Instruction Manual 9500 Valve D100380X012 July 2012 Fisherr 9500 Butterfly Control Valve Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hub Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Three-Way Valve Tandem Linkage . . . . . . . . . . . . . . 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Changing Disc Rotation and Action . . . . . . . . . . . . . 14 Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 1. Fisher 9500 Valve with 1052 Actuator and DVC6200 Digital Valve Controller W9224-2 Introduction Scope of Manual This manual provides installation, adjustment, and maintenance information for Fisher 9500 butterfly valves. These valves use splined shafts with actuator-mounted brackets and linear-motion actuators (see figure 1). Refer to separate manuals for instructions covering the power actuator or the manual handwheel actuator, positioner, and other accessories. Do not install, operate, or maintain 9500 valves without being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson Process Management sales office before proceeding. Description The 9500 valve is a fully lined butterfly valve for use with corrosive process fluids or wherever stringent shutoff is required. The nitrile or PTFE liner completely isolates the valve body and shaft from the process fluid. The valve is available with conventional or FISHTAIL™ disc designs. www.Fisher.com Instruction Manual 9500 Valve July 2012 D100380X012 Table 1. Specifications FISHTAIL Disc: Approximately equal percentage through 90 degrees of disc rotation Valve Sizes NPS J 2, J 3, J 4, J 6, J 8, J 10, or J 12 Flow Direction Valve Body Style Conventional Disc: Bidirectional FISHTAIL Disc: Forward flow - The tail of the disc opens into the downstream end of the valve (see figure 2). Flangeless (wafer-type) valve body to be installed between pipeline flanges End Connection Styles Flangeless (wafer-style) valve body mates with CL125 flat-face flanges per ASME B16.1, with CL150 and 300 raised-face flanges per ASME B16.34, or EN flanges Disc Rotation Conventional Disc On/Off Service: J 0 to 60 or J 0 to 90 degrees Maximum Allowable Inlet Pressure(1) Throttling Service: 0 to 60 degrees FISHTAIL Disc: 0 to 60 or 0 to 90 degrees for on/off or throttling Consistent with applicable pressure/temperature ratings for JCL125B per ASME B16.1, or JCL150 and 300 per ASME B16.34 unless limited by maximum allowable pressure drop specification or by material temperature capabilities in table 2 Shutoff Classification per ANSI/FCI 70-2 and IEC 60534-4 Nitrile Liner or PTFE Liner: Class VI Vacuum Service Mating Flange Capabilities All sizes compatible with welding-neck flanges; also see Installation section for slip-on flanges The valve is suitable for vacuum service to approximately 10-7 mm Hg absolute (3.4 x 10-12 mbar, absolute) Code Classifications Maximum Shutoff Pressure Drop(1) Dimensions meet MSS SP-67 specifications for face-to-face dimensions for flangeless valves Standard Operation Cast Iron Valve: 12.1 bar (175 psi) Approximate Weights (Valve Body Assemblies Only) Steel or Stainless Steel Valve: 15.2 bar (220 psi) Material Temperature Capabilities(1) NPS 2: 9 kg (20 lb) NPS 3: 11 kg (25 lb) NPS 4: 14 kg (30 lb) NPS 6: 20 kg (45 lb) NPS 8: 27 kg (60 lb) NPS 10: 32 kg (70 lb) NPS 12: 54 kg (120 lb) See table 2 Flow Characteristic Conventional Disc: Approximately equal percentage through 60 degrees of disc rotation 1. The pressure/temperature limits in this manual and any applicable standard or code limitation should not be exceeded. Table 2. Operative Temperature Disc Type Conventional or FISHTAIL 2 Liner Material Operative Temperature Nitrile -7 to 93_C (20 to 200_F) PTFE -18 to 121_C (0 to 250_F) Instruction Manual 9500 Valve D100380X012 July 2012 Installation WARNING Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal injury. Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed where service conditions could exceed the limits given in table 1 or on the appropriate nameplates. To avoid such injury or damage, provide a relief valve for over-pressure protection as required by government or accepted industry codes and good engineering practices. Check with your process or safety engineer for any additional measures that must be taken to protect against process media. If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual. These valves may be installed in many positions by referring to the Actuator Mounting procedures and figure 6 in this manual. For conventional discs, flow may be in either direction. For FISHTAIL discs, the leading edge of the disc must be located in the upstream end of the valve (see figure 2). CAUTION As noted in the following paragraphs, improper use of additional gasketing materials will damage the valve liner. The valve body liner extends past or overlaps the valve face producing the partial O-ring shown in figure 3. It also acts as the flange gasket. Improper use of additional gasketing materials will damage the valve liner. Care must be taken during installation to ensure that the pipe flanges are properly supported. Pipe flange support is required to avoid liner flange joint leakage or problems during valve operation. Slip-on pipe flanges may be used with NPS 2, 3, or 4 valves. An NPS 6 valve or larger will require flange adapters for complete liner support. Mating flanges or pipe flanges with inside diameters smaller than the minimum shown (see table 3) may interfere with the opening of the disc. Flanges or pipes with an inside diameter larger than the maximum shown (see table 3) may not be in full contact with the liner. Install flange adapters in each case, either to provide disc clearance or to fully contact the liner. Flexible, plastic flanges, fiberglass, slip-on, or weld-neck with other than standard inside diameters may not provide adequate support for the liner. Also, flexible mating flanges can be warped with excessive line bolt load. They may fail to support the liner at the inside diameter of the valve body. Use flange adapters, available from Emerson Process Management, during installation to avoid these problems. Whenever a flange adapter is used, a standard flange gasket must be installed between the line flange and flange adapter. Do not use a flange gasket between the valve and flange adapter. The partial O-ring on the liner acts as the flange gasket and any additional gasket here will damage the liner. The 9500 valve may be used as part of a three-way valve assembly. The actuator-valve linkage is adjusted at the factory; you won't need to adjust the linkage before placing the valve in service. If the valve and actuator are being re-installed, after removal, or if you suspect that the linkage is out of adjustment, refer to the Linkage portion of the Adjustments section before installing the valve in the pipeline. If the valve has been purchased separately, or if the actuator has been removed, complete the procedures in the Actuator Mounting section of this manual before proceeding. 3 Instruction Manual 9500 Valve July 2012 D100380X012 Table 3. Maximum and Minimum Allowable Mating Flange Diameters MAXIMUM AND MINIMUM DIAMETER OF MATING PIPING OR FLANGES Minimum VALVE SIZE, NPS 2 3 4 6 8 10 12 Maximum mm Inches mm Inches 30 64 89 145 196 246 297 1.20 2.50 3.50 5.70 7.70 9.70 11.70 64 92 117 171 222 273 330 2.50 3.62 4.62 6.75 8.75 10.75 13.00 Figure 2. Valve Shaft Marking NOSE OR LEADING EDGE OF DISC 1 LOCATION OF FLAT SPOT ON VALVE SHAFT 2 OPEN FLOW LOCATION OF INDEX MARK ON END OF VALVE SHAFT 1 TAIL OF FISHTAIL DISC WITH SPLINED VALVE SHAFT 1 EQUAL MEASUREMENTS BETWEEN VALVE FACE AND DISC EDGE AT TOP AND BOTTOM ENSURE FULLY CLOSED DISC. 2 FOR FISHTAIL DISC, PARTIAL KEYWAY OR FLAT SPOT IS ON SAME SIDE AS NOSE OF DISC. A2755-1 WARNING Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations: D Do not remove the actuator from the valve while the valve is still pressurized. D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure on both sides of the valve. Drain the process media from both sides of the valve. D Vent the power actuator loading pressure and relieve any actuator spring precompression. D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when loosening the packing box pipe plug. 4 Instruction Manual D100380X012 9500 Valve July 2012 Figure 3. Partial O-Ring Location PARTIAL O-RING A6017 LINER FACE-TO-FACE METAL FACE-TO-FACE 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. If continuous operation is required during inspection or maintenance, install a three-valve bypass around the control valve assembly. 2. Be certain the pipeline flanges are in line with each other and supported. CAUTION To avoid damaging valve seating surfaces, make sure the adjacent piping is free of pipe scale, welding slag, and any other damaging material. 3. Inspect the valve body to be sure it is free of foreign material. Make sure the adjacent piping is free of pipe scale, welding slag, and any other material that could damage valve seating surfaces. 4. Measure to be sure the distance between the pipeline flanges is approximately 1/4 inch greater than the valve face-to-face dimension. This will ensure easy installation without distorting the liner (figure 3). 5. For conventional discs, flow may be in either direction; for FISHTAIL discs, flow must be such that the tail of the disc (as shown in figure 2) will rotate into the downstream side of the valve. CAUTION To avoid damaging valve parts, observe the following precautions before inserting the valve in the line. a. The inside diameter of the mating piping or flanges must be large enough to allow the valve disc to rotate freely into the upstream and downstream piping, or the disc could be damaged. Do not use piping or flanges having an inside diameter smaller than the minimum shown in table 3. b. The inside of the mating flange must also be small enough to be in full contact with the partial O-rings on the liner faces. Leakage through the flange connections and damage to the liner could result if the partial O-ring 5 9500 Valve Instruction Manual July 2012 D100380X012 faces are not properly supported. Do not use flanges having an inside diameter larger than the maximum shown in table 3. NPS 6 to 10 valves must not be used with slip-on flanges unless flange adaptors are used to support the liner. When using slip-on flanges with other sizes, be certain the valve is carefully centered to ensure that the partial O-ring faces are in full contact with the adjacent flanges. c. When a flange adapter is necessary, a flange gasket must be installed between the line flange and the flange adapter. Do not use a flange gasket between the valve and the flange adapter. Additional gasketing material at this location could damage the liner. d. The valve disc must be in the closed position when the valve is being inserted into the pipeline. If the valve disc is not closed, it could be damaged against the mating piping or flanges. 6. Insert the valve into the pipeline. Insert four flange studs or bolts through the flanges to support the valve. 7. Center the valve carefully on the flanges by measuring equal distances at the top and bottom and equal distances at the sides. 8. Insert the remaining flange studs or bolts. Tighten the studs or bolts evenly. Normal flange bolt torques may be used because liner compression is limited by metal-to-metal contact between flanges and the valve body. 9. Rotate the valve disc manually to be certain the disc clears the adjacent piping or flanges as it opens. If necessary, disconnect the power actuator-valve linkage, but do not disturb the adjustment of the turnbuckle or adjustable linkage. If the disc hits the flange, loosen flange bolting temporarily while re-centering the valve. If the problem cannot be corrected in this manner, it will be necessary to use line flanges with larger inside diameters adjacent to the valve. 10. For hazardous atmosphere or oxygen service valves, read the following Warning, and provide the following bonding strap assembly if the valve is used in an explosive atmosphere. WARNING The valve drive shaft is not necessarily grounded to the pipeline when installed. Personal injury or property damage could result, if the process fluid or the atmosphere around the valve is flammable, from an explosion caused by a discharge of static electricity from the valve components. If the valve is installed in a hazardous area, electrically bond the drive shaft to the valve. 11. Attach the bonding strap assembly (key 131, figure 4) to the shaft with the clamp (key 130, figure 4). 12. Connect the other end of the bonding strap assembly to the valve flange cap screws. Adjustments Hub Seals Key number locations are shown in figure 7. Thrust sleeve assemblies (key 6) seal the disc hubs. In time, especially with frequent valve disc rotation, these seals may require adjustment. Adjust the seals if there is leakage through the valve body around the valve shaft. A small amount of leakage downstream (between the bushings and disc hubs) may also indicate a need for hub seal adjustment. 6 Instruction Manual 9500 Valve D100380X012 July 2012 Figure 4. Grounding Assembly ACTUATOR END PLATE 37A6528-A To adjust the hub seals: 1. Tighten both thrust-plate cap screws (key 10) 1/4 turn on one side (the side where shaft leakage is occurring). CAUTION To avoid excessive side thrust on the disc and possible liner damage, tighten cap screws on both sides of the valve alternately and in 1/4-turn increments. Do not over-tighten by continuous turning or by tightening one side only. Overtightening the cap screws will cause the liner to fail. 2. Tighten both thrust-plate cap screws 1/4 turn on the other side of the valve. 3. Repeat steps 1 and 2 until leakage stops. Note If this adjustment is being performed to stop minor leakage past the disc, check the leakage after turning the cap screws enough to move the thrust plates 0.8 mm (1/32 inch) closer to the valve body. If leakage has not stopped or diminished, the leakage is probably due to incorrect linkage adjustment or damaged valve parts. Refer to the Linkage section to check linkage adjustment; refer to the Maintenance section to inspect and replace parts. 4. If leakage around the shaft cannot be stopped by adjusting hub seals, refer to the Maintenance section to inspect and replace damaged parts. 7 Instruction Manual 9500 Valve July 2012 D100380X012 Figure 5. Tandem Linkage Adjustment for Three-Way Valve Assemblies FLOW ROTARY ACTUATOR HOUSING POWER VALVE CONNECTING ROD ASSEMBLY SLAVE VALVE FLOW B2144-1 FLOW FOR SPLINED VALVE SHAFTS Linkage If the linkage between the power actuator and valve is improperly adjusted, the actuator may reach the end of travel before (or after) the disc reaches the fully closed position. This could result in leakage past the disc. The linkage adjustment is set at the factory, and it should not be necessary to adjust linkage unless the actuator and valve have been separated and the adjustment altered. To check the linkage adjustment on FISHTAIL discs, the flat is on the same side of the shaft as the nose or leading edge of the valve disc (as shown in figure 2). When the valve disc is at the fully closed position, the flat will be either top-dead-center or bottom-dead-center in relation to the valve body. The top-dead-center position is shown in figure 2. A more accurate check of the fully closed disc position is obtained by removing the valve from the pipeline. WARNING To avoid personal injury and damage to the process system caused by the sudden release of pressure, isolate the control valve from all pressure and relieve pressure from the valve body before removing the valve from the line. Be sure the disc is closed so that it will not hit the mating flanges when being removed from the line. With the valve removed from the line, position the actuator to the valve-closed end of the travel. Measure the distance between the valve face and the top and bottom edges of the disc as shown in figure 2. The disc is at the fully closed position if the two measurements are equal. To adjust linkage, refer to the actuator instruction manual. Three-Way Valve Tandem Linkage If the valve is used as part of a three-way valve assembly, adjustment of the tandem linkage (see figure 5) may be necessary to ensure proper rotation of the slave valve disc. 8 Instruction Manual 9500 Valve D100380X012 July 2012 If the adjustment is being performed with the three-way valve assembly out of the line, temporarily bolt the valve bodies to the tee to compress the liner faces until there is metal-to-metal contact between the valve bodies and the tee. Check the rotation of the power valve disc per instructions in the Linkage section. If necessary, adjust the linkage between the actuator and the power valve. To check the fully closed position of the slave valve disc, use the partial keyway on the slave valve shaft or measure equal distances between the slave valve face and the top and bottom of the slave valve disc as described in the Linkage section. Tighten the locknuts on the tandem linkage when adjustment is complete. Maintenance Use table 4 to locate and correct possible leakage or mechanical linkage problems with the valve. WARNING Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations: D Do not remove the actuator from the valve while the valve is still pressurized. D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure on both sides of the valve. Drain the process media from both sides of the valve. D Vent the power actuator loading pressure and relieve any actuator spring precompression. D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when loosening the packing box pipe plug. D Check with your process or safety engineer for any additional measures that must be taken to protect against process media. 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Disassembly Key numbers locations are shown in figure 7. 1. Loosen all flange studs or bolts. Remove all but the bottom flange studs or bolts. CAUTION To avoid damage to the valve disc caused by the disc hitting the mating flange, be certain the disc is closed before removing the valve from the pipeline. 9 Instruction Manual 9500 Valve July 2012 D100380X012 Table 4. Troubleshooting Guide Fault Possible Cause 1. Leakage out sides of valve (at thrust plates) between thrust bushings and shaft. a. Hub seals require adjustment. 2. Leakage out sides of valve (at thrust plates) between valve body and thrust bushings, leakage at flanges, faces, or both a. Flange gaskets used. 3. Leakage through disc/liner seal a. Hub seals require adjustment. Correction a. Adjust using Hub Seals portion of Adjustments procedures. b. Taper pins are not sealed. b. Remove valve from line and re-seat taper pins or install new taper pins using Maintenance procedures. a. Check to see if flange gaskets are being used; if so, remove gaskets. b. Partial O-ring bead on liner faces damaged. b. Replace liner using Maintenance procedures. a. Adjust seals using Hub Seals portion of Adjustments procedures. b. Linkage requires adjustment. b. Refer to Linkage portion of Adjustments procedures. c. Actuator has insufficient torque output to close disc against pressure drop. (Actuators are selected to have sufficient torque output to shut off the flow against a specific pressure drop, not necessarily against the maximum allowable pressure drop. Be sure that the pressure drop for which the actuator is selected is not being exceeded.) d. Liner has been damaged by flowing medium or other valve parts damaged by being subjected to service conditions beyond those for which valve is designed. 4. Valve shaft will not rotate a. If actuator does not stall, but shaft does not rotate, the spline teeth on the valve shaft are sheared. b. If actuator stalls, shaft is binding in bushings due to linkage misalignment caused by excessive wear of linkage parts. c. If actuator stalls and linkage is not misaligned, actuator may have insufficient output torque to rotate disc against flow. 5. Valve shaft rotates, but valve does not control process fluid Taper pins (or drive shaft spline for coated-disc constructions) have been sheared due to obstruction to disc rotation or other internal parts damaged by being subjected to service conditions beyond those for which the valve was designed. c. If possible, check shutoff at lower pressure drops. If shutoff is obtained at low pressure drops, but actuator stalls and does not produce full disc rotation at service pressure drop, actuator output torque is too low. For piston actuators, it may be possible to increase output torque by increasing supply pressure. Do not exceed maximum allowable supply pressure of actuator. d. Inspect and replace parts using Maintenance procedures. a. Refer to the actuator instruction manual to remove actuator cover plate. Replace valve shaft using Maintenance procedures if spline teeth are sheared. b. Replace linkage parts. c. Check actuator operation with no pressure applied to the valve. If valve now functions properly, actuator is too small. Inspect and replace parts using the Maintenance procedures. 2. If necessary, pry flanges apart so that liner faces will not be damaged when the valve is being removed. Inspect the disc (key 3) and liner (key 2) for wear or damage. 3. Remove the actuator from the valve. Follow instructions in the appropriate actuator instruction manual. 4. From both sides of valve, unscrew thrust-plate cap screws (key 10) and remove thrust plates (key 9). 5. If taper pin (key 15) ends are peened, grind off the peened portions. Driving from the smaller end of the pins, drive the pins out of the disc (key 3) and shaft (key 4). WARNING Once the shaft has been removed, the disc may fall from the valve body, causing personal injury or disc damage. Support the disc before removing the shaft. 6. Pull the shaft out of the valve body. If the shaft cannot be pulled from the valve body, drive the shaft out but use care to avoid upsetting the end of the shaft. 7. Remove the disc from the valve body. 10 Instruction Manual 9500 Valve D100380X012 July 2012 8. Remove the liner (key 2) from the valve body. Some 9500 valves have the liner bonded to the valve body. If the valve has a bonded liner, burn or chip out the liner. To strip the liner out with solvent, use Dynasolve 185, or equivalent solvent. (Dynasolve is a product of DYNALOYt Inc.). Cover the valve with solvent bath or enclose the solvent bath around the liner. Remove all adhesive after the liner has been removed. Table 5. Taper Pin Details for 9500 Series Valves VALVE SIZE, NPS SHAFT DIAMETER mm (Inches) AMERICAN STANDARD TAPER PIN SIZE DRILL SIZE 2 3, 4 12.7 (1/2) 15.9 (5/8) 2 3 #20 (0.161 Inches) #16 (0.177 Inches) 6 8, 10 12 19.1 (3/4) 25.4 (1) 31.8 (1-1/4) 4 6 7 13/64 Inches 9/32 Inches 21/64 Inches Reassembly Before reassembling the valve, clean and inspect all parts. Key number locations are shown if figure 7. Refer to the Parts List section to obtain replacement parts. WARNING Do not lubricate parts when used in oxygen service, or where the lubrication is incompatible with the process media. Any use of lubricant can lead to the sudden explosion of media due to the oil/oxygen mixture, causing personal injury or property damage. 1. Insert the liner (key 2) into the valve body. A small amount of silicone grease applied to the outside surface of the liner will aid insertion of the liner. However, do not use grease if the valve is to be used for oxygen service. In vacuum service applications, upon customer request, you may use Eccobondr 285/24LV bonding agent (Fisher part number G1414006992) to bond the liner to the valve. Though bonding is not required, use the lettered steps below when bonding the liner to the valve body. If a different agent is to be used, follow instructions furnished by the bonding agent manufacturer. In absence of instructions, consult your Emerson Process Management sales office. a. Roughen bonding surface of liner with a stiff wire brush. De-grease bonding surfaces of the liner and valve body with solvent. b. Mix the two epoxy components thoroughly and spread a thin coat [approximately 0.38 mm (0.015 inches) thick] of the mixture over all bonding surfaces of the valve body and liner. c. Insert the liner into the valve body. Align the liner shaft holes with valve body shaft holes. Remove excess bonding agent from shaft holes and exposed liner surfaces. d. Insert the disc (key 3), thrust sleeve assemblies (key 6), and shaft (key 4) into the valve body. Be sure the thrust sleeve assemblies engage the liner recesses to ensure proper liner positioning. Rotate the disc to the closed position. e. Lay the valve on one valve face and add weights to the other face to ensure a tight bond. Allow to cure for 24 hours. Then, proceed with the following reassembly steps. 2. Insert the thrust sleeve assemblies into the valve body. Be sure that the thrust sleeve assemblies enter the liner recesses to align the shaft holes, by temporarily inserting the shaft(s) (key 4). 11 9500 Valve Instruction Manual July 2012 D100380X012 3. A new disc and shaft should be installed if the taper pin holes have been widened by loosening of the taper pins (key 15). Omit the following steps 4 through 8 if a new disc and shaft assembly is to be installed or if the old disc and shaft are to be reused. Use new taper pins whenever the disc has been removed. CAUTION If a new disc is required, a complete disc/shaft assembly must be purchased to avoid damage to valve parts. The old valve shaft cannot be used with a new disc. If a new shaft (without disc) has been purchased, be sure to mark the shaft to indicate the disc position as shown in figure 2. 4. Making certain the taper pin holes are on the actuator side of the valve body, insert the disc into the valve body. Position the disc at the fully closed position. 5. Installing splined shaft: a. If the old shaft is available, insert it into the valve body and disc. Line up the taper pin holes in the disc and shaft; measure and record the distance between the valve body and the splined end of the shaft. Remove the old shaft and insert the new, un-drilled shaft. Position the shaft so that there is the same distance between the valve body and the end of the shaft as noted above. b. If installing a new shaft, insert the new shaft into the valve body and disc. Measure between the valve body and the splined end of the shaft. Make certain that the distance is correct to engage the actuator coupling lever. Be certain that the flat spot or index mark on the end of the shaft is positioned as shown in figure 2. 6. Use a drill or center punch to mark the taper pin holes in the shaft. Remove the shaft and disc from the valve body. 7. Taper pins used in the 9500 valve shaft and disc are American Standard taper pins, as shown in table 5. Using the disc as a guide, drill taper pin holes through the shaft using drill size shown in table 5. 8. Use an American Standard taper pin reamer to ream the shaft holes. Be certain the reamer is of sufficient length for the disc hub thickness. Insert the shaft into the disc when reaming so the disc holes can be used as a gauge for reaming. Allow the reamer to just begin reaming the disc holes. This will ensure proper seating of the pins. 9. Install the disc and shaft into the valve body. Be sure the splined end of the shaft is on the actuator side of the valve body, that the direction of taper in the taper pin holes match, and that the flat spot or zero mark is positioned as shown in figure 2. 10. Using a metal sealing compound on the pins for a positive seal, insert the taper pins into the larger end of the taper pin holes. Drive the pins with a hammer to seat the pins. 11. Attach the thrust plates (key 9) with cap screws (key 10). When tightening the cap screws, do so in small increments, alternating from one cap screw to another and from one valve side to the other. Tighten the cap screws until the thrust plates contact the thrust sleeve assemblies snugly. Then rotate the cap screws enough to move the thrust plates 0.8 mm (1/32 inch) closer to the valve body. 12. Re-attach the actuator according to the steps in the Actuator Mounting section; then install the valve according to the steps in the Installation section. 12 Instruction Manual D100380X012 9500 Valve July 2012 Actuator Mounting 1. Refer to the appropriate actuator instruction manual to determine the desired actuator mounting style and position. With the valve out of the line, mount the actuator on the valve per instructions in the actuator instruction manual. 2. To determine the fully closed disc position, measure the distances between the valve face and the top and bottom edges of the disc as shown in figure 2. The disc is at the fully closed position when the two measurements are equal. Rotate the disc slightly if necessary to make the measurements equal. 3. Refer to figure 6 and locate the view that depicts the mounting style and position that is being used. In the appropriate view on the right of figure 6, note the positions of the index marks on the end of the valve shaft and actuator lever. For all positions and styles with 90-degree disc rotation, the shaft index mark is to be aligned with the appropriate lever index mark as shown in figure 6. This is also true for push-down-to-open action with 60-degree maximum disc rotation. However, for push-down-to-close action with 60-degree maximum disc rotation, the appropriate lever index mark must be offset one or two spline teeth counterclockwise from the shaft index mark. Refer to the appropriate actuator instruction manual for instructions covering attaching the lever and adjusting the turnbuckle. For FISHTAIL discs, be certain that the direction of rotation will be such that the tail of the disc (see figure 2) will rotate into the downstream side of the valve. 13 9500 Valve July 2012 Instruction Manual D100380X012 Changing Disc Rotation and Action Disc rotation can be changed from 0-90 degrees or vice versa by changing travel stops in the actuator and, if necessary, changing the position of the lever on the splined valve shaft. Action can be changed from push-down-to-open to push-down-to-close by removing the actuator and remounting it in the alternate mounting style. Refer to the appropriate actuator instruction manual for assistance in disassembly and reassembly to change travel stops and for instructions to change mounting style. Note Action for valves using a splined valve shaft can also be changed, without changing mounting style, by repositioning the actuator lever on the valve shaft. For FISHTAIL discs, it will be necessary to rotate the disc 180 degrees so that the tail of the disc will rotate into the downstream side of the valve. Use the following procedure. 1. Refer to the appropriate actuator instruction manual for assistance in disconnecting and removing the actuator lever. Avoid disturbing the actuator turnbuckle adjustment, if possible. 2. If the valve disc is a FISHTAIL disc, rotate the disc 180 degrees from the original position. 3. Position the disc in its fully closed position. To ensure that disc is fully closed, measure equal distances between valve face and top and bottom of the disc as shown in figure 2 or check to be sure that the flat spot or index mark on the valve shaft is in top-dead-center or bottom-dead-center in relation to the valve. WARNING To avoid personal injury, keep hands away from the actuator rod in the following procedure. 4. Note the position of the valve shaft index mark. Index mark alignments for reversed action are not shown in figure 6. To determine proper index mark alignment, proceed as follows: a. Stroke the actuator to the valve-closed end of travel and retain that position while performing the next step. b. Keeping hands away from the actuator rod, hold the actuator lever up to the valve shaft so that the lever end is in line with the actuator rod end bearing. The lever index mark that is most nearly in line with the valve shaft index mark is the index mark that must be used during reassembly. If changing to push-down-to-close action with 60-degree operation, the lever index mark will be offset 1 spline tooth from the valve shaft index mark for 12.7 through 19.1 mm (1/2 through 3/4-inch) valve shafts and 2 spline teeth from the valve shaft index mark for 25.4 and 31.8 mm (1 and 1-1/4 inch) valve shafts. This offset must be maintained during reassembly. 5. Record the alignment determined in step 4, remove the actuator lever, and shut off operating pressure to actuator. 6. Reassemble the lever to the actuator and adjust the actuator travel, if necessary, referring to the steps in the appropriate actuator instruction manual. Be sure to use the index mark alignment determined above rather than those shown in figure 6. 14 Instruction Manual 9500 Valve D100380X012 July 2012 Figure 6. Splined-Shaft Index Mark Alignment for Standard Mounting Position-Valve Action Combinations ACTUATOR ROD ACTUATOR HOUSING COVER ACTUATOR ROD END BEARING ACTUATOR LEVER LEVER INDEX MARKS (4) VALVE SHAFT INDEX MARK 14A7222-A 54A3246-B A1837-3 TYPICAL ACTUATOR (FISHER 1061) SECTIONAL THROUGH HOUSING 54A3246-B B1054-3* 1 2 3 FOR 60-DEGREE OPERATION WITH PUSH-DOWN-TO-CLOSE ACTION (EXTENDING ACTUATOR ROD CLOSES VALVE), ROTATE ACTUATOR LEVER COUNTERCLOCKWISE SO THAT LEVER INDEX MARK IS OFFSET 1 SPLINE TOOTH FROM VALVE SHAFT INDEX MARK FOR ½ THROUGH ¾ INCH VALVE SHAFTS AND 2 SPLINE TEETH FROM VALVE SHAFT INDEX MARK FOR 1 INCH AND LARGER VALVE SHAFTS. CURVED ARROWS INDICATE ROTATION REQUIRED TO OPEN VALVE (COUNTERCLOCKWISE WHEN VIEWED FROM ACTUATOR SIDE OF VALVE). ARROWS INDICATE DIRECTION OF ACTUATOR ROD TRAVEL REQUIRED TO OPEN VALVE. 15 Instruction Manual 9500 Valve July 2012 D100380X012 Parts Ordering A serial number is assigned to each valve body and stamped on the nameplate. Always refer to the serial number when corresponding with your Emerson Process Management sales office regarding spare parts or technical information. When ordering replacement parts, also specify the complete 11-character part number from the parts list information. WARNING Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management should not, under any circumstances, be used in any Fisher valve, because they may void your warranty, might adversely affect the performance of the valve, and could cause personal injury and property damage. Parts List Key Note Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office. Key Description 1 Valve Body If you need a valve body as a replacement part, order by valve size, serial number, and desired material. Liner Assy Nitrile NPS 2 F3897005562 NPS 3 F3897105562 NPS 4 F3897205562 NPS 6 F3897305562 NPS 8 F3897405562 NPS 10 F3897505562 NPS 12 F3897605562 PTFE/CR (Cloroprene) NPS 2 F3587505452 NPS 3 F3587905452 NPS 4 F3588005452 NPS 6 F3581005452 NPS 8 F3588105452 NPS 10 F3588205452 NPS 12 F3588305452 Disc Shaft S17400 (17-4 PH SST) CL125/150 NPS 2 L17986K0012 NPS 3 L17987K0012 NPS 4 L17988K0012 NPS 6 L17989K0012 NPS 8 L17990K0012 NPS 10 L17991K0012 NPS 12 L17992K0012 2* 3 4* 16 Part Number Description CL300 NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 S20910 CL125/150 NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 CL300 NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 S31600 (316 stainless steel) 1083 NPS 2 1083 NPS 3 1083 NPS 4 1083 NPS 6 CL125/150 NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 *Recommended spare parts Part Number F65117K0012 F61929K0012 F65480K0012 F65493K0012 F65484K0012 F66225K0012 F63606K0012 L17986K0042 L17987K0032 L17988K0042 L17989K0032 L17990K0032 L17991K0022 L17992K0032 F65117K0022 F61929K0022 F65480K0022 F65493K0022 F65484K0022 F66225K0022 F63606K0022 18A5865X022 18A5866X022 18A5867X022 18A5868X022 L17986K0032 L17987K0022 L17988K0032 L17989K0022 L1799035072 L1799135072 L17992K0022 Instruction Manual 9500 Valve D100380X012 Key 6* Description Sleeve/Bushing Assy (2 req'd) Stainless Steel/PTFE CL150 - CF8M body NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 CL300 - CF8M body NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 Steel/PTFE CL125/150 - Iron/steel body NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 CL300 - steel body NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 *Recommended spare parts July 2012 Part Number Key Description 9 10 15* Plate, Thrust (2 req'd) Screw,Cap, hex hd (4 req'd) Taper Pin (2 req'd) S31600 (316 SST) NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 S17400 (17-4 PH) NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 S20910 NPS 2 NPS 3 NPS 4 NPS 6 S20910 NPS 8 NPS 10 NPS 12 Nameplate Drive Screw, steel (2 req'd) Flow Tag, stainless steel (FISHTAIL disc only) FISHTAIL Disc Tag (FISHTAIL disc only) Flange Tag (not shown) Seal & Wire (not shown) Clamp, stainless steel Bounding strap assembly Flange Adapter (not shown) (2 req'd) 19A9333X022 19A9335X022 19A9337X022 19A9339X022 19A9347X012 19A9349X012 19A9351X012 19A9334X022 19A9336X022 19A9338X022 19A9340X022 19A9348X012 19A9350X012 19A9352X012 19A9333X012 19A9335X012 19A9337X012 19A9339X012 19A9341X012 19A9343X012 19A9345X012 19A9334X012 19A9336X012 19A9338X012 19A9340X012 19A9342X012 19A9344X012 19A9346X012 16 17 19 21 22 26 130 131 132 Part Number F1368135072 G1194435072 G1194235072 G1194035072 G1193835072 G1329135072 H1374835072 F1368135362 G1194435362 G1194235362 G1194035362 G1193835362 G1329135362 H1374835362 F13681K0022 G11944K0032 G11942K0012 G11940K0022 G11938K0032 G13291K0012 H13748K0032 17 9500 Valve July 2012 Figure 7. Fisher 9500 Valve Body Assembly PARTS NOT SHOWN: KEY 22 G34171-B 18 Instruction Manual D100380X012 Instruction Manual D100380X012 9500 Valve July 2012 19 9500 Valve July 2012 Instruction Manual D100380X012 Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user. Fisher and FISHTAIL are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management Marshalltown, Iowa 50158 USA Sorocaba, 18087 Brazil Chatham, Kent ME4 4QZ UK Dubai, United Arab Emirates Singapore 128461 Singapore www.Fisher.com 20 E 1976, 2012 Fisher Controls International LLC. All rights reserved.