C Red two band 4 D None 4 F White one band kgf cm G 50 4 D Purple one band F None 65 4 F Purple one band 15 4 A Blue one band 4 B Red one band 4 D White one band 4 F Blue two band 40 200kPaG 20 4 A Yellow one band 4 B Yellow one band 4 D Silver two band F Brown one band 25 4 A Brown one band 4 B Brown one band 4 D Black one band 4 F Red one band bes 2 0 38 6 C White two band 18 E None 18 G White one band kgf cm G 50 18 E Purple one band 18 G None 65 18 G Purple one band 15 4 White one band B White one band 4 D Purple two band 4 F White two band 20 4 A Green one band 4 B Green one band 4 D Red two band 4 F Brown two band 80 200kPa
8. Actuator to ORPaG Okgf cm G to let Valve Plug seat on the seating surface and set pointer position to indicate SHUT position 7 Increase decrease air pressure to the Actuator to check the valve operation to open or close smoothly Table 6 1 Rotations of Valve Stem for Model 3800 Actuator Mounted Control Valves Number of Rotations Valve Travel mm 25 38 50 65 Stem Screw Pitch Decimal Fractional Decimal Fractional Decimal Fractional Decimal Fractional Actuator Size Number Number Number Number Number Number Number Number N24 M9 1 25 12 11 4 N28 M9 1 25 12 11 4 1 6 13 N33 M12 1 75 0 86 n 1 14 1140 1 43 1 N40 M18 2 0 0 75 3 4 1 0 1 1 25 11 4 1 75 1 Adjustment Allowance mm 1 5 2 0 2 5 3 5 Model 01 05 83A 83 89 CIS GU A 6 2 Test After valve is assembled and adjusted check followings to assure integrity of the valve 1 2 3 4 Appearance Leakage from Actuator air piping connection Shell tightness of Valve Body YS He OH Operating performance Change of Valve Action and Actuator 7 1 Purpose Sometimes change of valve action stroke or spring would be required at site to cover the change of operating condition process condition or control condition To change valve action and Actuator follow the procedure below 7 2 Change of Valve Action 7 2 1 Model 3800 Actuator Mounted Valves Valve Body is
9. Before disassembling turn Handle till Indicator See Fig 8 1 reaches NEUTRAL position 2 Disassembling side mounted Handwheel in proper order See Fig 8 2 and Fig 8 3 3 When re assembling reverse the order of the disassembling Apply anti seize gleese to the threaded parts such as NEVER SEEZ 4 After Handwheel is assembled check movement to be smooth over entire stroke 27 Model 01 05 83A 83 89 IMOTOYAMAN Fig 8 2 Size 500 D R Side mounted Handwheel on Model 2800 Actuator Direct Action Reverse Action 1 z o Part Bush Adjuster Top stem Sleeve Diaphragm Plate Diaphragm Diaphragm Case Diaphragm Cover Worm Wheel 9o Body Cap Spindle Nut Indicator Plate Handle Fig 8 3 Size 650 D n Side mounted Handwheel on Model 2800 Actuator Direct Action Reverse Action i z o Part Adjust Flange Spring Case Sleeve Adjuster Top Stem Sleeve Diaphragm Plate Diaphragm Diaphragm Cover Diaphragm Case Body Worm Wheel Bearing Holder Indicator Pointer Indicator Plate 9060960 Attachment S Handle Indicator Disc
10. CAUTION Packing etc not to damage by Top Stem tip etc Otherwise leak may occur 2 Place Springs on Diaphragm plate and then place Spring Seat and Bearing Ball 3 Place Cover and tighten Bolts evenly 4 Screw in Adjust Screw until it contacts to the Springs 5 Connect air piping to Air Connector on Yoke i P 5 4 3 Adjustment and Checking after Assembling 1 Attach a pressure gauge or manometer to air piping Turn Adjust Screw to tighten springs and gradually apply air pressure observing pressure indicator Adjust clamping force of springs so that Top Stem starts to move right at the starting pressure of the spring range 2 For reverse acting Actuator adjust the spring range first and then lock Adjust Screw and screw Cap in 3 Apply air pressure of 350kPaG 3 5kgf cm G from Air Connector and check leakage from outer edges of Diaphragm Case and Cover using forming agent 4 Reciprocate Actuator to check that it smoothly operates over the entire stroke Both Actuators Model 3800 and Model 2800 are spring incorporated type A CAUTION When disassembling follow the procedures described in this instruction Manual strictly Otherwise Spring may be popped out strictly 19 20 Model 01 05 83A 83 89 CIS GU TA Fig 5 10 Model 2800 Direct Acting Actuator Air Connector Cover Diaphragm Assembly note a Diaphragm Assembly Bolt Nut
11. direct action Actuator reduce air pressure to be OkPaG Okgf cm G on reverce acting Actuator apply air pressure to Actuator to keep Valve Stem at full open position Hold flat face of Tee Head and lossen Stem Nut Holding Tee Head loosen Tee Head Retainer to disconnect Valve Stem from Top Stem See Fig 10 1 B Loosen and remove York Nut York Bolt Lift up Actuator straight up and remove from Valve Body 3 4 5 6 wea Fig 10 1 Stem Coupling Portion Top Stem Top Stem Stem Coupling Tee Head Retainer Tee Head Pointer Stem Nut Valve Stem Valve Stem Model 01 05 83A 83 89 IMOTOYAMAN 10 2 Disassembling and Re assembling of Formed Bellows Assembly See Fig 10 2 10 2 1 Diasssemling of Formed Bellows Assembly 1 Loosen Bonnet tightening Nut to free Bonnet At this time check that process fluid is not leaking inside of Bonnet 2 3 4 5 Place a Lock Nut top face position marking on Valve Stem with a scriber Hold Nut and loosen and remove Lock Nut to take out Seal Ring and Bellows Assembly from Valve Stem On push down close Valve Body loosen Nut that tighten Adaptor Spool and remove Adaptor Spool On the push down open Valve Body Model 01 and Model 05 loosen Nut that tigten Bottom Cover and remove Bottom Cover and Valve Plug Then remove Adapter Spool 2 3 4 5 Fig 10 2 Formed Bellows Seal Type Bellows
12. other than 20 100kPaG 0 2 to 1 0kgf cm G cover Spring Guides over the Spring 2 Insert Top Stem of Diaphragm Assembly into Stuffing Box of the Case Set Lift Stopper to the direction of the Clamping Bolt in the Case 3 Place Cover on Case by aligning with Air Connector and tighten two Eye Bolts at specified places evenly 4 Put Hexagon Bolts in the remaining places and tighten Case and Cover evenly 5 Connect air piping to air pipe connector on Cover 5 3 2 2 Reverse Acting Actuator 1 Insert Top Stem of the Diaphragm Assembly into Stuffing Box of Case Assembly Pay attention to avoid damage to the seal When inserting Top Stem into Stuffing Box pay attention to Guide or Seal A CAUTION Packing etc not to damage by Top Stem tip etc Otherwise leak may occur 2 Place springs on Spring Guides in Diaphragm Assembly See Fig 7 2 If spring range is other than 20 100kPaG 0 2 to 1 0kgf cm G cover Spring Guides over the Spring 3 Place Cover on Case by aligning with exhaust hole and tighten two Eye Bolts at specified places evenly 4 Put Hexagon Bolts in the remaining places and tighten Case and Cover evenly 5 Screw in Exhaust Cap with fingers Until it does not get loose CN 6 Connect air pipe to the connector below Case 5 3 3 Checking after Assembling Check followings after Assembling is completed 1 Apply air pressure of 360kPaG 3 6kgf cm G from Air Connector and che
13. pressure Regulator Valve 7 Inappropriate resistance or volume of Install valve or volume tank in signal amp Signal Air pressure Controller circuit 5 fluctuates 2 Controller fault Check controller 9 Check Pilot Valve amp Positioner fault Tighten Positioner connections i o Neither supply Air nor Large friction on Valve Stem Check and repair Valve Stem and Guide signal Air pressure gt fluctuates but valve Large friction on Gland Packing Replace Packing Reduce differential pressure Change Actuator higher rigidity Install rectify straight pipe on upstream Model 01 05 83A 83 89 IMOTOYAMAY Troubles Too slow stroke both direction Presumed causes Clogged guide with slurry or solids Corrective action Disassemble and clean Change valve type Angle type Deteriorated and hardened gland Packing Change packing and grease Change packing material Too Slow Action Too slow stroke one way Thrust by large differential pressure to Plug Install Positioner Install big Actuator Actuator Air volume is big Install Positioner or booster Air leakage from Actuator Check Actuator Large hysteresis error Valve Stem and Guide no alignment Check Valve Stem alignment Deteriorated and hardened gland Packing Change Packing Foreign matter entrapped in Valve Plug Disassemble and clean up Clogged Valve Stem or Guide with
14. slurry or solid Disassemble and clean up Valve no move beyond certain travel Manual Handle position is not set at NEUTRAL Set Handle position NEUTRAL Lack of supply air pressure Check supply air pressure Valve Stem fully closed position Corrosion erosion or damage on Valve Seat Check Seat and repair or lap Cavity in Valve Body Repair or replace Body Corrosion or erosion of thread in Valve Seat Change Seat Ring or Gasket Impossible to move to fully closed position Large Leakage Large differential pressure Large differential pressure Foreign matter entrapped in Valve Plug Disassemble and clean up Guide or port seizure Repair or replace damaged parts Control position changed range ability decreased Corrosion or erosion of Valve Plug or Cage Change Valve Plug or Cage Leakage from Gland Packing Loose Gland Nut Re tighten uniformly Deteriorated and hardened Gland Packing Change Packing Change Packing material Incorrect insert of Gland Packing Re insert correctly No Grease Add Grease Corrosion erosion or damage of Valve Stem Repair or change Valve Stem Caution If any improvement can not be made even by taking above mentioned corrective actions Please contact our sales office for further solution 39 Model 01 05 83A 83 89 CIS GU TA 42 Recommended Spare Parts All the p
15. 00 cycles ambient temperature gt 6 Valve Stem 5 al Q9 Guide Bushing 5 Same for Valve Plug E Gland Flange 10 gt Stud Bolt 5 Same for Nut Gland Bolt 5 Same for Nut KB York Bolt York Nut 10 Gasket 2 Change on every overhaul 3 Wiper 5 Change when any damage or scratch found Gland Bushing 10 5 Gland Packing 2 Change on every overhaul Lantern Ring 10 t Packing Ring 10 Yoke 10 9 1 Diaphragm Case 10 9 2 Diaphragm Cover 10 Diaphragm Stem 10 Diaphragm Plate 10 o 02 Diaphragm Rubber 10 Change when any damage found 3 Spring 10 Same as above lt Spring Seat 10 Q5 Adjustment Screw 5 Adjustment Guide 5 7 Seat Bearing 5 Daistat Daisthread 5 Change on every overhaul Q9 Dust Seal O Ring Seal Packing 5 Same as above 41 42 Model 01 05 83A 83 89 Control Valve Parts and Constructio Parts Number on below sketch is the Number of the Table Estimated Life Cycle of Control Valve Parts page 41 Note Some parts for reveres action type are not shown on the sketch See page 12 13 16 17 and 20 for details Model 3889 Single Seated Top Guide Control Valve N Direction of Fluid Flow md This manual is supplied for information purpose only and should not be considered certified marketability and conformability of this product Bulletin No MIE B3001P Model 01 05 83A 83 89 CIS GU TA
16. 1 1 above 9 2 2 Direct Action Upward Limiting DU 1 To restrict closed position of push down open DUS Apply air pressure to Actuator and open valve as desired Loosen Lock Nut and turn Spindle clockwise to lower it to desired limiting travel Then tighten Lock Nut 2 To restrict opened position of push down close DUO Adjustment is the same as the procedure in 9 2 2 1 above Do not Turn Spindle counterclockwise too much or Spindle will come out A CAUTION from O Ring and make Actuator in operative It is the limit when Diaphragm Stem stops 31 32 Model 01 05 83A 83 89 IMOTOYAMAN 9 2 3 Reverse Action Downward Limiting RD To restrict closed position of push down close RDS 1 Model 3800 Actuator Travel Stopper Loosen Lock Nut and tighten until desired travel can be obtained while applying air pressure and then lock Lock Nut Model 2800 Actuator Travel Stopper While applying air pressure insert a tool into a hole on Spindle Guide head to prevent Spindle from 5 turning Also insert a tool into a hole on Lock Nut head turn it counterclockwise and loosen the lock to lower until desired limiting trvel is obtained Then turn Spindle Guide clockwise to screw in to desired limiting travel After positioning tighten Lock Nut 9 2 4 Reverse Action Upward Limiting RU H To restrict opened position of push down close RUO 1 Model 3800 Ac
17. 365 395 Noe Notes 1 See catalogues for each Valves masses 2 Actuator mass is for direct action 3 Only when using four 4 Eye Bolts for 650S L and 650XS L Actuator Other size of Actuator allowable lifting load is permissible using two 2 Eye Bolts Ambient temperature and humidity for Valves should be 20 C 70 C and be less than 9096 RH WARNING Never use Valves on service condition exceeding rating and standard of connection to prevent Valves from damage breakage and or leakage Model 01 05 83A 83 89 IMOTOYAMAN 3 2 Installation on System Piping 1 Remove all vvelding chips scales and other foreign matters from internal of the piping line before installing Valves in between 2 Be sure to match arrow mark on Valve Bogy to the flow direction when installing 3 Piping Gasket shall be installed properly not to be stuck out into Body bore diameter 4 Be sure the concentricity and parallelism of Valve inlet and outlet piping are correct Tighten Bolts and Nuts equally Be sure not to give the excessive stress to Valves D When tightening be sure not to give excessive load piping stress to A CAUTION Valves which would cause damage deformation and leakage 2 Either Body or Actuator or both should be supported by proper way 5 Blow off scales rust and foreign matters in pneumatic piping by compressed Air before connecting pneumatic piping to Actuator a
18. Assembly Lock Nut Hs Seal Ring Bonnet Nut Gasket a Bellows Washer Bellows Gasket Bellows Assembly Valve Stem Adapter Spool 10 2 2 Reasssemling of Formed Bellows Assembly When re assembling reverse the order of the disassembling D Replace Seal Ring with a new one C AUTI ON 2 When tightening Lock Nut fitting the mark on Valve Stem apply appropriate grease to external surface of Seal Ring Also apply antiseize grease to Sleeve thread See 10 2 1 2 35 Model 01 05 83A 83 89 10 3 Disassembling and Re assembling of Welded Bellows Assembly See Fig 10 3 10 3 1 Diasssemling of Welded Bellows Assembly 1 Loosen Bonnet tightening Nut to free Bonnet At this time check that process fluid is not leaking inside of the Bonnet 2 Check that Bellows Washer is not stuck to Adapter Spool Then pinch flat face of Bellows Stem and turn to separate Bellows Stem from Locking Stem 3 Remove Adapter Apool following the procedure in 10 2 1 4 and 10 2 1 5 above Fig 10 3 Welded Bellows Seal Type Bellows Assembly Bonnet Valve Stem Bellows Washer Bellows Bellows Stem Gasket Gasket Bellows Assembly Adapter Spool Locking Stem Locking Bush A A
19. Bulletin No MIE B3001P MOTOYA MA INSTRUCTION MANUAL USER S MANUAL Model 01 05 83A 83 89 Globe Type Control Valves USER S MANUAL MOTOYAMA ENG WORKS LTD Model 01 05 83A 83 89 CIS GU A Introduction Thank your very much for choosing MOTOYAMA Control Valves To use this product safely and to optimize its performance it is recommended that following instruction should be read carefully and followed General D Keep this instruction manual in operator s hand 2 Before using Control Valves read this instruction manual carefully and fully understand it for operation 3 This instruction manual does not cover Accessories installed to Control Valves Kindly refer appropriate Accessories Instruction Manual along with this manual For Safety Use To use this Control Valves safely this instruction manual describes symbols and signal terms in accordance with JIS Z2901 and ANSI Z5351 which shall call your attention to keep safety manner or to give caution of handling together with notes Important information has been marked and emphasized with following symbols in this Instruction Manual Symbols and Explanation Signal Terms P WARN NG A direct endangerment of a person s health or life may occur if the Warning was not observed CAUTION If the Caution was not observed minor personal injuries and or property damages may result El Note MOTOYAMA is
20. G asi 2 A 8 4set Silver one band 6 C Silver one band 4 D Yellow one band 4 F Blue one band r de 2 A kgf cm G 12 6set 2 black band 8 E Brown one band 8 G Yellow one band 50 ESE 16 8set Silver one band 8 G Green one band Paint Color Brown Red TO 15 4 D None 4 F None 120 280kPaG 20 4 D Red one band 4 F Blue one band 1 2 2 8 25 8 E Blue one band 4 F White one band arena 38 8 E White one band 8 G Black one band 50 8 G Brown one band Note 1 ID colors are marked as follows Marking of one pitch or more 2 1 is common to 20 100kPaG spring range quantity of springs differs 3 2 indicates double spring with same ID color 4 The type beside number of springs indicates types of spring arrangement drawings Fig 7 2 Spring Arrangement for Model 3800 Actuator Arrangement Arrangement B Type N28 C Type N28 D Type N33S L X DA X RA Notes 1 Hatchings indicate spring guides where springs are arranged 2 X represents hexagon bolt location 25 26 Model 01 05 83A 83 89 CIS GU TA El Hand Wheel Mounted on Actuator 8 1 Operating Disassembling and Re assembling of Side Mounted Handwheel 8 1 1 Side mounted Handwheel on Model 3800 Actuator 8 1 1 1 Operating 1 Don t operate Handwheel under perssure loading to Actuator 2 To ope
21. Head with Stem Nut Pointer and Tee Head Retainer to Valve Stem 2 Apply operating air pressure to Actuator to lower Top Stem down to the lowest level 3 Screw Tee Head Rerainer to Stem Coupling with fingers to lightly lock Stem Nut Then reduce air pressure of Actuator OkPa Okgf cm G to raise Top Stem 4 Set temoprarily by placing Pointer so that Indicator Scale points OPEN 5 Gradually apply operating air pressure to Valve Stem until Pointer points SHUT 6 Loosen Stem Nut and Tee Head Retainer and turn Tee Head to lower Valve Plug further unitil Valve Plug seats on the seating surface 7 Tighten the Tee Head Retainer and secure it with Stem Nut 8 With the Valve Plug Seat on the seating surface put SHUT on the Indicator Scale to the Pointer 10 4 2 Reverse Acting Type push down close control valves Reverse Acting Actuators Apply operating air pressure to Actuator to fully raise Top Stem Lower Valve Plug until it seats on the seating surface Fully screw Stem Nut Pointer and Tee Head with Tee Head Retainer to Valve Stem Reduse air pressure to Actuator ORPaG Okgf cm G and turn Tee Head to raise it until it touches the bottom face of Stem Coupling Screw Tee Head Retainer to Stem Coupling with fingers for temporary seting Increase air pressure to Actuator by about 50 of operating air pressure valve is semi opened For Model 3800 Actuator turn Tee Head by specified number of turns Valve Stem See T
22. Nut i _ Diethread Case Stopper Spring Diaphragm Yoke Spring Seat gt Diaphragm Plate icc Top Stem Exhaust Hole Thrust Ball Bearing Adjust Screw Ps Fig 5 11 Model 2800 Reverse Acting Actuator Cap Adjust Screw __ Spring Seat Bearing Ball Spring Diaphragm Assembly Spring Case Nut Diaphragm Plate Bolt Diaphragm Nut O Ring Holder Case O Ring Yoke 7 Top Stem Air Connector Stuffing Box Model 01 05 83A 83 89 IMOTOYAMAN 6 Adjustment and Test 6 1 Adjustment Diaphragm operated Control Valves require no on load adjustment To adjust travel after re assembling Actuator to Valve Body follow the procedure below see Fig 5 3 to Fig 5 7 and Fig 5 10 to Fig 5 11 6 1 1 Direct Acting Push Down Close Control Valves Direct Actuators 6 1 1 1 Model 3800 Actuator 1 Install Actuator to Valve Body and tighten Yoke Nut Yoke Bolt firmly 2 Connect air piping to Air Connector in Cover 3 Fully thread Valve Stem into Top Stem 4 Apply operating air pressure to Top Stem to lower Actuator Stem down its lowermost level 5 Turn Valve Stem to further lower Top Stem until Valve Plug seats on the seating surface 6 Reduce air pressure to be about 5096 of the operating air pressure valve is semi opened to lift Valve Stem once and turn Valve Stem specified rotations See Table 6 1 to lower Valve Stem and th
23. Section Ti Valve Plug gt pp 10 3 2 Re asssemling of Welded Bellows Assembly When re assembling reverse the order of the disassembling CAUTION Exercise care to well match the Hexagon of the Locking Bush to the position and angle of the Locking Stem 10 4 Connection and Adjustment of Valve Stem See Fig 10 1 10 4 1 Direct Acting Type push down close control valves Direct Acting Actuators 10 4 1 1 Model 3800 Actuator 1 2 1 Lower Valve Plug until it Seats on the seating surface 2 Fully screw Tee Head with Stem Nut Pointer and Tee Head Retainer to Valve Stem 3 Apply operating air pressure to Actuator to lower Top Stem down to the lowest level 4 Turn and raise Tee Head until it hits to the bottom face of Stem Coupling 5 5 Screw Tee Head Rerainer to Stem Coupling by fingers for temporary setting Model 01 05 83A 83 89 IMOTOYAMAN 6 Reduce air pressure to be about 5096 of the operating air pressure valve is semi opend and loosen Tee Head Retainer Then turn Tee Head by specified numbers to lower Valve Stem See Table 6 1 7 Hold Tee Head and lightly lock Stem Nut by hand Screw Tee Head Retainer to Stem Coupling and tighten it by Stem Nut 8 Apply operating air pressure to touch Valve Plug Seat on seating surface and adjust Pointer position to indicate SHUT on Indicator Scale 10 4 1 2 Model 2800 Actuator 1 Fully screw Tee
24. able 6 1 For Model 2800 Actuator turn Tee Head 3 4 turn to lower Valve Stem Hold Tee Head and lightly lock Stem Nut with hand Screw Tee Head Retainer to Stem Coupling and secure it with Stem Nut Return air pressure to OkPaG Okgf cm G to let Valve Plug seat on seating surface and place on Indicator Scale to Pointer 10 4 3 Reverse Acting Type push down open control valves Direct Acting Actuators The Valve Plug seats on the seating surface in reverse direction of reverse acting type push down close Control Valves Connect Top Stem and Valve Stem and adjust travel by considering this difference and in accordance with procedure as stated in 10 4 2 37 38 Model 01 05 83A 83 89 ul Trouble Shooting Following is a list of general Troubles Causes and Corrective Actions in routine operation of Control Valves Table 11 1 Trouble Shooting Valve fails to operate Troubles No signal nor supply air pressure Presumed causes Air pressure source compressor fault Corrective action Check compressor Large leakage on Air piping Check air piping No supply Air pressure Clogged or leaking on Air piping Check air piping Pressure Regulator Valve fault Check and repair Pressure Regulator No signal Air pressure Controller fault Check controller Clogged or leaking on signal Air piping Check air piping No Positioner output Pilot Valve in Positioner fault Chec
25. and pressure gradually without changing them rapidly A CAUTION 2 Heating up speed shall be less than 150 C Hr for Model 01 Model 05 Model 89 and shall be less than 100 C Hr for Model 83A Model 83 3 During heating up be sure to avoid sudden operation 4 2 Greasing to the Gland Packing 1 To use Braided Packing it is required to use Greases to elevate the sealing and lubricating property on Valve Stem 2 Greasing device to inject the Grease is called Lubricator See Fig 4 1 for details of Lubricator 3 To supply Grease in routine work follow the procedure below D Turn Handle clockwise to make Spindle closed If Pressure Screw is removed holding Spindle open Grease may flow out reversely by internal pressure from Valve Body Take out Pressure Screw from Cylinder Insert designated Grease from this open port Use designated Grease specified on Name Plate attached on Actuator 4 Compress Grease into Lubricator by Pressure Screw 5 Under compressing Grease by Pressure Screw turn Handle counter clockwise to make Spindle open Then compress Grease further by Pressure Screw After compressing turn Handle clockwise and close Spindle lt Repeat above operation several times and fill Grease into Connection Pipe and Cylinder Do not fill Grease to strong or too much to prevent over flow from Bonnet CAUTION Staffing Box or to prevent the damage of Gland Packing itself Pay atten
26. arts of Control Valves are designed and manufactured utilizing MOTOYAMA flow Control technology accumulated over past years To continue stable operation of Control Valves it is recommended that the following genuine parts should be changed periodically as recommended in Table 12 1 Table 12 1 Overhaul Internal and Recommended Spare Parts Component Replacement Part Disassembling Interval Replacement Interval Gland Packing Body Gasket Packing 2years Change the parts when disassembled Diaphragm Daisthread Daistat Actuator O Ring 5years Check and change when necessary Seal Packing Dust Seal 1 When ordering spare parts be sure to inform us Parts Name and the serial numbers of Valves which is specified on Name Plate Be sure to use the Genuine Parts only CAUTION Also use the specified Grease described in this manual MOTOYAMA has no responsibility for the troubles in correct or imitated parts and grease were used 13 Disposal of Control Valves and Parts D Be sure to blow out all the pressures and fluids left in the piping line before dismounting the Control Valves A WAR N N G 2 When harmful fluid remains in the body of the dismounted Valve disassemble the Body See Paragraph 5 on page 9 and clean up internals Otherwise human accident or environmental pollution may be induced 1 Basically Control Valves component parts do not contain any harmfu
27. ck leakage from outer edges of Diaphragm Case and Cover using foaming agent For Actuator size of N33S and N40 check leakage with air pressure 480kPaG 4 8kgf cm G 2 Reciprocate Actuator to check that it smoothly operates over entire stroke 15 Model 01 05 83A 83 89 Fig 5 7 Model 3800 Actuator h Stuffing Box Assembly 4 b a Model 3800 Direct Acting Actuator b Model 3800 Reverse Acting Actuator No Part Name C D Case Ss Cover Is 8 Diaphragm Assembly em Spring Assembly Hexagon Bolt Hexagon Nut Eye Bolt Stem Nut Pointer Indicator scale Screw Name Plate 3 Round head slotted revet Exh Cap Locking Plate Note XLocking plate is mounted only for actuator size N33 and N40 ref Fig i p c Cover d Cover Direct i Reverse E M lt I A i e Diaphragm Assembly f Diaphragm Assembly See Fig 6 2 spring arrangement Air connector or Exh hole No Part Name No _ Part Name Diaphragm D Diaphragm Plate Plate Stopper Stopper No Part Name Top Stem Top Stem D Case
28. continuously improving and upgrading its products design specifications and or dimensions Information included herein is subject to change without notice MOTOYAMA ENG WORKS LTD SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING PERFORMANCE OR USE OF THIS MATERIAL Model 01 05 83A 83 89 IMOTOYAMAN Transportation Unpacking Check and Storage Transportation When loading or unloading and transportation of Control valves pay full CA TION attention not to drop or not to give shock with hitting or bumping etc It U would make Valves and its accessories mechanical troubles or damages as of precision instrument If any cautions instructions or care marks are indicated on package follow them as it is EJ Unpacking 1 There are two types of packages used for Control Valves wooden crate box and carton In either case unpack crate box or carton indoor or in warehouse Never unpack package of Control Valves outdoor place where rain falls on A TION damp and wet ground and or dust is in the air C U It would make the Valves and its accessories mechanical troubles or damage because of precision 2 When unpacking the wooden box follow the procedure described below unless otherwise specified D Pull off round pegs around edge protectors at each corner and remove them 2 Pull o
29. d down 11 12 Model 01 05 83A 83 89 CIS GU TA Fig 5 2 Seal Ring Check before Assembling Gland Packing Stud Bolt For general use PTFE Braid Packing Braid Packing Wiper Gland Bushing Hu Ta i t Adapter raid Packing Seat Packing Braid Packing El REIZ PTFE V Ring A oN O R Lantern Mr R Packing Seat i Spring Sheet ing Braid Packing eS Packing Packing Seat E Lantern Ring Ring Lantern Ring Spacer Braid Packing Packing Ring Fig 5 3 Model 01 push down close Fig 5 4 Model 05 push down close Stem Nut Pointer Pointer Stem Nut 7 Valve Stem S Lubricator Gland Nut Gland Nut Gland Flange Gland Bolt Gland Flange HU B Gland Bolt ZR Yoke Nut Yoke Nut 4 Qi NS Bonnet Gland Packing Bonnet Gasket Body 7 EP SSY A CCN Seat Ring Valve Plug Valve Plug Seat Ring Body Seat Ring Stud Bolt Stud Bolt Gasket Bottom Cover Nut Nut Gasket Bottom Cover Model 01 05 83A 83 89 IMOTOYAMAN Fig 5 5 Model 83A Model 83 Fig 5 6 Model 89 Size 1 inch or smaller Yele Siem Gland Flange la
30. el 3800 Actuator n8 14 5 4 Disassembling and Re assembling Model 2800 Actuator n8 18 6 Adjustment and Test 6 1 Adjustment 21 6 2 Test T 23 7 Change of Valve Action and Actuator 7 1 Purpose Tn LA 23 7 2 Change of Valve Action Hee 23 7 3 Change of Stroke and Spring Range 24 8 Hand Wheel Mounted on Actuator 8 1 Operating Disassembling and Re assembling of Side Mounted Handwheel 26 8 2 Operating Disassembling and Re assembling of Top Mounted Handwheel 29 9 Travel Stopper On Actuator 9 1 Classification kki kkk kkk kkk kki 31 9 2 Adjustment of Travel Stopper 31 10 Bellows Seal Type Valve 10 1 Split of Actuator from Valve Body 34 10 2 Disassembling and Re assembling of Formed Bellows Assembly 35 10 3 Disassembling and Re assembling of Welded Bellows Assembly 36 10 4 Connection and Adjustment of Valve Stem Cece ccc cc cree crc cece cece cece e cee eee see eeeeeeeceees 36 11 Trouble Shooting ee ee WR ERU KR OD OE DER LAO OLLI Et 38 12 Recommended Spare Parts HII 40 13 Disposal of Control Valves and Parts POPPE CeCe eee reer eee eee eee ee eee eee eee eee ee ee ee ee es 40 Refere
31. en P I EG secure it with Stem Nut 7 Apply operating air pressure to Actuator to let Valve Plug seat on the seating surface Then align Pointer to SHUT position on Indicator Scale and secure Pointer with machine screw 8 Increase decrease air pressure to Actuator to check the valve operation to open or close smoothly 6 1 1 2 Model 2800 Actuator 1 Install Actuator to Valve Body and tighten Yoke Bolt firmly 2 Connect air piping to Air Connector in Cover 3 Fully thread Valve Stem into Top Stem and lightly lock Stem Nut Temporarily set Pointer to OPEN position on Indicator Scale 4 Gradually apply operating air pressure to Actuator to lower Valve Stem until Pinter meets SHUT position Loosen Stem Nut and turn Valve Stem to lower until Valve Plug seats on seating surface Tighten Stem Nut to secure Top Stem With Valve Plug seated on seating surface place Pointer position to indicate SHUT position Increase decrease air pressure to Actuator to check the valve operation to open or close smoothly 7 8 pg aa 21 Model 01 05 83A 83 89 CIS GU TA 6 1 2 Reverse Acting Push Down Close Control Valves Reverse Actuators Connect air piping to connector in Case Apply operating air pressure to Actuator to place Actuator Stem at its uppermost level completely Install Actuator to Valve Body and tighten Yoke Nut firmly Fully thread Valve Stem into Top Stem and reduce a
32. er filling Grease See Table 4 1 to select appropriate Grease for each service Please contact MOTOYAMA sales office when replacement Grease is required D If more than 6 months past before starting operation of system re tighten CAUTION Gland Nuts before starting pressure tightness test 2 After re tighten Gland Nuts reciprocate the Valves at least 10 times from fully open to fully close to fit Gland Packing for operation Table 4 1 Grease Climax Lubricants amp Equipment Co Three Bond Co LTD Grease No 400 650 750 1901 Operating Temp C 29 230 40 260 0 300 300 Color Red Blue Black Black Amine Chloride Acetylene Asphalt Steam Acid Chlorine Vinyl Coke oven gas General high Alkali Food Chloride Coal tar temperature fluid Alcohol Bleach General Gas Steam Ammonia Cyanide Hydrocarbon Phosphorus Brine Milk Mineral Oil Water Sulfur Paints Freon Services Stick Bulk Can Note No Lubricator is installed for services fluid temperature is lower than 40 C or higher than 450 C or the pressure rating is Class 2500LB or greater 5 When Handwheel is mounted be sure Handle is set to Neutral or auto operation position which does not restrain Valve opening 6 Carry out loop test with Controller to check that Valves open or close smoothly Model 01 05 83A 83 89 IMOTOYAMAN D If Valves must be heated up increase temperature
33. ff round pegs stuck on roof top and remove the roof top 3 Remove waterproofing materials if applied inside of the box 4 Pull off round pegs stuck on frame at side and remove side plates 5 Pull off round pegs stuck on frame at end and remove end plates If the goods are fixed with square lumbers or bolts and nuts remove them Remove waterproofing materials such as polyvinyl packing covering the goods Edge protector 9 Roof Top plate T form peg Round peg End plate Note T form pegs are not required to be pull off when unpacking ii Model 01 05 83A 83 89 IMOTOYAMAN El Check of Products Caution After receiving goods unpack package promptly and check if goods delivered are complying with your order specification D When taking out goods from box pay attention not to give any physical shock to Accessories attached to Valves Take out spare parts if they are enclosed 2 Check Name Plate attached to Yoke of Actuator whether Valve specification complying with your request 3 If any clarification required on received goods please contact MOTOYAMA sales office specifying Serial Numbers and Model Number indicating on Name Plate attached to the Valves p ex e mot MOTOYAMA ENG WORKS LTD SENDAI JAPAN P1051 Storage D If goods need to be stored before installation store goods warehouse or equivalent indoor storage facility covering whole goods with co
34. g replying control signal such as 4 20mA DC or 20 100kPa from controller of instrumentation system to keep the flow specific and or constant process conditions 2 2 Construction Model 01 05 83A 83 and 89 consist of Body Assembly and Actuator Assembly Body has controlling mechanism actually control the process flow and Actuator has driving mechanism to activate Valve Plug receiving air power source Fig 2 1 show typical constructions of Globe Type Control Valves Body Assembly including valve Body Bonnet Bottom Cover are jointed together with Studs Nuts and Gaskets provides pressure container parts where process flow runs though or stays Valve Plug is hold by Guide Bush or Cage and is kept at proper control position flowing to the control signal to Actuator Spring Loaded Diaphragm Actuator converts variation of air pressure into thrust power for axial motion by the balance of Diaphragm and Spring and keeps or controls the Plug opening at proper position 2 3 Specification See individual catalogue for following Models Valve Model Bulletin No 01 MCE B1101 05 MCE B1501 83A 150 300 600LB MCE B4306 83A BS 83A BSH MCE B4307 83 900 1500LB MCE B4302 89 MCE B4102 C AUTION Do not use the products beyond the selected specification code standard and or regulations to secure the safety of the delivered products Model 01 05 83A 83 89 Fig 2 1 Globe Type Control Valve
35. hould be cleaned and checked as follows 1 Check seat surface of Seat Ring on Valve Body Valve Plug Guide and Cage to be free from any damage and or deformation 2 Check Body and Bonnet wall thickness decreased Check Body and Bonnet sealing surface of Gasket Packing and Gland Packing to be free from any damage and or deformation 8 Check the appearance of Valve Plug Stem Holder Cage and sliding surfaces of each parts to be free from corrosion erosion damage and or deformation If any damage and or deformation are found on each parts repair or replacement are required To request repair or spare parts be sure to inform MOTOYAMA sales office the Serial Numbers of Valves specified on Name Plate 5 2 3 Re assembling Procedure D Be sure to apply anti seize grease NEVER SEEZ or equivalent on Seal CAUTION Ring surface of Gasket 2 For Oil Free requirement apply Fluorine type grease DEMNAM GREASE L200 or equivalent slightly Note NEVER SEEZ products of BOSTICK DEMNAM GREASE L200 products of DAIKIN 10 Model 01 05 83A 83 89 IMOTOYAMAN 5 2 3 1 Model 01 Model 05 Top and Bottom Guide Type 1 Mount Gasket to sealing surface on the other side of Seat at bottom of Body and fit Bottom Cover properly into sealing surface of Body 2 Apply an appropriate anti seize compound to Bottom Cover fastening Bolt and tighten lightly 3 If Seat Ring had been removed th
36. ing Apply anti seize gleese to the threaded parts such as NEVER SEEZ 8 2 2 2 Reverse Acting Actators See Fig 8 5 1 Disconnect air piping 2 Trun Handle to lower Screw Shaft fully and put the position in automatic operation 3 Remove Cap Hadle Hexagon Nut Thrudt Ball Bearing Diaphragm Cover with Bonnet Screw Shaft and Handle Lock in order This completes disassembling of Top mounted Handwheel 4 When re assembling reverse the order of the disassembling Apply anti seize gleese to the threaded parts such as NEVER SEEZ 8 2 3 Checking after Assembling 1 Check Handle operation to be smooth over the entire stroke 2 Check leakage from outer edges of Diaphagm Case or Cover with soap water by applying air pressure of 360kPaG 3 6kgf cm G 350kPaG 3 5kgf cm G for Model 2800 Actator to Actuator from the air connector 30 Model 01 05 83A 83 89 IMOTOYAMAN Fig 8 4 Top mounted Handwheel on Model 3800 Fig 8 5 Top mounted Handwheel on Model 3800 Actuator direct action Actuator reverse action 7 2 Q 3 No Part Name No Part Name O Bonnet O Bonnet Spindle Diaphragm Handle Handle Handle Lock Handle Lock Plate Screw Shaft Spring Washer Paralle
37. ir pressure to OkPaG Okgf cm G Turn Valve Stem to lower it until Valve Plug seats on the seating surface For Model 3800 Actuator increase air pressure to be about 50 of the operating air pressure Valve is semi opened to lift Valve Stem once and turn Valve Stem specified rotations to lower it and then secure it with Stem Nut At this time use number of rotations shown in Table 6 1 for reference 7 For Model 2800 Actuator after procedure 5 above increase air pressure to be about 50 of the operating air pressure valve is semi opened to lift Valve once and turn Valve Stem by 3 4 turn to lower it and then secure it with Stem Nut 8 Reduce air pressure to Actuator to ORPaG Okgf cm G to let Valve Plug seat on the seating surface and set pointer position to indicate SHUT position 9 Increase decrease air pressure to Actuator to check the valve operation to open or close smoothly 6 1 3 Reverse Acting Push Down Open Control Valves Model 2800 Direct Acting Actuators 1 Install Actuator to Valve Body and firmly tighten Yoke Bolt 2 Connect air piping to Air Connector in Cover 3 Fully thread Valve Stem into Top Stem 4 Turn Valve Stem to lift it until Valve Plug seats on the seating surface 5 Increase air pressure to be about 50 of the operating air pressure valve is semi opened to lift Valve once and turn Valve Stem by 3 4 turn to lower it and then secure it with Stem Nut 6 Reduce air pressure to
38. k and repair Pilot Valve Large leakage on Actuator Check Actuator Diaphragm Valve no movement even Air press is working on Actuator Valve Stem or Guide stick Disassemble Body and check repair or replace Bend or breakage on Valve Stem Repair or replace Valve Stem Foreign matter entrapped on Seat or between Guide clearances Disassemble and check valve port Vibration and noise in all range of opening Large clearance between Guide and Plug Repair or replace Valve Plug and Guide Loose connections Valve Stem and Valve Plug Valve Stem and Top Stem Top Stem and Diaphragm Re tighten connection hunts Resonance with fluids turbulent wave motion fluctuations in stem s thrust due to changes in fluid pressure 2 Poor de aeration of fluid De aerate fluid Flashing at outlet of the Valve Plug Change valve type 6 Valve vibrates at middle Natural vibration double sealed valves 5 to maximum openings except for cage type generate when Change valve type ex cage type unbalanced force of Valve Plug reverses Plug chatter at almost Change valve Cv or Plug and control fully closed position Fluid flow to close Valve Plug flow close position Shock waves occur at A 1 valve outlet Valve size too small steam Enlarge valve size Supply Air pressure Insufficient Air source capacity Add compressor fluctuates Pressure Regulator fault Repair or replace
39. l Key Hexagon Bolt Cap FT Hexagon Nut Model 01 05 83A 83 89 IMOTOYAMAN 9 Travel Stopper On Actuator 9 1 Classification Travel stopper are uesd vvith follvving classification according to the purpose of Control Valves Table 9 1 Classification of Travel Stopper Y Stem Limiting Valve Travel Actuator Action Direction Symbol Limiting Direction Application Symbol Close S To restrict closed position of push down close DDS Downward D DD Open O To restrict opened position of push down open DDU Direct Action Close S To restrict closed position of push down close DUS Upward U DU Open O To restrict closed position of push down close DUO Downward D RD Close S To restrict closed position of push down close RDS Reverse Action Upward U DU Open O To restrict opened position of push down open DUO Note Travel stopper for Actuator size 500L and 650L cannot be used for limiting travel of 30 or less 9 2 Adjustment of Travel Stopper See Fig 9 1 Fig 9 2 9 2 1 Direct Action Downward Limiting DD 1 To restrict closed position of push down close DDS Loosen Lock Nut and tighten it until desired travel can be obtained for the dimension from Bonnet top end to Lock Nut bottom end while applying air pressure and then tighten Lock Nut 2 To restrict opened position of push down open DDO Adjustment is the same as the procedure in 9 2
40. l materials for pollution When necessary scrap Control Valves as general metal discarding materials 2 When there is any discarding restriction for asbestos material check Model Number of Gland Packing and Gasket on Name Plate and if it is confirmed as asbestos type take Gasket and Gland Packing out from Body then discard it separately from other metal parts 40 Model 01 05 83A 83 89 IMOTOYAMAY Reference Data Estimated Life Cycle of Control Valve Parts Generally estimated life cycle of Control Valves component parts are shown in following table Whereas the life of each parts differ by temperature pressure frequency or operation and environment in service It is recommended to use this table for reference for your consideration Accordingly please be noted that estimated life cycle below do not mean the warranty value by MOTOYAMA MOTOYAMA general warranty period for Control Valves is one 1 year after shipment Estimated Life Cycle of Control Valves Parts Unit Years No Part Name Life Cycle Notes D Body 10 years Bonnet 10 rib wall thickness decreased to 90 of 8 Bottom Cover 10 _ Valve Plug 5 Change when clearance became 0 1mm larger Guide Cage 5 than design value Seat Ring 5 Weld Bellows 10 000 cycles However under the conditions without corrosion in Form Bellows 5 0
41. lower Locking Plate together Thread size of Valve Stem and Top Stem is as follows Fig 5 1 Removing Actuator Actuator size Thread N28 M9 P1 25 N33 M12 P1 75 N40 M18 P2 0 500 W3 4 10 650 W7 8 9 4 Turn the stem nut to lower the valve stem and remove the valve stem from the top stem 5 Loosen and remove the yoke nut yoke bolt 6 Lift the actuator stralght up and remove it from the valve body Model 01 05 83A 83 89 IMOTOYAMAN 5 2 Disassembling and Re assembling of Valve Body To disassembling or re assembling Valve Body follow the procedure below See Fig 5 2 5 6 5 2 1 Disassembling Procedure 1 Remove Stud Bolt Nuts 2 Pull up Valve Plug together with Bonnet upright and split it from Valve Body 3 Loosen Bottom Cover Clamping Nuts and remove Bottom Cover 4 5 Loosen Gland Nuts and release the tension of Gland Packing Pull down Valve Plug from Bonnet CAUTION For Models 01 and 05 with push down open Bodies remove D Bottom Cover 2 Valve Plug and Bonnet in order 6 Remove Gland Bushing Gland Packing Lantern Ring and Packing Ring from Bonnet gland 7 To remove the Seat Ring only when required a special tool is required 8 For Cage Guide Type Control Valves Model 83A Model 83 remove Cage from the Body 5 2 2 Inspection of the Parts After disassembling each parts s
42. nce Data Estimated Life Cycle of Control Valve Parts 555060066066 41 Model 01 05 83A 83 89 CIS GU TA EN Purpose of this Instruction Manual 1 This Instruction Manual provides essential information for optimizing MOTOYAMA Control Valves Model 201 4205 Bottom Guided and Single seated Double seated Globe Valves 483A 83 Cage Guided Globe Valves and 89 Top Guided and Single Seated Globe Valves 2 Read this manual carefully before installing operating or overhauling MOTOYAMA Diaphragm Globe Type Control Valves Model 01 05 83A 83 and 89 read this manual carefully 3 Together with this manual read following Accessories manuals before using when applicable Valves and Accessories Bulletin No Model EA10S S MIE B6111 Intelligent Valve Positioner Model EA91A and EA90A Electro Pneumatic Valve Positioner MIESBOTUT aM UM D MIE B2008 Pneumatic Valve Positioner Model MR2000 MIE B Air Filter Regulator diii Model 83A BS and 83A BSH MIE B4301 Seal Ring Balance Type Cage Guided Control Valves 4 If any other Accessories are installed on Valves delivered kindly request our sales office appropriate Instruction Manual if necessary Model 01 05 83A 83 89 CIS GU TA B Application and Construction 2 1 Purpose of Use Model 01 05 83A 83 and 89 Control Valves are installed in process piping and used to control process flow activating Valve Plug open and close or throttlin
43. nd Check 1 Before disassembling turn Handle till Indicator See Fig 8 1 reaches NEUTRAL position 2 Loosen Hexagon Nut to remove Handwheel from Actuator 3 Remove Handwheel Bearing Holder Shaft and Crank in order This complete disassembling 4 When re assembling reverse the order of the disassembling Apply anti seize gleese to the threaded parts such as NEVER SEEZ 5 After Handwheel is assembled check movement to be smooth over entire stroke Note Use exclusive spanner equipped with Crank Cace for tightening Gland Bolt when Actuator size is N24 N28 or N338S See Fig 8 1 8 1 2 Side mounted Handwheel on Model 2800 Actuator 8 1 2 1 Operating 1 Don t operate Handwheel under perssure loading to Actuator 2 Grip tightly and turn Handle Turning Handle clockwise to lift Top Stem on 650S L and to lower Top Stem on 500S L in either case Actuator is direct or reverse acting type 3 To return to the automatic operation turn Handle to be NEUTRAL D Be sure to operate Handle manually and do not give any excessive force by tools such as Handle turning device etc 2 Never turn it further from fully open position to open direct action type or A CAUTION never turn it further from fully closed position to close on reverse action type In any case such a further turning may cause deformation or damage of related parts 8 1 2 2 Disassembling Re assembling and Check 1
44. nd N cana Nun Yoke Nut Gland Bolt Gland Packing Nut Bonnet Stud Bolt a Gasket C x Gasket B Valve Plug Ser Valve St aive otem Gasket A s x a Gland Bolt e Gland Nut Yoke Yoke Nut Gland Packing Note Please be noted that configuration of Cage between Stud Bolt Model 83 and Model 83A is different depending on Nut valve size For the details please refer to our Body catalogue on each Model Gasket Guide Seat Ring Valve Plug Size 11 2 inch or Larger 5 2 3 2 Model 83A Model 83 Cage Guide Type 1 Install Spiral Wound Gasket A on Body lower groove and Serrated Gasket B on Body upper groove Install Cage and Guide on Gasket A and B 2 Insert Valve Plug and Stem assembly into Guide and Cage 3 Insert serrated Gasket C on Cage or Guide cover Bonnet and fit on sealing surface At this point be sure to align Body Guide Valve Plug and Bonnet 4 Follow the procedure on Paragraph 5 2 3 1 3 11 for further assembly 5 2 3 3 Model 89 Top Guide Type Follow the procedure on Paragraph 5 2 3 1 3 11 for further assembly 13 14 Model 01 05 83A 83 89 IMOTOYAMAN 5 3 Disassembling and Re assembling Model 3800 Actuator This Multi Spring Type Diaphragm Actuator requires no site adjustment To modify Actuator or parts replacement disassemble or re assemble as follows See Fig 5 7 to 5 9 for reference Actuator should be placed vertically
45. nd accessories 6 Refer to each instruction manuals for wiring conduits of electric equipments 7 For Finned or Extension Bonnet Valves do not cover Bonnet with heating or cooling insulation 3 3 Inspection after Installation 1 Carry out leakage test to check leakage from connection piping 2 Check leakage from Gland or Gasket after test pressure is applied to the piping If any leakage is found reduce pressure and retighten Gland Nuts or Stud Nuts with equally D If more than 6 months past before starting operation of system retighten CAUTION Gland Nuts before starting pressure tightness test 2 After re tighten Gland Nuts reciprocate the Valves at least 10 times from fully open to fully close to fit Gland Packing for operation Model 01 05 83A 83 89 IMOTOYAMAN 4 Operation Maintenance and Check 4 1 Precautions and Check before Operation 1 Spring range and Off balance for Model 2800 series Actuator is adjusted properly to the required specification when shipped Do not turn Adjusting Screw unless otherwise it should be 2 Before start operation check Stem Nuts Actuator Bolts and Nuts and other screws to be tightened Re tighten if necessary 3 Some Gland Packing might have leakage because of stress relaxation Check tightness of Gland Nuts and re tighten if necessary 4 When Lubricator is equipped on Bonnet page 7 and 8 check if Grease filled enough Be sure to close Stop Valve aft
46. push down close To change from direct action to reverse action or from reverse action to direct action it is recommended to replace a complete set of Actuator assembly Valve Stems may also be needed to be replaced Please contact MOTOYAMA s sales office to change parts 7 2 2 Model 2800 Actuator Mounted Valves 7 2 2 1 Model 2801 and Model 2805 Control Valve Valve Body is either push down close or push down Fig 7 1 Valve Stem Connection open for Valve Pulg action and is combined with direct acting actuator It is possible to change from push down open to push down close or rice versa as follws without changing any parts 1 Diassemble Valve Body following the procedues in chapter 5 and then take out the Valve Plug 2 Remove grooved pin that secures the Valve Plug to Valve Stem to remove Valve Stem See Fig 7 1 3 Remove grooved pin that secures the Valve Plug to Valve Stem to remove Valve Stem See Fig 7 1 4 Screw Valve Stem to the opposite side of Valve Plug most of valves have already been threaded and drill a pin hole away from the original place Then fammer a grooved pin Pay attention not to drill a new hole over the original pin hole on Stem Model 01 05 83A 83 89 IMOTOYAMAN 5 After pin is hammered check alignment of the Stem Turn Valve Pulg on V block by supporting Guide and check straightness of Plug assembly If any run out is found bend or correct Stem to be s
47. rate Actuator manually release Handle Lock that restrains Handle grasp the grip tightly and then turn Handle Turning Handle clockwise to lower Top Stem in either case Actuator is direct or reverse acting type 3 To return to the automatic operation turn Handle to be NEUTRAL and make Handle Lock ettective D Be sure to operate Handle manually and do not give any excessive force by tools such as Handle turning device etc Never turn it further from fully open position to open direct action type or A CAUTION never turn it further from fully closed position to close on reverse action type In any case such a further turning may cause deformation or damage of related parts Fig 8 1 Side mounted Handwheel on Model 3800 Actuator No Part Name No Part Name D Case Eye Bolt 49 Q Yoke Indicator Scale 1 Stuffing Box Cross Heatd Y Sy F O Ring Crank Case 8 Ton i ER 6 Arrow View Dust Steal Handle Q9 Cover Crank e Diaphragm Shaft Y Plate Screw Block 8 Top Stem Bearing Holder Lift Stopper Handle Lock NEUTRAL Diethread Stud Bolt Spring Hexagon Nut Spring Guide Indicator Hexagon Bolt Spanner Hexagon Nut Model 01 05 83A 83 89 CIS GU A 8 1 1 2 Disassembling Re assembling a
48. read Seat Ring into Body and tighten it firmly with a special tool 4 Align Valve Plug to Stem and insert it into Body 5 Install Gasket to sealing surface at the top of Body and put Bonnet in place on the sealing surface A CAUTION D Seat Ring if removed 2 Bonnet 3 Valve Plug and Bottom Cover For Valves with push down open Bodies assemble order 6 Apply anti seize grease on Stud Bolts and tighten Nuts slightly 7 Be sure to check smooth movement of Valve Stem up and down Insert Gland Packing one by one into Bonnet Gland with applying grease on it See Fig 5 12 and Table 4 1 on page 6 Be sure to install each Packing uniformly around Stem On braided Packing each cut end should be placed opposite position 180 degree apart 8 Install Gland Bushing Wiper and Gland Flange in order Tighten Gland Nuts alternately and uniformly Required torque is as follows unit N cm kgf cm Actuator size PTFE V Packing Braid Packing Braid Packing N28 N33S 100 500 10 50 200 800 20 80 N40 650 150 700 15 70 1000 2500 100 250 Note Required torque is varies depend on type of Gland Packing service condition temperature and pressure This table shows standard torque for reference 9 Install Stem Nuts and Pointer 10 Tighten Stud Nuts alternately and uniformly 11 Be sure to confirm smooth movement of Valve Plug Valve Stem up an
49. s IMOTOYAMAY a Globe Type Single Seated Control Valve Top and Bottom Guide Type Model 3801 Direct Action b Globe Type Double Seated Control Valve Top and Bottom Guide Type Model 3805 Direct Action c Cage Guide Type Control Valve Model 3883A 3883 Direct Action d Globe Type Single Seated Control Valve Top Guide Type Model 3889 Direct Action Model 01 05 83A 83 89 CIS GU TA Installation 3 1 General In general Control Valves shall be installed in vertical to piping line or Valve Stem to be vertical to the ground Keep sufficient space to the Valves to be accessible to operate safely and to make maintenance work inspection and testing easily Eye Bolts Nuts on Diaphragm case assembly must be used only for hanging Actuator assembly Do not hang up complete Valves using Eye Bolts after assembling Body and Actuator In any case following mass shall not be exceeded to hang up Unit kg Model No Actuator Size Hei V Actuator Masses N24 80 12 3800 15 A N33S 150 24 N40 220 51 CA UTIO N 500 S L 220 85 102 2 2800 650 S L 900 t 270 275 tesa 650X S L 900 sees
50. tion over flow from Staffing Box Guide Bush and or Valve Stem when greasing Turn Handle clockwise to make Spindle closed and Greasing is completed After greasing open and close the Valves several times around 10 times to create uniformed grease film Abetween Gland Packing and Valve Stem Model 01 05 83A 83 89 CIS GU TA Fig 4 1 Lubricator Part Name Part Name Body Body Bonnet For low pressure Bonnet For high pressure Spindle Spindle Gland nut 600LB or lower Gland nut 900 1 500LB Handle wheel Handle wheel Washer Washer Lock nut Lock nut Connection pipe Connection pipe Sloans Cylinder com Cylinder Pressure screw Pressure screw Gasket Gasket Oring Packing ring Gland packing 8 S S O JO F Gland bushiuy QOONODLO ODONOLBOE eo 4 3 Maintenance and Check To maintain maximum efficiency on Control Valves it is recommended to check or proceed maintenance work as follows See Paragraph 11 Trouble shooting on page 38 39 1 Daily Check Check leakage abnormal sound vibration and or hunting 2 Periodical Check Annually Check each part of Valves re tighten Gland and replenish replace Grease if necessary 3 Overhaul Body Once in every
51. to disassemble or re assemble WARN NG Before disassembling be sure Actuator operating pressure to be zero 0 to prevent accident 5 3 1 Disassembling 1 2 3 4 Put matching mark on Cover and Case Remove air pipes and accessories Loosen and remove Case clamping Hexagon Bolts and Nuts 1 2 3 4 Alternately loosen Eye Bolts and Nuts evenly and remove them Springs are under initial compression by these Eye Bolts The initial compressing length is fixed according to rated travel and Spring Range independent of Actuator size See Table 5 1 Table 5 1 Initial Compressing length of springs Unit mm Rated Travel mm 15 20 25 38 50 65 Spring Range kPaG kgf cm G 20 100 0 4 1 75 2 4 5 8 10 13 40 200 0 4 2 0 80 200 0 4 2 0 9 12 15 23 31 40 120 280 1 2 2 8 9 13 17 27 36 5 Remove Cover 6 For direct acting Actuator pull upward Diaphragm assembly and take out springs 7 For reverse acting Actuator take out springs and pull upward Diaphragm assembly 8 Inspect disassembling parts for damage deformation corrosion or paint flaking A CAUTION Numbers of Spring Guide is different depend on the spring range Model 01 05 83A 83 89 CIS GU A 5 3 2 Re assembling 5 3 2 1 Direct Acting Actuator 1 Place Springs on Spring Guides in Case Assembly See Fig 7 2 If spring range is
52. traight 6 Turn over Body and fit Bonnet to the side where Bottom Cover had been installed Then insert Valve Plug from the opposite side Hereafter re assembling Valve Body by follwing procedures as stated in chapter 5 7 Turn over the Indicator Scale and install it by reversing OPEN and SHUT indications 7 2 2 2 Model 2883A Model 2883 and Model 2889 Control Valve The Valve Body is push down close To change valve action a complete set of Aactuator must be replaced 7 3 Change of Stroke and Spring Range 1 When change of valve stroke and or spring range required it is recommended to repace a complete set of Actuator assembly Following parts are required to change Table 7 1 Parts Required for Changing Stroke or Spring Range Actuator Model No 3800 2800 Part Name Stroke Change tees Stroke Change e Diaphragm Plate metet Lift Stopper Q Dar Q Spring O Q O Gin Spring Guide O Motet Spring Seat O Q Distat Diethread Noted Indicator Scale O Name Plate O O O O Notes 1 Depending on spring range classification replacement of above parts may not be reuired 2 Diestat Diethread is trade name of Mitsubishi Electric Wire Co Ltd 2 Identification and quantity of Spring used for Model 3800 Actuator is listed in Table 7 2 and spring allocation is shown in Fig 7 2 24 Model 01 05 83A 83
53. tuator Travel Stopper Loosen Lock Nut and turn Spindle counterclockwise to lift to the desired limiting travel After positioning tighten Lock Nut 2 Model 2800 Actuator Travel Stopper Hold limiter with a spanner to prevent from turning and loosen Lock Nut with another spanner Turn limiter counterclockwise to lift to the desired limiting trvel and tighten Lock Nut after positioning Model 01 05 83A 83 89 Fig 9 1 Model 2800 Actuator Travel Stopper No Part Name No Part Name Bonnet D Bonnet Spindle Spindle Cap Cap Lock Nut Lock Nut No Part Name No Part Name D Bonnet Bonnet Spindle Spindle Cap Cap Lock Nut Lock Nut No Part Name No Part Name D Bonnet D Spring Case Q Cap Q Cap Spindle Seat Grease Spindle Diaphragm Cover Adjuster Diaphragm Bush Diaphragm Plate Sleeve Diaphragm Stem Spindle Guide
54. ver like polyethylene sheet and protect goods from high temperature moisture Dust and vibration etc During storage of goods protect Conduit connection of electrical instrument A CAUTION from moisture or water which would give breakdown of electricity and cause trouble on products 2 If a period of storage is exceeding one 1 year after delivery re calibration of Valve action and check of gland and gasket leakage before installation shall be required Please contact MOTOYAMA sales office when re calibration is requested iii Model 01 05 83A 83 89 IMOTOYAMAN CONTENTS Page 1 Purpose of this Instruction Manual MMMMMRSMe eHHHMM M MMHHHHHHes 1 2 Application and Construction 2 4 Purpose ja 2 2 2 Construction eee 2 2 3 Specification meme 2 3 Installation 3 1 General eee Tee eee Terre eee Tee eee eee eee eee eee eT ee eee ee Tee eee ee ee eee eee ee eee eee eee eee eee ee eee ey 4 3 2 Installation on System Piping 5 3 3 Inspection after Installation mme 5 4 Operation Maintenance and Check 4 1 Precautions and Check before Operation ere eee rere eee ee eee eee eee ee ee ee 6 4 2 Greasing to the Gland Packing Peer c cece ere e eee kki kkk kkk kki 7 4 3 Maintenance and Check eee kkk 8 5 Disassembly amp Assembly 5 1 Split of Actuator from Valve Body 000000000040 nnn 9 5 2 Disassembling and Re assembling of Valve Body 10 5 3 Disassembling and Re assembling Mod
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