User Manual - Badger Meter, Inc.
Contents
1. DWG NO ISSUE Iss CHANGE BY DATE UNLESS OTHERWISE SPECIFIED ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER mem GAP 09 0596 DIMENSIONS FOR REFERENCE ONLY SHOWN ON THIS DRAWING ARE THE EXCLUSIVE C D 9 52036 01 03 S E gae LENGTH UNITS ARE INCHES PROPERTY OF BADGER METER INCORPORATED NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv CHAR ITEM NO PART NO QTY DESCRIPTION MATERIAL 2 NOMINAL STROKE 1 00 27 1 1 3 RECOMMENDED SPARE PARTS ARE BRONZE 52 4 6 2 527193 0001 1 BRONZE B62 OPTIONAL SPARE PARTS ARE 1 1 STEM 316L SST TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE 1 1 INNVERVALVE 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT 3c NOTE 1 1 SEAT 3161 SST PARTS PROVIDE FACTORY THE VALVE 4 512893 0001 1 GASKET COPPER ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 1 GLAND 316 SST NAMEPLATE ON THE ACTUATOR 6 543242 0001 1 PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1 SPRING 302 SST 9 430002 0115 2 WASHER 316 SST 3125 24 UNF 3a 1 09 2 31 1 1252. 2 NPT 7 00 06 m 4 50 CERTIFIED FOR APPROVALS DATE z3 BA DGER M ETER r SERIES 9000 CONTROL VALVES P O 2 CAST GLOBE BODY Mm SEM 2222 STANDARD BONNET CV RING PACKING SERIAL NO iin MODEL 9106 W HALL 06 23 00 VAR ENGINEER SIZE SCALE DWG NO ISSUE PREPARED BY DATE M A LOBO 10 30 00 A 7 16 952008 01 03 August 2015 RCV UM 00588 EN 02 Page 13 ing Drawings ineeri Eng DWG NO ISSUE 155 BY DATE NOTES PARTS amp MATERIAL LIST GAP Pelee DENOTES QUANTITY OF SPRINGS IN UNIT AT TIME OF CD 952009 01 05 4 ECN 9217 06 23 98 ORIGINAL FACTORY SHIPMENT DOES NOT INDICATE RANGE QUANTITIES ARE FOR ONE 1 UNIT ONLY OR TRAVEL 01 05 CLIII CD H amp TM 06 En PART NO DESCRIPTION MATERIAL 2 STROKE TRAVEL SCALE SPRINGS OTHERS OPTIONAL SIGNALPS QTY PART NUMBER 1 527247 0
3. w RCV Process Control Valves Research Control Research Control ReCo Valves ReCo Valves Model 9100 Badger Meter RCV UM 00588 EN 02 August 2015 User Manual Process Control Valves Model 9100 CONTENTS 3 Unpacking and Inspection SUE RE e Ae RU Io x c 3 S IIS ae ee SPSS E 3 B cl s 7 TT a 5445 w k US 4 scr M OrPr rm 5 Re Orienting the 1 5 instalation GONSIGCIQUONS 5 55 5 b oP S 5 Sh E SE Y wk Om K Q 43 3 22 9 3 6 Adjusting Actuator Spring T Schematic of ATO Valve with Standard Moore 750 Positioner and Airset Piped 8 Removing the Actuator from the Valve 5 lt 8 Disassembling the Valve 5 9 Re Assembling the Valve 5 9 Engineering Drawings 1544544454444 11 Page ii RCV UM 00588 EN 02 August 2015 Scope of This Manual SCOPE OF T
4. 66 6Z F0 TIVH M ON 1135 1237905 JHL NI SLHOIY ASV L3ludOUd TIY 0016 13qQOW NOILV201 OLV NI OS S HO1VRLOV 66 81 11 30199 9 eed Nava me 2 d35QVg STWAOUddV 804 9141332 5114 WILS LAN WF QNO23S 3321 eria uid 96 91 6 WH38WfIN 5NIHdS 7 5 5 3AOW3H i CO Ld _ KINO A18W3SSV SST 62 96 15 10 31551 3 334 SIHL 1014 Ce dHOO 30 X VIW3OVHL V 51 NVTAX s YIWATOd SLONGOUd gt 5 LEZ o 155 1 1000 16525 6c ONIH33NIDN3 WSC 40 V SI NOHLVTAN D 155 3455 C 6100 10000 85 Td AS 7115 1SnHHL H3HSVM 1 LOO0 CEV ZS ZZ MIDS 9 2000 611925 97 215 INIA 1000 250925 SZ 155 JLYIdIWYN 1000 516215 vC 155 3375 135 9500 900007 0 71 31 2513 1 Z3ION zz 87 01 TIIBLIN NOSUV2 1359 1 1000 12215 12 373 ONR O 1 5000 81006 OZ U3AA 10d ONIHSQSHAI 1000 61009 61 NOHLVTAN 9NIHSn8Ndn 1 1000 08815 81 155 U3HSVM tC 1010 20008 71 155 IN Wu ZL 0900 10001 91 155 U3HSVMOH ZL Lzoo roover SL 155 MOS NIY ZL 2000 1000 vl 155 LANWaIs c 8500 10001 l U3INIOd HAVEL 000 6 871S cl TANIA ALO Duds AYOLIV4A LINSNOD LL 155 9 100 gt 000
5. EXCLUSIVE C D 9 5 203 5 01 03 mus ears EUR oco 0621 09 LENGTH UNITS ARE INCHES PROPERTY OF BADGER METER INCORPORATED NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv CHAR ITEM wo PART NO DESCRIPTION MATERIAL 2 NOMINAL STROKE 750 1 527304 0001 1 BODY BRONZE B62 3 RECOMMENDED SPARE PARTS ARE 46 2 527195 0001 1 BRONZE B62 OPTIONAL SPARE PARTS ARE AOI ZIEM oLa TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE 1 1 INNVERVALVE 316L SST 3c NOTE 1 1 SEAT 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT PARTS PROVIDE FACTORY THE VALVE s ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 1 GLAND 316 SST NAMEPLATE ON THE ACTUATOR 6 543242 0001 I PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1 SPRING 302 SST 9 430002 0115 2 WASHER 316 SST 3125 24 UNF 3a 5 1 1 09 2 31 7 1 1 125 12 UNF 6 01 125 2 4 4 44 b 3C Z 64 722 AUN z 1 39 d pt 1 3 4 4 50 06 02 72 CERTIFIED FOR APPROVALS DATE gt BA DG ER METER ie Um SERIES 9000 CONTROL VALVES 3 4 CAST GLOBE BODY ms G PRICE 11 07 95 STANDARD BONNET CV RING PACKING oi MODEL 9102 W HALL 06 23 00 ENGINEER SIZE SCALE DWG NO ISSUE LOBO 10 30 00 12 CD 952035 01 03 16 RCV UM 00588 EN 02 August 2015 Engineering Drawings
6. gasket leakage nnervalve shut off Process Actuator spring load Inlet Hydro test of bonnet body castings amp 450 psi with no leakage of the castings Female Size stamped on body Figure 1 Part identification Page 4 RCV UM 00588 EN 02 August 2015 Installation INSTALLATION 1 Remove protective plugs from body and air signal connection NOTE Leave vent in place 2 Install valve in pipeline using PTFE tape or other suitable pipe thread sealant USE HEX ON BODY TO TIGHTEN PIPE INTO BODY NEVER USE THE ACTUATOR AS A LEVER 3 Install a suitable 1 4 NPT fitting in the air signal connection using TFE tape or other sealant Re Orienting the Actuator IF THE AIR CONNECTIONS IN THE ACTUATOR NEED TO BE RE ORIENTED DO NOT SIMPLY TURN THE ACTUATOR IF THE UNIT IS AIR TO OPEN ATO THE FORCE ON THE INNERVALVE FROM THE CLOSURE SPRINGS WILL DAMAGE THE INNERVALVE If you must re orient the actuator Apply an air signal to the actuator to raise the innervalve off the seat approximately mid travel Loosen the yoke locknut Re orient the actuator Tighten the yoke locknut and THEN release the air signal pressure To accomplish this there is no reason to loosen either the bonnet joint or the connection between the innervalve stem and actuator stem i te If the unit comes equipped with a positioner or other devices refer to the instructions accompanying the accessory Installation Considerat
7. 001 1 YOKE STL EPOXY 75 527233 0002 12 3 5100310149 2 526041 0001 1 SPRING CASE STL EPOXY 100 527233 0001 12 3 51031 0157 526042 0001 1 PRESSURE CASE STL EPOXY 4 NOTE2 SPRING 17 7 PH SST 3 RECOMMENDED SPARE PARTS ARE ITEMS 5 18 amp 20 5 512698 0002 1 DIAPHRAGM NITRILE POLYESTER 4 WHEN ORDERING REPLACEMENT PARTS PROVIDE FACTORY r THE VALVE SERIAL NUMBER FROM THE NAMEPLATE ON THE 6 512883 0001 1 RETAINER STL ZN PL 2 4 8 6 9 1 4 ACTUATOR 7 527315 0001 1 STEM 316 SST 8 512882 0001 1 PISTON ALUM ANODIZED 5 d 9 400013 0085 1 5 16 68 8 SCR STL ZN PL 7 10 430004 0014 6 WASHER LOCK SST 14 11 CONSULT FACTORY 1 DECAL SPRG OTY VINYL 12 512879 0002 1 TRAVEL POINTER NYLON II c 13 410001 0058 2 STEM NUT SST 14 400013 0002 12 RIM SCREW SST 15 15 430004 0021 12 LK WASHER SST 16 7 16 410001 0060 12 RIM NUT SST 17 17 430002 0107 24 WASHER SST 10 18 512880 0001 1 UPRBUSHING NYLATRON 6 19 460019 0001 1 LWRBUSHING POLYMER 20 490018 0003 1 O RING ELF NITRILE 21 28 1047562500 21 512712 0001 1 YOKE GASKET CARBON NITRILE 18 ia 24 22 NOTE2 1 TRAVEL SCALE ALUMINUM 0 111 23 400006 0056 1 SET SCREW SST 9 24 512915 0001 1 NAMEPLATE SST I 25 526037 0001 1 VENTPLUG PLASTIC Pm WU WAWQI 26 526119 0002 6 SCREW STL XYLAN COATED A 27 527432 0001 1 WASHER THRUST STL SILV PL LJ 28 400001 0013 1 SCREW SST 29 5
8. 0588 EN 02 August 2015 Engineering Drawings DWG NO ISSUE 155 CHANGE BY DATE UNLESS OTHERWISE SPECIFIED ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER 01 02 ECN 8882 GAP 09 05 96 DIMENSIONS FOR REFERENCE ONLY SHOWN ON THIS DRAWING ARE THE EXCLUSIVE C D 9 5 2008 01 03 LENGTH UNITS ARE INCHES PROPERTY OF BADGER METER INCORPORATED 01 03 ECN 9160 EM 2001 06 21 00 NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv CHAR ITEM NO PART NO QTY DESCRIPTION MATERIAL 2 NOMINAL STROKE 1 00 1 527190 0001 1 BODY BRONZE B62 3 RECOMMENDED SPARE PARTS ARE 4 6 2 527193 0001 1 BONNET BRONZE B62 OPTIONAL SPARE PARTS ARE 38 NOTE SIEM TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE 1 1 INNVERVALVE 316L SST 3c NOTE 1 1 SEAT 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT PARTS PROVIDE FACTORY THE VALVE L a ee ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 GLAND 316SST NAMEPLATE ON THE ACTUATOR 6 543242 0001 1 PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1 SPRING 302 SST 9 430002 0115 2 WASHER 316 SST B 13125 24 UNF 1 09 2 31 1 125 12 UNF 1 125 5 62 W 207
9. 12 UNF 01 125 1 5 22 1 97 gt lt gt ZZ 1 1 4 NPT 04 00 6 25 06 CERTIFIED FOR APPROVALS DATE gt BA DG ER METER PA SERIES 9000 CONTROL VALVES 1 1 4 CAST GLOBE BODY mes G PRICE 11 09 95 STANDARD BONNET CV RING PACKING CHECKED MODEL 9104 W HALL 07 14 00 TAG NUMBER ENGINEER SIZE SCALE DWG NO ISSUE MB M A LOBO 10 31 00 A 7 16 CD 952036 01 03 August 2015 RCV UM 00588 EN 02 Page 17 Engineering Drawings Page 18 DWG NO ISSUE 155 BY DATE UNLESS OTHERWISE SPECIFIED ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER 20 DIMENSIONS FOR REFERENCE ONLY SHOWN ON THIS DRAWING ARE THE EXCLUSIVE C D 9 52482 01 01 d DGD 062000 LENGTH UNITS ARE INCHES PROPERTY OF BADGER METER INCORPORATED NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv CHAR ITEM PART NO aY DESCRIPTION MATERIAL 2 1 527759 0001 1 BODY BRONZE B62 3 RECOMMENDED SPARE PARTS ARE 46 2 527195 0001 1 BONNET BRONZE B62 OPTIONAL SPARE PARTS ARE 3e NOTE L STEM TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE 1 1 INNVERVALVE 316L SST NOTE 1 1 SEAT 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT E PARTS PROVIDE FACTORY THE VALVE T i ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 1 GLAND 316 SST NAMEPLATE ON THE AC
10. 2 3 RECOMMENDED SPARE PARTS ARE 4 6 2 527193 0001 1 BONNET BRONZE B62 OPTIONAL SPARE PARTS ARE NONE SIM TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE1 1 INNVERVALVE 316L SST 3c NOTE 1 1 SEAT 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT PARTS PROVIDE FACTORY THE VALVE ae ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 GLAND 316 SST NAMEPLATE ON THE ACTUATOR 6 543242 0001 1 PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1 SPRING 302 SST 9 430002 0115 2 WASHER 316 SST 3125 24 UNF 3a 5 1 09 2 31 7 6 3 1 125 12 UNF 01 125 N S S N s 28 oOo N NX NS 4 NC e ON A N hw N b 5 22 3c 9 z 2 ps Kee o M 4 S s3 gt 1 97 12 NPT E 6 25 06 04 00 CERTIFIED FOR APPROVALS DATE gt BA DG E R M ETE R FN DRAN SERIES 9000 CONTROL VALVES 8 1 1 2 CAST GLOBE BODY m G PRICE 11 09 95 STANDARD BONNET CV RING PACKING MIU CHECKED MODEL 9105 W HALL 06 30 00 SIZE SCALE DWG NO ISSUE DNE M A LOBO 10 30 00 A 7 16 952007 01 03 Page 12 RCV UM 0
11. 25944 0001 1 SST a 59 30 500458 0025 GREASE NYLATRON IYA TRADEMARK OF DSM ENGINEERING PLASTIC PRODUCTS INC POLYMER CORP DIV 21 12501000 XYLAN IY A TRADEMARK OF WHITFORD CORP CERTIFIED FOR APPROVALS DATE BADGER METER UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE FOR REFERENCE ONLY LENGTH UNITS ARE INCHES DRAWN SERI ES 9000 CONTROL VALVES P O W HALL 06 05 96 ACTUATOR 35 SQ IN LOCATION CHECKED MODEL 9100 ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER SERIAL NO W HALL 04 29 99 SHOWN ON THIS DRAWING ARE THE EXCLUSIVE PROPERTY OF BADGER METER INCORPORATED TAG NUMBER ENGINEER SIZE SCALE DWG NO PREPARED DATE M A LOBO 04 29 99 A 3 8 CD 952009 01 05 August 2015 RCV UM 00588 EN 02 Page 14 wings Page 15 ng Dra ineeri Eng RCV UM 00588 EN 02 SO LO 0 10256 42 8 V 66 67 70 OgO1 VW vd anssi ON 5Md IVS 37is 833NI9N3 38WN DYL GALVYOdYOONI H 13W 3908 40 ALY3dOYd AAISN1DX43 JHL 38H V DNIMVHG SIH L NO NMOHS
12. 4 and 1 valves 200 225 ft lbs 1 1 4 to 2 valves 450 475 ft Ibs Bonnet Torque High Vibration Areas 3 4 and 1 valves 300 350 ft lbs 1 1 4 to 2 valves 650 700 ft lbs With air still on actuator if ATO lower actuator onto body assembly e Install yoke lock nut and tighten A hammer and punch can be used to tighten nut Thread innervalve stem into Using the input signal stroke the valve to actuator stem check function The bench setting can be adjusted Place the nylon travel pointer disc back in the Ignore if using fixed rate springs V groove of the stem such as 6 15 9 15 or 10 15 range Adjust the travel scale so that the disc points at this point by varying the amount to the bottom mark when the valve is closed of innervalve stem threads Check for external leakage at the points engaged into the actuator stem indicated using 50 100 psig air and a Once the proper amount is soap water solution achieved Not to exceed 4 psi on If there is leakage in the stem packing area 3 Spring unit or 8 psi on 6 Spring tighten the gland 1 2 turn and recheck unit UNLOCK the two stem nuts f desired seat leakage can be checked using and lock the upper nut against the 20 30 psi air at the inlet of the valve with O actuator stem Then lock the pressure in the actuator on ATO units or 15 psi bottom nut against the upper nut air in the actuator on ATC units DO NOT rotate the actua
13. HIS MANUAL This manual explains how to install and operate the Model 9100 Control valve Read this manual carefully before attempting any installation or operation Keep the manual accessible for future reference UNPACKING AND INSPECTION Upon opening the shipping container visually inspect the product and applicable accessories for any physical damage such as scratches loose or broken parts or any other sign of damage that may have occurred during shipment NOTE If damage is found request an inspection by the carrier s agent within 48 hours of delivery and file a claim with the carrier A claim for equipment damage in transit is the sole responsibility of the purchaser SAFETY The installation of the valve must comply with all applicable federal state and local rules regulations and codes Follow your company s safety rules concerning equipment installation or repairs Read the user manual and brochure before attempting repairs Never use this or any valve in an application that is above the limits of the unit Never use the valve above the pressure temperature rating listed in the brochure Never use the valve in applications that attack bronze materials De pressurize the system before disassembling the valve Never rotate the innervalve when in the closed position Rotation of metal on metal components causes galling and will affect the function and shutoff capability of the unit ON ACTUATORS WITH TWO 2 LONG AC
14. OL 1d NZ 115 47583996 1 5800 51000 6 G3ZIQONV NOISId 1000 788716 8 1 59 JHL NO 31V1d3WVN JHL WO 838IAN 1 1935 JHL 155 91 amp WS AYOLDY4 SL Vd LN3W32 V 1d3H DNIH3OHO N3HM t 19 NZ S TINI 9 078 81 S SW31I JYY SLYYd GIGNSWWODIY WovsHdVId 1 2000 869216 S 1960 155 4 41 5 TILON r c910 LE001S ZL LOOO EEZLZS 001 AXOd3 115 35 39055394 1000 270955 SERIES T AXOd3 115 352 5NIHdS 1 1000 10925 c AXOd3 115 1 L000 C CS 1 SH3H1O SONINdS ITVS T3AVMI 390315 WIMALVW NOlLdIlHDS3Q ON Lad ON 1 66 90 70 qoq H QD IIl 12 5010 ATNO LINN 1 303 53 1 2 D ama wow S0 LO OLOCS6 C D S806 N23 010 LSI IVIH3LVW 9 SLYVd SALON A8 JONVHD SSI 305 August 2015 Engineering Drawings DWG NO ISSUE 155 CHANGE BY DATE UNLESS OTHERWISE SPECIFIED ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER 0102 8882 GAP 09 0596 DIMENSIONS FOR REFERENCE ONLY SHOWN ON THIS DRAWING ARE THE
15. SPRING 302 SST 9 430002 0115 2 WASHER 316 SST 3125 24 UNF i 1 09 7 2 31 6 1 125 12 UNF 01 125 4 44 1 39 05 1 4 50 06 CERTIFIED FOR APPROVALS DATE gt BA DG E R M ETE R DRAWN SERIES 9000 CONTROL VALVES P O 1 CAST GLOBE BODY mid G PRICE 11 07 95 STANDARD BONNET CV RING PACKING POM SHEER MODEL 9103 i W HALL 06 23 00 SIZE SCALE DWG NO ISSUE ii EAE M A LOBO 10 30 00 A 12 CD 952006 01 03 August 2015 RCV UM 00588 EN 02 Page 11 Engineering Drawings DWG NO ISSUE ISS CHANGE BY DATE UNLESS OTHERWISE SPECIFIED ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER 01 02 ECN 8882 ane booo DIMENSIONS FOR REFERENCE ONLY SHOWN ON THIS DRAWING ARE THE EXCLUSIVE C 0 95 2007 01 03 LENGTH UNITS ARE INCHES PROPERTY OF BADGER METER INCORPORATED 01 03 ECN 9160 EM 2001 06 21 00 NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv CHAR PART NO QTY DESCRIPTION MATERIAL 2 NOMINAL STROKE 1 00 1 527191 0001 1 BODY BRONZE B6
16. TUATOR 6 543242 0001 PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1 SPRING 302 SST 9 430002 0115 2 WASHER 316 SST 3125 24 UNF 1 09 5 si 2 31 7 HD 1 125 12 UNF 01 125 4 44 i 1 39 22 1 2 NI CERTIFIED FOR APPROVALS DATE z3 BADGER METER eN DENN SERIES 9000 CONTROL VALVES P o 1 2 CAST GLOBE BODY G PRICE 05 27 98 STANDARD BONNET CV RING PACKING T 9101 W HALL 07 14 00 TAGHBHNIBERS ENGINEER SIZE SCALE DWG NO ISSUE M A LOBO 10 30 00 A 12 CD 952482 01 01 RCV UM 00588 EN 02 August 2015 User Manual INTENTIONAL BLANK PAGE August 2015 RCV UM 00588 EN 02 Page 19 Process Control Valves Model 9100 Control Manage Optimize RESEARCH CONTROL is a registered trademark of Badger Meter Inc Other trademarks appearing in this document are the property of their respective entities Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists O 2015 Badger Meter Inc All rights reserved www badgermeter co
17. TUATOR BOLTS THE SPRINGS ARE UNDER TENSION EVEN WHEN ACTUATOR IS OFF THE VALVE WHEN DISASSEMBLING ACTUATOR REMOVE LONG NUTS LAST TO RELIEVE SPRING COMPRESSION DO NOT ROTATE THE ACTUATOR STEM USE A BACKUP WRENCH TO KEEP STEM FIXED DURING CONNECTION OF THE INNERVALVE TO THE STEM ROTATION OF THE STEM WILL CAUSE THE SPRINGS TO SHIFT WHICH WILL CAUSE THE ACTUATOR TO MALFUNCTION e Never use the actuator as a lever to tighten the valve body onto a pipe or fitting Never clamp the body in a vice on the sides of the body Always clamp end to end Replace any damaged components It s less expensive than a shut down Remove the actuator before disassembling the valve sub assembly August 2015 RCV UM 00588 EN 02 Page 3 Description EVEN THOUGH THE MODEL 9100 IS A RUGGED VALVE IF THE UNIT WILL BE INSTALLED IN A HIGH VIBRATION SITUATION THE ACTUATOR SHOULD BE BRACED AN ANGLE BRACKET KIT FITTING THE ACTUATOR RIM SCREWS IS AVAILABLE FOR THIS PURPOSE THE BRACKET CAN ALSO BE USED TO MOUNT ACCESSORIES TO THE ACTUATOR DESCRIPTION Vent for Air To Open actuator Input air for Air To Close actuator Input signal for Air To Open actuator Vent for Air To Close actuator Refer to nameplate for signal range Do not exceed max signal pressure Nameplate w serial number Safety travel pointer Travel indicator Yoke lock nut Standard Tests And Adjustments Bonnet Performed Prior To Shipment Packing load leakage Body
18. Z Issa l b gt gt gt C Lower TFE adapter jme N N D 3 chevron rings E E Upper adapter F Follower Re Assembling the Valve Subassembly iss p DDD ci ss b gt gt gt TO Install stuffing box components in the order shown over stem Be careful when sliding the packing rings over the stem threads Lubricate w silicone grease all TFE parts and threads Insert new innervalve into empty bonnet Install 2 jam nuts onto stem bottom of threads and lock together with wrenches Tighten packing gland until there is a 0 04 05 1 1 5 mm or about the thickness of a quarter gap between the bottom of the gland hex and the top of the bonnet Install packing gland Tighten finger tight Note If packing leakage occurs the gland can be tightened down all the way if necessary to the bonnet without damaging the packing August 2015 RCV UM 00588 EN 02 Page 9 Schematic of ATO Valve with Standard Moore 750 Positioner and Airset Piped e Install new gasket and thread bonnet into body Use lubricant on gasket and bonnet threads Caution To preclude galling innervalve onto seat pull stem up until it stops before threading bonnet into body install new seat ring Use lubricant on threads and seat chamfer Torque to 3 4 and 1 valves 50 60 ft Ibs 1 1 4 and 1 1 2 valves 100 110 ft Ibs 2 valves 150 160 ft lbs Bonnet Torque Normal Applications 3
19. al From controller or i P Note Refer to the enclosed tansducer positioner instructions to set Zero and Span of the positioner The safety nylon pointer disc can be popped out of it s groove and slid up the stem to facilitate maintenance if necessary f actuator is ATO Input air signal stroking the valve to full open Not necessary if actuator is Unscrew innervalve stem from actuator stem using wrench on jam nuts e Unscrew yoke lock nut Lift actuator off valve subassembly Note The air signal can be left on the actuator if the actuator is not going to be disasembled DO NOT use pliers on innervalve stem Scratches will damage packing rings Page 8 RCV UM 00588 EN 02 August 2015 Schematic of ATO Valve with Standard Moore 750 Positioner and Airset Piped Disassembling the Valve Subassembly Bonnet Innervalve JE Unscrew and LL Pull innervalve remove bonnet li stem up until it C stops lt w Body Seat ring 4 land Hemove packing glan m p 99 Pull innervalve out bottom of bonnet Remove stuffing box components Normally the parts shown can be forced out the top of the bonnet by pushing the components out with a plastic or wooden rod 3 8 g through the bottom of the bonnet Using special D A SST Flat washers tool or flat plate Zum B 2 B SST Spring remove seat ring F i bp DP
20. ed in the general brochure If your valve has 6 force springs and no positioner it will be stamped 3 27 or 6 30 indicating a 24 psi span If your valve is an Air To Close version it will be set so the innervalve touches the seat at approximately 14 5 psi Several factors determine a valves ability to close off with an acceptable degree of tightness Three significant factors are e Upstream pressure e Orifice diameter e Actuator spring loading the case of an Air To Open valve In the case of an Air To Close valve maximum output air pressure working against the innervalve and springs determine shutoff tightness If the upstream pressure P1 is multiplied by the innervalve orifice area the upward force in pounds of linear force acting on the valve stem is determined If that is divided by the effective area of the actuator the minimum bench setting is known Normally 1 4 to 1 psi extra is required to achieve shutoff depending on orifice diameter seat tightness desired and the seat innervalve material For example 1 100 psi Orifice 0 7854 Actuator 35 in 2 Calculation 100 x 0 7854 78 54 Ib of upward force 35 in 2 25 psi air This means that the spring loading needs to be adjusted so that if a 3 15 psi signal is nominal we add 2 75 1 2 psi extra to the minimum signal pressure 3 we know that when the controller output is 3 psi we have the 2 75 psi extra loading to close the valve With
21. ions e Although the actuator can handle higher pressures Do Not exceed the signal range stamped on the nameplate If a positioner is used there is normally no need to use more than 40 psi of supply air unless the unit will not achieve full travel Do use FE tape to pipe positioners Small shreds of Teflon can cause malfunction of the positioner Donot repeatedly remove air from the actuator when an ATO valve is open Slamming the innervalve shut when dry can cause galling of the innervalve August 2015 RCV UM 00588 EN 02 Page 5 Operation OPERATION The Model 9100 is a modulating control valve It is normally supplied with a 35 sq in pneumatic multi spring opposed diaphragm actuator in either Air To Open ATO or Air To Close ATC action The actuator spring loading of your valve has been pre adjusted If your size 35 actuator is an Air To Open version and the signal range stamped on the nameplate is 3 15 the unit is equipped with 3 force springs and should achieve full travel with approximately 12 psi of signal change Since the bench setting is done with no upstream pressure a 3 15 range unit is normally set to open at 3 25 3 5 psi This provides a minimum of closing force to shut off the innervalve under minimal upstream pressures depending on innervalve size and upstream pressure If your valve does not close against the upstream pressure the springs can be adjusted to shut off up to the maximum levels indicat
22. m The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de Pedro Luis Ogaz n 32 Esq Angelina 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Europe Middle East Branch Office Badger Meter Europe PO Box 341442 Dubai Silicon Oasis Head Quarter Building Wing C Office 209 Dubai UAE 971 4 371 2503 Czech Republic Badger Meter Czech Republic s r o Ma kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 06 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 Legacy Document Number 941379
23. out upstream pressure the valve would require 342 75 5 75 psi of air lift the innervalve off the seat With 100 psi of upstream pressure the valve should lift off the seat at approximately 3 psi If you need assistance in performing this calculation feel free to contact Technical Support for assistance Page 6 RCV UM 00588 EN 02 August 2015 Adjusting Actuator Spring Loading ADJUSTING ACTUATOR SPRING LOADING Not applicable for spring ranges 6 15 9 15 and 10 15 psi In the Air To Open configuration the seating force of the actuator springs can be adjusted to provide sufficient load to shut off the innervalve If the unit is not closing completely when the minimum signal is sent to the actuator the spring force needs to be increased based on the calculation above best done on workbench To increase the seating force 1 Pipe a manual air regulator with output gauge to the air connection in the lower actuator housing The regulator should be capable of controlling pressure over the range indicated on the nameplate 2 Using the regulator raise and lower the air pressure to determine where the valve seats It the seating load needs to be increased stroke the valve to about 1 2 travel 3 Place a 1 2 open end wrench on the lower stem nut 4 With another 1 2 in wrench loosen the upper nut and turn counterclockwise about 1 4 turn 5 Lower the air pressure to determine the signal pressure now needed to
24. seat the valve Using the stem as the adjustor keep threading the stem in or out as desired until the proper seating position is achieved 6 When the proper loading is reached place a wrench on the flats machined on the actuator stem and tighten the upper nut against the actuator stem 7 Place a wrench on the upper nut and lock the lower nut to the upper nut The unit is now ready for operation NEVER TURN THE NUTS OR INNERVALVE STEM WHILE THE VALVE IS SEATED THIS WILL RESULT IN INNERVALVE DAMAGE AND PREVENT THE INNERVALVE FROM SEATING PROPERLY In the Air To Close configuration the same procedure is used However the action of the unit is in reverse Adjustments are made while checking the seating position with increasing air signal pressure Typically an ATC actuator should be set to seat the innervalve at about 1 4 1 2 psi prior to maximum signal pressure Air connection for ATO operation Upper and lower lock nuts Do not rotate stem DO NOT use pliers on innervalve stem Scratches will damage packing rings Figure 2 Adjusting spring loading August 2015 RCV UM 00588 EN 02 Page 7 Schematic of ATO Valve with Standard Moore 750 Positioner and Airset Piped SCHEMATIC OF ATO VALVE WITH STANDARD MOORE 750 POSITIONER AND AIRSET PIPED NOTE Actual piping may look different than shown Airset supply air Positioner output to actuator Airset Output to Positioner Supply port Input Sign
25. tor stem Use a back up wrench to hold the stem firmly in place during connection Please provide valve serial number when calling the factory with questions tightening The valve is now ready to be re installed into the pipeline Page 10 RCV UM 00588 EN 02 August 2015 ENGINEERING DRAWINGS Engineering Drawings DWG NO ISSUE SS CHANGE BY DATE ECN 8882 GAP 09 05 96 CD 952006 01 03 01 03 9160 EM 2001 DGD 06 21 00 UNLESS OTHERWISE SPECIFIED DIMENSIONS FOR REFERENCE ONLY LENGTH UNITS ARE INCHES ALL PROPRIETARY RIGHTS IN THE SUBJECT MATTER SHOWN ON THIS DRAWING ARE THE EXCLUSIVE PROPERTY OF BADGER METER INCORPORATED NOTES PARTS amp MATERIAL LIST 1 TRIM ASSEMBLY P N QUANTITIES ARE FOR ONE 1 UNIT ONLY Cv HAR ER NO PART NO QTY DESCRIPTION MATERIAL 2 NOMINAL STROKE 750 1 527192 0001 1 BODY BRONZE B62 3 RECOMMENDED SPARE PARTS ARE 4 6 2 527195 0001 1 BONNET BRONZE B62 OPTIONAL SPARE PARTS ARE NOIE AEN ST6ESST TRIM SET ITEMS 3 PACKING ITEMS 7 8 amp 9 3b NOTE 1 1 INNVERVALVE 316L SST 3c NOTE 1 1 SEAT 316L SST 4 WHEN ORDERING SPARE OR REPLACEMENT PARTS PROVIDE FACTORY THE VALVE ERA ASSEMBLY SERIAL NUMBER FROM THE 5 525950 0001 1 GLAND 316 SST NAMEPLATE ON THE ACTUATOR 6 543242 0001 1 PACKING SET TFE 7 527241 0001 1 FOLLOWER PFA 8 510031 0158 1
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