A-T Controls Triac 88 Series Instruction Manual


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
1
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
Contents
1. SCOPE ............................................................................................................................................................ 2
2. INSTALLATION ........................................................................................................................................... 2
3. VALVE OPERATION ................................................................................................................................... 3
4. DISASSEMBLY ............................................................................................................................................. 3
5. ASSEMBLY ................................................................................................................................................... 4
6. REPAIR KITS ................................................................................................................................................ 5
7. BILL OF MATERIALS .................................................................................................................................. 6


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
2
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
1. SCOPE
1.1. CAUTION
1.1.1. For your safety, read this manual before installation or service.
1.1.2. Before installing or servicing, please ensure the line pressure has been relieved and any hazardous fluids have been drained or
purged from the system.
1.1.3. Ensure that all Lockout and Tagout procedures for the system have been properly implemented.
1.2. USE
1.2.1. Maximum results and long life of the valves can be maintained under normal working conditions and according with
pressure/temperature rating and corrosion data chart.
2. INSTALLATION
2.1. GENERAL INFORMATION FOR INSTALLATION
2.1.1. The valve can be installed in any position on the pipeline.
2.1.2. Before installation of the valves, the pipe must be flushed clean of dirt, burrs, and welding residues, or the seats and ball surface
can be damaged. The pipe must be free from tension and in proper alignment. Check to ensure that all connections are free
from defects.
2.2. INSTALLATION OF THREADED VALVES
2.2.1. Use conventional sealant, such as hemp core, Teflon, etc. on the threads. Apply wrench only on the hexagon of the valve ends.
Tightening by using the valve body or lever can seriously damage the valve. In some applications, screwed valves are back
welded on site. These valves must be treated as per instructions for weld end valves before back welding.
2.3. INSTALLATION OF WELD-END VALVES
2.3.1. Tack weld the valve on the pipe in four points on both end caps.
2.3.2. With the valve in the open position, (lever to be parallel to the axis of the pipe), remove all the body bolts except one. Loosen
the nut on the remaining bolt. Swing the body outside the pipe. Finish welding both end caps on the pipe.
2.3.3. When cooled down, clean both end caps and body surface.
2.3.4. Swing the body back in position and replace the bolts. Tighten all nuts slightly. This operation is very important to keep the
body and end caps perfectly parallel, thus preventing distortion of the end caps. Tighten body bolts evenly (see section 5.5).
Make sure that maximum tightening torque is observed. Check proper operation of the valve.


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
3
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
3. VALVE OPERATION
3.1. MANUAL
3.1.1. HANDLE
3.1.1.1. To OPEN the valve, turn the handle counterclockwise until the handle is parallel with the pipeline and the handle has
contacted the handle stop.
3.1.1.2. To CLOSE the valve, turn the handle clockwise until the handle is perpendicular with the pipeline and the handle has
contacted the stop.
3.1.1.3. A handle lock is incorporated into the handle.
For sizes up to 2”: To use, slide the lock into the mounting pad, in the full open or full closed position. Insert an
appropriate size lock or hasp into the hole in the handle. If it can be performed safely, try to turn the handle to ensure that the
valve has been locked properly.
For sizes larger that 2”: To use, turn the handle to the full open or full closed position. Insert an appropriate size
lock or hasp into the hole in the handle and through the mounting pad. If it can be performed safely, try to turn the handle to
ensure that the valve has been locked properly.
3.1.2. GEAR
3.1.2.1. To OPEN the valve, turn the hand wheel counterclockwise. The indicator will be pointing to the open position and stop
rotating when fully opened. The flow can be adjusted by stopping the indicator anywhere between open and close.
3.1.2.2. To CLOSE the valve, turn the hand wheel clockwise. The indicator will be pointing to the close position and the hand wheel
will stop rotating when fully closed. The flow can be adjusted by stopping the indicator anywhere between open and close.
3.2. AUTOMATED
3.2.1. A-T Controls 88-Series Ball Valves can be mounted with quarter turn actuators. Valves with actuators shall be checked for
proper valve stem alignment. Angular or linear misalignments may result in high operational torque and unnecessary wear on
the valve stem. See the actuator IOM for information on operating the actuator.
4. DISASSEMBLY
!!! WARNING!!!
CAUTION, FLUIDS CAN BE TRAPPED IN THE BODY OF THE VALVE, POSSIBLY UNDER HIGH PRESSURE. FOR
YOUR SAFETY, IT IS IMPORTANT THAT PRECAUTIONS ARE TAKEN BEFORE REMOVAL OF THE VALVE
FROM THE LINE OR ANY DISASSEMBLY.
4.1. Remove actuator or gear if equipped.
4.2. Care should be taken to not damage the surface finish of the valve components.
4.3. Remove the ends (2) from the body (1) by removing the body bolts (15) and body nuts (16).


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
4
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
4.4. Remove the seat (4) and body gasket (5) from both sides of the body (1). Once removed, with the valve in the fully closed
position, the ball (3) should slide freely out of the body (1).
4.5. If equipped, remove the handle nut (25), handle (12), and the handle stop assembly items (18 & 19).
4.6. While holding the stem (7) stationary, remove the packing nut (11). Once removed, the locking saddle (10), Belleville washers
(17) and packing bushing (9) should be free to remove.
4.7. While holding the bottom of the stem (7), push the stem (7) through the inside of the valve body (1).
4.8. Remove the packing set (8) and stem seal (6).
4.9. Inspect all components for damage and if necessary clean or replace.
5. ASSEMBLY
5.1. Care should be taken to not damage the surface finish of the valve components.
5.2. Place stem seal (6) on the stem (7) and install it by going through the body (1). Insert V-style packing set (8) over stem (7), with
the V pointing away from the valve (see Bill of Materials for correct orientation).
5.3. Install the packing gland (9), the Belleville washers (17), locking saddle (10), and packing nut (11). While holding the stem (7),
tighten the packing nut (11) to the torque listed in the Fastener Torque Chart. Tighten further if needed in order to be able to
place the locking saddle (10) over the packing nut (11).
5.4. Ensure the stem (7) is in the closed position with the body tang parallel with the flow of the valve. Insert a seat (4) and body
gasket (5) in one side of the body (1). Carefully slide the ball (3) into the body (1) and insert the other seat (4) and body gasket
(5).
5.5. Assemble ends (2) onto body (1). Insert all body bolts (15) and nuts (16) into valve and tighten to finger tight, making sure that
the ends (2) are flat against the body (1). Tighten all body bolts (15) (on both sides for valves 2-1/2”-4”) from the nut (16) side
(if equipped) in a star pattern to 50% of the final torque shown in the Fastener Torque Chart. Using the handle (12) or an
adjustable wrench, cycle the valve 3 times. Tighten all body bolts (15) to the final torque in a star pattern. Check each body bolt
(15) torque and tighten if needed a final time. It is acceptable for the torque to relax slightly over time due to relaxation of the
polymer components, but the valve will still seal properly. If leakage is detected, repeat the steps for tightening the body bolts.
5.6. If required, assemble the locking device (21), handle stop (18 & 19), handle (12), and handle nut (25).


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
5
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
Fastener Torque Chart
Valve Size
50% of Max Body
Bolt Torque
(In-lbs.)
Max Torque of Body Bolt
(In-lbs.)
Max Torque of Stem Nut
(In-lbs.)
¼”
50
100
69
3/8”
50
100
69
½”
65
130
78
¾”
80
160
78
1”
100
200
122
1-1/4”
110
220
122
1-1/2”
188
375
165
2”
203
405
165
2-1/2”
220
440
191
3”
243
485
191
4”
258
515
217
6. REPAIR KITS
Repair kits are available to replace all soft goods. See Bill of Materials for components that are included in the repair kits.


88 SERIES
Full Port Ball Valve
Installation & Maintenance Manual
6
August 5, 2019
www.a-tcontrols.com
IOM07001 REVISION 01
7. BILL OF MATERIALS
A-T Controls product, when properly selected, is designed to perform its intended function safely during its useful life. However, the purchaser or user of
A-T Controls products should be aware that A-T Controls products might be used in numerous applications under a wide variety of industrial service
conditions. Although A-T Controls can provide general guidelines, it cannot provide specific data and warnings for all possible applications. The
purchaser / user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of A-T
Controls products. The user should read and understand the installation operation maintenance (IOM) instructions included with the product and train its
employees and contractors in the safe use of A-T Controls products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only. Because
A-T Controls is continually improving and upgrading its product design, the specifications, dimensions and information contained in this literature are
subject to change without notice. Should any question arise concerning these specifications, the purchaser/user should contact A-T Controls.
For product specifications go to https://a-tcontrols.com/Downloads/
A-T Controls, Inc. • 9955 International Boulevard, Cincinnati, OH 45246 • Phone: [phone] • Fax: [phone] • www.atcontrols.com