Installation, Operation and
Maintenance Instructions
MODEL 5400 / 5450
April 2003
CONTENTS
1.0
GENERAL
1.1
1.2
1.3
1.4
Model Number -------------------------------------------------------------------------------------------------------Specifications --------------------------------------------------------------------------------------------------------Parts List ---------------------------------------------------------------------------------------------------------------1.3.1 Model 5400 Direct ----------------------------------------------------------------------------------------1.3.2 Model 5400 Reverse -------------------------------------------------------------------------------------1.3.3 Model 5400 Reverse with Manual Override Handwheel ----------------------------------------1.3.4 Model 5450 Direct ----------------------------------------------------------------------------------------1.3.5 Model 5450 Reverse -------------------------------------------------------------------------------------Dimensions -------------------------------------------------------------------------------------------------------------
2
3
6
6
8
10
12
14
16
2.0
INSTALLATION ------------------------------------------------------------------------------------------------------------- 18
3.0
MAINTENANCE
3.1
3.2
3.3
3.4
3.5
Trim Replacement ---------------------------------------------------------------------------------------------------Packing Replacement ----------------------------------------------------------------------------------------------Actuator Diaphragm Replacement ------------------------------------------------------------------------------3.3.1 Direct (Fail Open) Actuators ---------------------------------------------------------------------------3.3.2 Reverse (Fail Closed) Actuators ----------------------------------------------------------------------Preventive Maintenance -------------------------------------------------------------------------------------------3.4.1 Valve Body --------------------------------------------------------------------------------------------------3.4.2 Valve Trim --------------------------------------------------------------------------------------------------3.4.3 Packing -----------------------------------------------------------------------------------------------------3.4.4 Actuator Assembly ---------------------------------------------------------------------------------------Troubleshooting -------------------------------------------------------------------------------------------------------
19
19
20
20
20
21
21
21
21
21
22
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.0
GENERAL
1.1
Model Number Information
Sample Model Number:
5450 - 2
S
5
–
G
73
R
B
STYLE
CODE
Open Yoke
00
Close-Coupled
50
BODY SIZE
CODE
1”
1
2”
2
END CONNECTIONS
CODE
Female NPT
S
Raised Face (RF) Flange
F
Ring Type Joint (RTJ) Flange
J
Other
(special)
ANSI CLASS (PRESSURE RATING)
CODE
150 ( 275 psig @ 100°F)
1
300 ( 740 psig @ 100°F)
3
600 (1480 psig @ 100°F)
6
900 (2220 psig @ 100°F)
9
1500 (3750 psig @ 100°F)
5
FNPT, Socket Weld, Butt Weld Ends (4000 psig @ 200°F)
MATERIALS OF CONSTRUCTION
CODE
WCC Steel – Standard Service
WCC Steel – Marine Service
M
WCC Steel – NACE MR-01-75
N
WCC Steel – Marine Service and NACE MR-01-75
P
Other
(special)
BODY STYLE
CODE
Globe
G
Tee (1”) or Angle (2”)
T
Globe with Tapped Pressure Ports
P
ACTUATOR SELECTION
CODE
Size 35 Actuator with 3-15 Spring
33
Size 35 Actuator with 6-30 Spring
36
Size 70 Actuator with 3-15 Spring
73
Size 70 Actuator with 6-30 Spring
76
ACTUATOR TYPE
CODE
Reverse Acting (fail-close)
R
Direct Acting (fail-open)
D
Reverse Acting (fail-close) with Manual Override Handwheel
H
(only available with open yoke style, size 70 actuator with 3-15 spring)
SEAL MATERIAL
CODE
Buna-N
B
Viton
V
Other
(special)
TRIM MATERIAL
17-4PH SST
Tungsten Carbide
Other
TRIM SIZE
1/4”
3/8”
1/2”
3/4”
1”
TRIM CHARACTERISTIC
Quick Opening (On/Off)
Modified Percent (Throttling)
Page 2
-
1
4
Q
CODE
1
2
(special)
CODE
2
3
4
6
8
CODE
Q
M
1.2
Specifications
Available Configurations
Open Yoke (Model 5400), fail-open or fail-close
Close-coupled (Model 5450), fail-open or fail-close
Body Styles
Globe: 1” and 2”
Angle: 2” only
Tee:
1” only
End Connections / Pressure Ratings
FNPT:
• 4000 psig from -20 to 200°F (276 bar from -29 to
93°C)
• 4000 psig at -40°F (276 bar at -40°C)
• 3540 at 500°F (1949 bar at 260°C)
1
Flanged :
• 150# RF
275
psig ( 19 bar)
• 300# RF
740
psig ( 51 bar)
• 600# RF
1480
psig (102 bar)
• 600# RTJ
1480
psig (102 bar)
• 900# RF
2220
psig (152 bar)
• 900# RTJ
2220
psig (152 bar)
• 1500# RF
3750
psig (259 bar)
• 1500# RTJ
3750
psig (259 bar)
Available Trim Sizes
1/4”, 3/8”, 1/2”, 3/4”, and 1”
Flow Characteristic
Modified Percent (Throttling)
Quick Opening (On/Off)
Flow Coefficients
See Table 3
Flow Direction
Either direction, to suit the application
Flow up (under the seat) recommended for throttling
applications
Actuator Size (Diaphragm Effective Area)
Size 35 (35 in2)
Size 70 (70 in2)
Air Pressure to Actuator
3–15 Spring: 0 to 20 psig control signal recommended
6–30 Spring: 0 to 35 psig control signal recommended
Actuator Housing Maximum Pressure:
• Size 35: 50 psig
• Size 70: 35 psig
Maximum Pressure Drops
See Tables 1 and 2
Note: For trim with soft-seat insert, maximum pressure
drops are equal to values in Tables 1 and 2 or
1000 psi (69 bar), whichever is less.
Assembled Valve Temperature Limits
5450 (close-coupled)
WCC body with Buna-N seals: -20 to 180°F (-29 to 82°C)
WCC body with Viton seals:
-20 to 200°F (-29 to 93°C)
LCC body with Buna-N seals: -40 to 180°F (-40 to 82°C)
5400 (open yoke)
WCC body with Buna-N seals:
WCC body with Viton seals:
WCC body with Kalrez seals:
LCC body with Buna-N seals:
-20 to 180°F (-29 to 82°C)
-20 to 450°F (-29 to 232°C)
-20 to 500°F (-29 to 260°C)
-40 to 180°F (-40 to 82°C)
Materials of Construction / Temperature Limits
See Table 4
Shutoff Classification
17-4PH SST or Tungsten Carbide Trim: ANSI
Class IV
17-4PH SST Trim with Soft-Seat Insert: ANSI
Class VI
1.
Pressure ratings at 100°F (38°C).
Page 3
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
Table 1. Maximum Allowable Shutoff Pressure Drops1, Reverse-Acting (Fail-Close) Actuator
Signal to Actuator
Actuator
Size
Flow
Direction
Up
35
Down
Up
70
Down
1.
Trim Size
Inches
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
3 to 15 psig
psi
3800
2050
1100
320
110
4000
4000
3350
1580
770
4000
3210
1650
530
230
4000
4000
4000
2080
970
0 to 20 psig
(3-15 spring)
bar
psi
262
4000
141
3280
76
1680
22
560
8
220
276
4000
276
4000
231
4000
109
2300
53
1100
276
4000
221
4000
114
3190
37
940
16
420
276
4000
276
4000
276
4000
143
2800
67
1460
bar
276
226
116
39
15
276
276
276
159
76
276
276
220
65
29
276
276
276
193
101
6 to 30 psig
0 to 35 psig
(6-30 spring)
bar
psi
276
4000
235
4000
126
2300
48
950
22
490
276
4000
276
4000
276
4000
174
3270
86
1680
276
4000
276
4000
276
4000
139
2800
66
1460
276
4000
276
4000
276
4000
259
4000
173
2950
psi
4000
3410
1830
690
320
4000
4000
4000
2530
1240
4000
4000
4000
2020
960
4000
4000
4000
3780
2510
bar
276
276
159
66
34
276
276
276
226
116
276
276
276
193
101
276
276
276
276
203
For valves with soft-seat inserts, maximum allowable pressure drop is 1000 psi (69 bar) or the values in the table, whichever is less.
Table 2. Maximum Allowable Shutoff Pressure Drops1, Direct-Acting (Fail-Open) Actuator
Actuator
Size
Flow
Direction
Up
35
Down
Up
70
Down
1.
2.
Signal to Actuator
Trim
Size
Inches
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
1/4
3/8
1/2
3/4
1
psi
4000
2700
1370
410
140
4000
4000
3800
1750
860
4000
4000
2540
730
230
4000
4000
4000
4000
1840
2
3 to 15 psig
6 to 30 psig
(3-15 spring)
(6-30 spring)
bar
276
186
94
28
10
276
276
262
121
59
276
276
175
50
16
276
276
276
276
127
psi
4000
4000
2880
1080
520
4000
4000
4000
1940
940
4000
4000
4000
2020
960
4000
4000
4000
4000
2790
For valves with soft-seat inserts, maximum allowable pressure drop is 1000 psi (69 bar) or the values in the table, whichever is less.
Actual signal pressure to actuator includes an additional 5 psig (0.3 bar) of supply pressure to the controller.
Page 4
bar
276
276
199
74
36
276
276
276
134
65
276
276
276
139
66
276
276
276
276
192
Table 3. Flow Coefficients (CV)
Modified Percent
Body
Size
1”
2”
Orifice
Size
0.25
0.38
0.50
0.75
1.00
0.25
0.38
0.50
0.75
1.00
Angle
Body
Globe Body
10
.284
.311
.502
.882
1.01
.284
.311
.592
.882
1.08
20
.506
.621
1.05
1.76
2.02
.506
.621
1.17
1.81
2.12
30
.657
.942
1.59
2.76
3.44
.657
.942
1.76
2.98
3.58
40
.767
1.28
2.09
3.82
5.07
.767
1.28
2.34
4.11
5.43
50
.875
1.64
2.61
4.93
6.78
.875
1.64
2.95
5.74
7.46
Valve Opening (% Travel)
60
70
80
.989
1.10
1.20
2.07
2.51
2.93
3.14
3.72
4.27
6.17
7.49
8.85
8.42
10.3
12.4
.989
1.10
1.20
2.07
2.51
2.93
3.70
4.57
5.50
7.03
8.49
10.1
9.27
11.4
13.7
90
1.32
3.35
4.96
10.0
14.3
1.32
3.35
5.95
11.5
15.8
100
1.40
3.70
5.62
11.0
15.4
1.40
3.70
6.08
12.9
17.1
100
1.64
4.23
6.61
15.1
20.8
1.66
4.35
6.90
15.2
21.1
Quick Open
Globe
Angle
Body
Body
100
1.68
3.82
5.70
11.6
15.5
1.68
3.82
6.19
13.0
18.0
100
1.92
4.34
6.72
15.2
20.9
1.98
4.47
7.00
15.8
22.0
Table 4. Materials of Construction
Part
Body
Bonnet (Packing Plug)
Hammer Nut
Trim
Valve Stem
Packing
Actuator Housing
Actuator Spring
Seal O-Rings
Diaphragm
1.
1
Material
A216 WCC Steel
A352 LCC Steel
316 Stainless Steel
1018 Carbon Steel
316 Stainless Steel
A216 WCC Steel
A350-LF2 LCC Steel
17-4PH Stainless Steel
Tungsten Carbide
17-4PH Stainless Steel with TFE or UHMW soft-seat insert
303 Stainless Steel
316 Stainless Steel
PTFE V-Ring
Heavy-Reinforced PTFE V-Ring
Steel
Steel
Buna-N
Viton
Aflas
Kalrez
Nylon-Reinforced Buna-N
Temperature Limits
°F
°C
-20 to 1000
-29 to 538
-50 to 1000
-45 to 538
-50 to 1000
-45 to 538
-20 to 1000
-29 to 538
-50 to 1000
-45 to 538
-20 to 1000
-29 to 538
-50 to 1000
-45 to 538
-50 to 1000
-45 to 538
-50 to 1000
-45 to 538
-50 to 400
-45 to 204
-50 to 1000
-45 to 538
-50 to 1000
-45 to 538
-50 to 450
-45 to 232
-50 to 500
-45 to 260
-20 to 1000
-29 to 538
-20 to 1000
-29 to 538
-40 to 180
-40 to 82
-20 to 450
-29 to 232
-20 to 450
-29 to 232
-20 to 500
-29 to 260
-20 to 200
-29 to 93
Actual diaphragm upper temperature limit is 180°F. Additional 20°F for heat dissipation is allowed on close-coupled (Model 5450) valves. For open yoke
(Model 5400) valves, diaphragm is not a temperature-limiting factor.
Page 5
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.3
Parts List
1.3.1
Page 6
Model 5400 Direct
Page 7
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.3.2
Page 8
Model 5400 Reverse
Page 9
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.3.2
Model 5400 Reverse with Manual Override Handwheel
Page 10
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
44
45
PART NO.
51260
51311
51255
51257
51250
51188
51274
51556
51346
51554
51552
51294
51501
51548
51511
51516
51518
51522
51524
51526
51540
51195
51203
51205
51210
51198
51189
51191
51147
51131
51186
51181
51558
51328
51259
51251
51314
51316
51264
51546
51562
55114
51309
DESCRIPTION
Packing Plug
Snap Ring
Position Indicator Scale
Screw
Actuator Yoke
Valve Stem
Lower Diaphragm Housing, #70
Diaphragm
O-Ring
Diaphragm Plate
Lower Spring Retainer, #70 3-15
Actuator Spring, #70 3-15
Upper Spring Retainer, #70 3-15
Upper Diaphragm Housing, #70
Stem
Spring Tensioner
Jam Nut
Handwheel
Bushing
Thrust Bearing - Handle
Slot Assembly
Hammer Nut
Packing Retainer, Brass
Teflon Packing
Lower Packing Retainer
Spring Packing Inconel
Packing Washer
O-ring
Cage/Seat
Plug
Solid Drive Pin
O-Ring
Lock Nut
Washer
Valve Body (see other Parts List drawings for part numbers)
Hex Nut
Travel Indicator
Actuator Housing Screw
Actuator Housing Nut
O-Ring
Hex Jam
Stem Assembly
Roll Pin
Breather Plug
QTY.
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
12
12
1
2
1
1
1
Page 11
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.3.4
Model 5450 Direct
Page 12
Page 13
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.3.5
Model 5450 Reverse
Page 14
Page 15
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
1.4
Dimensions
Valve Assembly Dimensions (Inches)
End
Connection
Style
NPT
150# RF
300# RF
600# RF
600# RTJ
900# RF
900# RTJ
1500# RF
1500 RTJ
1”
Globe Body
A
6.25
7.25
7.75
8.25
8.25
9.38
9.38
9.38
9.38
B
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.56
2”
Globe Body
C
3.69
3.69
3.69
3.69
3.69
3.69
3.69
3.69
3.69
A
7.50
10.00
10.50
11.25
11.38
12.88
13.00
12.88
13.00
B
1.69
1.69
1.69
1.69
1.69
1.69
1.69
1.69
1.69
1”
Tee Body
C
3.69
3.69
3.69
3.69
3.69
3.69
3.69
3.69
3.69
G
4.69
5.19
5.44
5.69
5.69
6.25
6.25
6.25
6.25
H
3.13
3.63
3.88
4.13
4.13
4.69
4.69
4.69
4.69
2”
Angle Body
G
5.44
6.69
6.94
7.31
7.38
8.13
8.19
8.13
8.19
H
3.75
5.00
5.25
5.63
5.69
6.44
6.50
6.44
6.50
Valve Assembly Dimensions (mm)
End
Connection
Style
NPT
150# RF
300# RF
600# RF
600# RTJ
900# RF
900# RTJ
1500# RF
1500 RTJ
Page 16
1”
Globe Body
A
159
184
197
210
210
238
238
238
238
B
40
40
40
40
40
40
40
40
40
2”
Globe Body
C
94
94
94
94
94
94
94
94
94
A
190
254
267
286
289
327
330
327
330
B
43
43
43
43
43
43
43
43
43
1”
Tee Body
C
94
94
94
94
94
94
94
94
94
G
119
132
138
144
144
159
159
159
159
H
79
92
98
105
105
119
119
119
119
2”
Angle Body
G
138
170
176
186
187
206
208
206
208
H
95
127
133
143
144
163
165
163
165
Actuator Assembly Dimensions (Inches)
5400
Actuator
Size
Size 35
Size 70
5450
Direct
D
17.06
18.56
E
9.50
12.50
Reverse
1
D
14.31
15.44
J
5.50
7.00
E
9.50
12.50
Direct
F
16.31
17.44
D
11.44
12.94
E
9.50
12.50
Reverse
1
J
5.50
7.00
D
8.69
9.81
E
9.50
12.50
F
10.69
11.81
Actuator Assembly Dimensions (mm)
5400
Actuator
Size
Size 35
Size 70
1.
5450
Direct
D
433
471
E
241
317
Reverse
1
J
140
178
D
363
392
E
241
317
Direct
F
414
443
D
290
328
E
241
317
Reverse
1
J
140
178
D
221
249
E
241
317
F
271
300
Clearance required for spring cover removal.
Page 17
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
2.0
INSTALLATION
1.
Prior to valve installation, inspect the unit for damages which might have occurred during shipment and
handling. Remove any items covering the process connections of the valve. Inspect the inlet and outlet
connections to assure that no debris has become lodged inside the valve.
2.
When installing the valve into the pipeline, consult the engineering specifications to ensure that the valve is
installed according to the intended flow pattern (Flow-Up or Flow-Down). As a general rule of thumb, the flow
pattern (direction) is “Flow-Up” for throttling applications, and “Flow-Down” for snap (on/off) applications. The
following symbol is cast into the valve body to help you determine the correct flow pattern.
Valve Body
Flow-Up
3.
Flow-Down
Install valve using good piping practices.
WARNING: Working pressure of control valve body does not necessarily reflect the shut-off
pressure of which the actuator is capable. Check actuator shut-off charts or call the factory.
4.
Connect instrument air to the actuator.
5.
Adjust actuator spring as follows:
Reverse (Fail Close) Actuators: To increase shut-off capability, increase spring pre-load by turning spring
adjusting screw clockwise. To decrease spring pre-load, turn spring adjusting screw counter-clockwise.
Direct (Fail Open) Actuators: To increase opening capability, increase spring pre-load by turning spring
adjusting nut clockwise. To decrease spring pre-load, turn spring adjusting nut counter-clockwise.
Reverse (Fail Close) Actuators with Manual Override Handwheel: To increase shut-off capability, increase
spring pre-load by turning spring adjustment screw clockwise. To decrease spring pre-load, turn spring
adjustment screw counter-clockwise. NOTE: As you adjust the spring pre-load, you must make offsetting
adjustments with the handwheel (clockwise spring adjustment should be offset with counter-clockwise
handwheel adjustment) to account for stem movement.
Caution: If you feel the spring adjustment screw “bottom out” while adjusting, STOP – do not
attempt to continue adjusting with increasing force. TO PREVENT INTERNAL DAMAGE, adjust the
handwheel in the counter direction to provide the spring adjustment screw with more adjustment
room.
Page 18
3.0
MAINTENANCE
WARNING: System pressure must be bled off to 0 psig or the valve must be isolated with the
pressure bled off prior to any maintenance involving disassembly of the valve or valve actuator.
Caution: TO PREVENT DAMAGE TO TRIM SEATING SURFACES, always ensure that the valve plug
is in the “up” position (lifted off the seat) prior to disassembly or reassembly.
3.1
Trim Replacement
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
3.2
Prior to unscrewing the hammer nut:
A. For Reverse (fail close) actuators, apply air supply to the actuator so that the plug is lifted off the
seat.
B. For Direct (fail open) actuators, remove air supply pressure from the actuator so that the plug is
lifted off the seat.
C. For Reverse (fail close) actuators with manual override handwheel, follow procedure in 1A or
optionally turn handwheel counter-clockwise to lift the plug off the seat.
Unscrew hammer nut (counter-clockwise) from valve body.
Lift actuator straight up and off valve body and set down. Valve plug will be attached to the end of the
valve stem.
Pull seat/cage out of seat pocket and lift out of valve body. A seat-pulling tool may be required.
Clean seat pocket in valve body as required.
Place new seat/cage into seat pocket in valve body and push down until it “pops” into place. Be sure
o-ring is in place around bottom of seat/cage prior to installation.
Take actuator assembly and drive retaining pin out of valve plug and unscrew the plug from the valve
stem.
Screw new plug onto the valve stem until pinning holes line up and drive new retaining pin into place.
To prevent damage to seating surfaces, make sure the plug is in the “up” position prior to reassembling the valve body, as described in 1A, 1B, or 1C (as applicable).
Place actuator assembly with new valve plug onto valve body sliding the plug into the new seat / cage
carefully until it “drops” into place.
Screw hammer nut onto valve body until tight.
Reconnect instrument air supply to actuator as required.
Adjust actuator spring, if necessary, as outlined in Step 5 of Section 2.0, “Installation”.
Packing Replacement
1.
2.
3.
4.
Prior to unscrewing the hammer nut:
A. For Reverse (fail close) actuators, apply air supply to the actuator so that the plug is lifted off the
seat.
B. For Direct (fail open) actuators, remove air supply pressure from the actuator so that the plug is
lifted off the seat.
C. For Reverse (fail close) actuators with manual override handwheel, follow procedure in 1A or
optionally turn handwheel counter-clockwise to lift the plug off the seat.
Unscrew hammer nut (counter-clockwise) from valve body.
Lift actuator straight up and off valve body and set down. Valve plug will be attached to the end of the
valve stem.
Proceed as follows:
A. 5400 (Open Yoke):
a. Disconnect lower stem from upper stem and pull lower stem out of packing plug.
b. Remove packing washer and packing load spring.
c. Remove the old packing and packing retainers from packing plug.
d. Slide the upper “thick” packing retainer into the packing gland.
e. Slide the new packing set into the packing gland. (Note: the packing V-rings must be
oriented so that they are pointed toward the pressure.)
f. Slide the lower “thin” packing retainer into the packing gland.
g. Slide lower stem back into place.
h. Reconnect lower stem to upper stem.
Page 19
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
B.
5.
6.
7.
8.
9.
10.
11.
3.3
Page 20
5450 (Close-Coupled):
a. Drive retaining pin out of valve plug and unscrew plug from the valve stem.
b. Remove packing washer and packing load spring.
c. Place actuator assembly back onto valve body and screw hammer nut onto valve body
until tight (as a means of “holding” the packing plug to remove the upper actuator).
d. Unscrew lower housing from packing plug and remove.
e. Unscrew hammer nut (counter-clockwise) from valve body.
f. Remove the old packing and packing retainers from the packing plug.
g. Place actuator assembly back onto valve body and screw hammer nut onto valve body
until tight (as a means of “holding” the packing plug for re-assembly of the upper
actuator).
h. Slide valve stem into packing plug and screw lower housing onto packing plug.
i. Unscrew hammer nut (counter-clockwise) from valve body.
j. Slide the upper “thick” packing retainer over the valve stem and into the packing gland.
k. Slide the new packing set over the valve stem and into the packing gland. (Note: the
packing V-rings must be oriented so that they are pointed toward the pressure.)
l. Slide the lower “thin” packing retainer over the valve stem and into the packing gland.
Replace the packing load spring and packing washer onto the valve stem.
Screw the valve plug onto the valve stem until the retaining pin holes align and install retaining pin.
To prevent damage to seating surfaces, make sure the plug is in the “up” position prior to reassembling the valve body, as described in 1A, 1B, or 1C (as applicable).
Place actuator assembly with new valve plug onto valve body sliding the plug into the new seat / cage
carefully until it “drops” into place.
Screw hammer nut onto valve body until tight.
Reconnect instrument air supply to actuator as required.
Adjust actuator spring, if necessary, as outlined in Step 5 of Section 2.0, “Installation”.
Actuator Diaphragm Replacement
3.3.1
Direct (Fail Open) Actuators:
1.
Prior to unscrewing the hammer nut, remove air supply pressure from the actuator so that
the plug is lifted off the seat.
2.
Unscrew hammer nut (counter-clockwise) from valve body.
3.
Lift actuator straight up and off valve body and set down. Valve plug will be attached to the
end of the valve stem.
4.
Remove spring cover and remove all actuator spring pre-load by unscrewing adjusting nut.
5.
Remove flat washer, upper spring retainer, and actuator spring.
6.
Remove screws and nuts around diaphragm housing.
7.
Slide upper diaphragm housing up and off of the upper actuator stem.
8.
Remove retaining pin from the upper actuator stem and unscrew upper actuator stem from
lower actuator stem. (Note: If using a tool to unscrew the stem, care should be taken not to
damage the outside diameter of the stem as it is an o-ring sealing surface)
9.
Remover upper bearing washer.
10. Remove actuator diaphragm and replace with new diaphragm. If required, replace o-ring seal
in upper actuator housing prior to reassembling actuator.
11. Reassemble by reversing steps 1-9. NOTE: If you experience difficulty reconnecting upper
actuator stem to lower actuator stem, remove breather plug from lower diaphragm housing
and apply air supply to lower diaphragm housing, to lift the lower actuator stem for easier
access.
3.3.2
Reverse (Fail Close) Actuators:
1.
Prior to unscrewing the hammer nut, apply air supply to the actuator so that the plug is lifted
off the seat. For Reverse (fail close) actuators with manual override handwheel, follow same
procedure or optionally turn handwheel counter-clockwise to lift the plug off the seat.
2.
Unscrew hammer nut (counter-clockwise) from valve body.
3.
Lift actuator straight up and off valve body and set down. Valve plug will be attached to the
end of the valve stem.
4.
Remove air supply from actuator.
5.
Remove spring pre-load by unscrewing adjusting screw.
6.
Remove screws and nuts around diaphragm housing.
7.
Remove the two (2) retaining nuts and lock washer.
8.
9.
10.
3.4
Remove upper spring retainer, actuator spring, lower spring retainer, and diaphragm plate.
Remove actuator diaphragm and replace with new diaphragm.
Reassemble actuator by reversing steps 1-9
Preventive Maintenance
The following preventative maintenance should be performed periodically as dictated by the severity of the
application or by maintenance schedule.
3.4.1
Valve Body
The internal valve body should be inspected every time trim is replaced, packing is changed, or
the actuator is worked on. Under normal operating conditions the valve body should show no signs
of wear. If wear is noticed within the valve body from high pressure drops, abrasive flows, or
chemical corrosion, the valve body should be replaced to assure safety during valve operation.
3.4.2
Valve Trim
Check the valve plug and seat for wear that might be caused by high pressure drops, abrasives in
the media, or corrosion. If signs of wear are present, then trim replacement is recommended for
optimum valve performance.
3.4.3
Packing
Check the “weep” hole in the packing plug for discharge. Discharge is a sign of packing leakage. If
discharge is present then packing replacement is recommended.
3.4.4
Actuator Assembly
Visually inspect the actuator operation of the valve by observing the travel indicator assembly
(5450 Model) or the stem connector (5400 Model) while the valve is stoking for a smooth,
consistent movement. Jerking type movements may indicate a problem within the valve. Depressurize the valve and inspect it internally.
Listen for a “hissing” sound during operation. This may indicate a worn seal or diaphragm. Replace
any worn seal or diaphragm.
Page 21
Model 5400 / 5450
Installation, Operation and Maintenance Instructions
3.5
Troubleshooting
Problem
Valve leaks when closed
Valve will not open
Discharge evident from packing
plug “weep” hole.
Supply air leaking out of breather
plug during operation
Page 22
Possible Cause
Fix
Reverse Acting: Actuator spring
load not sufficient.
Reverse Actuator: Increase actuator
spring pre-load.
Direct Acting: Inadequate air
supply pressure.
Direct Acting: Increase air supply
pressure but do not exceed
maximum rating on nameplate.
Debris between the plug and seat
preventing tight shut-off.
Remove debris.
Plug and seat are not sealing.
Re-lap trim.
Plug and seat are worn out.
Replace trim.
Actuator force not enough for
shut-off (actuator to small).
Consult factory or local
representative for proper actuator
sizing.
Check air supply source and
tubing to the actuator connection.
Reverse Acting: Not receiving air
supply.
Reverse Acting: To much spring
pre-load.
Decrease spring pre-load by
turning adjusting screw counterclockwise.
Direct Acting: Inadequate spring
pre-load.
Increase spring pre-load by turning
adjusting nut clockwise.
Debris lodged behind valve plug.
Packing is worn.
Remove debris.
Replace packing.
Diaphragm is worn out or torn.
Replace diaphragm
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