Azbil CV3000 Series User manual

OM2-8113-0202
CV3000 Series
Control Valves
Model: HCB,HCU,HCN,HPC
User's Manual

NOTICE
While this information is presented in good faith and believed to
be accurate, Azbil Corporation disclaims the implied warranties of
merchantability and fitness for a particular purpose and makes no
express warranties except as may be stated in its written agreement
with and for its customer.
In no event is Azbil Corporation liable to anyone for any indirect,
special or consequential damages, e information and specications
in this document are subject to change without notice.
© 2012-2014 Azbil Corporation All Rights Reserved.

i
Table of Contents
Chapter 1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1-1. Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Major components of control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2-1. Maximum lifting loads of eyebolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Installing valve in process pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Item to be checked after installation and before starting operation . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 3. Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chapter 4. Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4-1. Detaching actuator from valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-2. Disassembly and assembly of valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-3. Disassembly and assembly of actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Disassembly and assembly of model PSA 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Disassembly and assembly of model HA2, HA3, or HA4 actuator. . . . . . . . . . . . . . . . . . . . . . . . 21
4-6. Disassembly and assembly of model PSA6 actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-7. Disassembly and assembly actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 5. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 6. Direct / Reverse Action Type Conversion and Spring Range
Change of Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6-1. Direct / Reverse action change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6-2. Stroke and range spring change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 7. Instructions for Top Handwheel of Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7-1. Model PSA1 actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7-1-1. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7-1-2. Disassembly and assembly of top handwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7-2. Model HA2, HA3, or HA4 actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7-2-1. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7-2-2. Disassembly and assembly of top handwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chapter 8. Instructions for Side Handwheel of Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8-1. Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8-2. Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8-3. Disassembly of side assembly of side handwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Chapter 9. Instructlons for Bellows Sealed Type of Control Valves. . . . . . . . . . . . . . . . . . 63
9-1. Structures (Model HCB Control Valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-2. Disassembly and assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter 10. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 11. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1
Chapter 1. General
1-1. Scope
This manual covers the instructions for the following Control Valves:
Model HCB : Pressure-Balanced Cage-Type control valves
Model HCU : Pressure-Unbalance Cage-Type control valves
Model HCN : Low-Noise Cage-Type control valve
Model HPC : Pressure-Balanced High-Pressure Cage-Type control valve
For the valve positioners, refer the following operators manuals.
Model VPE OM2-8310-0410 Pneumatic valve positioner for small actuators
Model HTP OM2-83 10-0200 Pneumatic valve positioner (Single Acting type)
Model HEP 15, l6, l7 OM2-8313-0100 Electro-Pneumatic Valve Positioner
(Single Acting Type)
Model AVP 300/301/302/200/201/202
CM2-AVP300-2001 Electro-pneumatic positioner
Model AVP 303/203 CM2-AVP303-2001 Electro-pneumatic positioner
Model AVP701/702 CM2-AVP702-2001 Smart valve positioner 700 series (HART)
Model AVP703 CM2-AVP703-2001 Smart valve positioner 700 series
(FOUNDATION Fieldbus)
1-2. Major components of control valves
Each control valve is comprised of two major components, namely, a valve body and an
actuator. Various combinations of valve body and actuator are available to meet various type
of uses with different valve sizes, pressure ratings, types of connections, types of materials, and
actuator sizes.
(For details of specifications, refer to Specification Sheets SS2-8113-1100, -1120, and -1200.)

2
1-3. Structures
The structures of typical CV3000 Series control valves are shown is Fig. 1-1 through 1-4.
The valve body is connected to the bonnet with stud bolts and nuts. A gasket is (two gaskets
are) provided at the connection section to seal against the internal fluid or to let the valve
body make up a pressure vessel. The valve plug is supported by the guide ring and cage, and
driven by the actuator. The actuator has multiple springs and a diaphragm, and converts the
pneumatic control signal into a mechanical (positional) control signal with which to position
the valve plug.
Figure 1-1 Pressure-Balanced Cage-Type
Control Valve Model HCB
Figure 1-2 Pressure-Unbalanced Cage-Type
Control Valve Model HCU
Figure 1-3 Low-Noise Cage-Type
Control Valve Model HCN
Figure 1-4 Pressure-Balanced High-Pressure
Cage-Type Control Valve Model HPC

3
1-4. Nameplate
A nameplate as shown in Fig. 1-5 is posted on each control valve. The nameplate indicates
the model number, valve size, pressure rating, trim material, date of manufacture and other
major specifications of the control valve. Before installing the control valve, make sure that the
specifications indicated on the nameplate conform with the conditions of use. The nameplate
indicate also the product number (PROD.NO.) of the control valve. Please mention this
number also when consulting your Azbil Corporation agent for replacement of parts or other
modification of the control valve.
Figure 1-5 Nameplate

4
Chapter 2. Installation
2-1. Maximum lifting loads of eyebolts
The diaphragm case has a pair of lifting eyebolts. These eyebolts primarily are for lifting the
actuator alone. When using the eyebolts for other purposes (such as lifting an actuator bed
to its valve body or other components), note that the allowable maximum lifting loads of the
eyebolts are as shown in the following table.
Table 2-1 Maximum Lifting Loads of Eyebolts
Actuator model No. Allowable Maximum Lifting
Load of Eyebolts
Weight of Actuator Alone
PSA1
HA2
HA3
HA4
160 kg
160 kg
160 kg
220 kg
8 kg
16 kg
32 kg
68 kg
Note: The eyebolts may be used to lift the actuator together with its valve buy (castglobe
valve) of up to pressure rating “Class 600”. When doing this, be extremelycareful so that
no shock or other abnormal force is applied to the actuator or thevalve body.
2-2. Installing valve in process pipe
(1) Before installing the valve in the process pipe, remove foreign matter (such as scales and
welding chips) from both upstream and downstream sides of the process pipe.
(2) Confirm that the direction of process fluid flow conforms with that of the arrowhead
mark provided on the valve body.
(3) Pay attention so that the pipe connection gaskets do not extrude into the process pipe
inside. Be sure to use gaskets made of material which is suitable for the process fluid. The
welding type of valve employ no gaskets.
(4) Pay attention so that no excessively large stress is conveyed from the process pipe to
the valve body. Uniformly tighten the bolts of the process pipe connection flange. The
high pressure type of valves have no flanges, since they are connected to the process by
welding.
(5) Before connecting the air pipes to the actuator and positioner, blow the pipes to clean
them.
(6) Do not install any heating or cooling provisions on the bonnet.

5
2-3. Item to be checked after installation and before starting operation
(1) Check that there is no leak from air piping.
(2) Check that the bolts and nuts of the diaphragm case are not loose. Standard tightening
torques are as follows:
(3) Tighten the packing flange nuts to prevent leak from the gland packing section. Standard
tightening torques are as shown in Table 2-2.
Table 2-2 Tightening Torques of Packing Flange Nuts
Valve Stem
Diameter
(mm)
V PTFE
Packing
PTFE Yarn
Packing
(P4519)
Graphite Yarn Packing V PTFE + PTFE
P6610CH + P6528
P6610CH + M8590
T2200 + P6710CH (Type2)
Yarn Packing
PTFE + V7233
PTFE + TK2006
10
1 {8}
9 {90} 5 {50} 3 {30}
13 15 {150} 8 {80} 5 {50}
16 24 {240} 13 {130} 8 {80}
20 32 {320} 18 {180} 10 {100}
25 - 28 {280} 15 {150}
30 66 {660} 36 {360} 20 {200}
Note: The tightening torques mentioned in the above are only to give you reference values.
Note that tightening torques may vary depending on the type of packing.
Nut
Packing
Flange
Bonnet
V PTFE Packing
Blind
Plug
PTFE Yarn Packing Graphite + Graphite Yarn Packing V PTFE + PTFE Yarn Packing
V PTFE
Packing
Stem
PTFE Yarn
Packing
Graphite
Packing
Graphite
Yarn
Packing
Lubricator
Figure 2-1 Gland Section
(4) If the valve is provided with a lubricator as shown in Fig. 2-2, check whether the bonnet
section has been lubricated or not. To do this, loosen the lubricator handwheel and
turn the squeeze screw. If the squeeze screw turn lightly, and grease in the lubricating
procedure mentioned below. (If the squeeze screw turns heavily, this means that grease
has been applied.)

6
Squeeze
Screw Lubricator
Handwheel
G1/2
Figure 2-2 Lubricator (Class 600 or under) Figure 2-3 Lubricator for High Pressure Valve
(Class 600 or higher)
Lubricating Procedure
(a) prepare grease of the type indicated on the nameplate.
(b) Tightly close the lubricator handwheel.
(c) Remove the squeeze screw, apply grease, and set the squeeze screw.
(d) Loosen the lubricator handwheel and drive grease by turning the squeeze screw.
(e) Repeat the procedure of (b), (c) and (d) until turning of the squeeze screw becomes
heavier. Tightly close lubricator handwheel.
(5) Pressurizing valve, check that there is no leak from the gasket sections for connection to
the valve body and process pipe. If leak is found, tighten the nuts. (Especially when the
process fluid temperature is 400 or higher, tighten the nuts again after raising temperature
of the valve in order that it may serve for a longer period without requiring immediate
maintenance service.) Standard tightening torques are shown in Tables 2-2 of Chapter 2,
Table 4-3 of Chapter 4.
(6) When raising temperature of a valve which is used for high temperature service, raise
temperature gradually (standard rate is 100 per hour) and do not operate the valve when
its temperature is being raised.

7
Chapter 3. Inspection and Maintenance
Inspect and service the actuator as follows:
(1) Tightening the gland:
Tighten the gland once in every 6 months or thereabout. The tightening procedure is as
given in Section 2-3-(3).
(2) Lubricating the gland:
Lubricating the gland once in every 6 months or thereabout. The lubricating procedure is
as given in Section 2-3-(4).
(3) Check for hunting of valve Position:
Refer to Chapter 10 'TROUBLESHOOTING.
(4) Check for abnormal noise and vibration:
Refer to Chapter 10 'TROUBLESHOOTING.

8
Chapter 4. Disassembly and Assembly
This chapter covers the disassembly and assembly procedures of the actuator for its overhaul
or modification.
4-1. Detaching actuator from valve body
See Fig. 4-3.
(1) Apply to the actuator an air pressure so that the valve position pointer is at a point of 10%
- 20% above the fully closed point.
(2) Loosen the clamping-bolts of the stem connector, remove the stem connector, and detach
the actuator stem from the valve stem.
(3) Remove the clamping-nut of the yoke.
(4) Raise the actuator to detach it from the valve body.
Precautions: For detaching the actuator from the valve body which is kept installed in the
process pipe, be sure to shut down the process for and release the process
pressure before detaching the actuator.
4-2. Disassembly and assembly of valve body
To disassemble or assemble the valve body, refer to Fig. 4-1 through 4-2 and proceed as
described below.
(For handling of the bellows sealed type (optional type) of valves, see Chapter 9.)
Disassembly Procedure
(1) Loosen the hex nuts of the packing flange.
(2) Remove the hex nuts (1) of the bonnet (extension bonnet).
(3) Raise and detach the bonnet from the valve body.
Precautions: If the valve plug comes out together with the bonnet, remove the plug from the
bonnet by rotating the plug. When doing this, exercise care not to damage the
valve stem.
Inspection
Inspect the disassembled parts for damage. If any damage is found, replace the parts.
(When ordering parts, mention also the Prod. No. of the valve which is indicated on the
nameplate.)
(1) Do not re-use the removed gland packing. Use fresh packing when assembling the valve.
(2) Check that the seating surfaces of plug and seat ring are not damaged.
(3) Check that the gasket-contacting surfaces of valve body, bonnet and guide ring are not
damaged. Do not re-use the removed gasket. Use fresh gasket when assembling the valve.
(4) Check that the plug guide section, the stem, and the internal guiding sections of guide
bushing are not damaged..

9
Assembly Procedure
(1) For an integral-type cage valve, put a spiral gasket in the valve body. For a splittype cage
valve, securely fix the seated ring into the valve body with threads, using the special tools.
(Apply lubricant “Neverseize” to the gasket, except those of the oil-inhibited valves. For
the tightening torque of HPC, see Table 4-1.)
(2) Put the gasket (2) in the valve body.
(3) Put the cage in the valve body.
(4) Put the gasket (1) on the cage.
(5) Put the bonnet on the valve body and check that the bonnet is correctly, mate with the
indented section of the valve body. Tighten the nuts uniformly, paying attention so that
they are not tightened unevenly (tighten alternately the ones located at symmetrical
positions). For the tightening torque, see Table 4-3.
(6) Insert the gland packing as shown in Fig. 2-1.
Note: When yarn packing sheets are used, overlap sheets in such manner that their cut
ends are positioned alternately.
(7) Place the packing follower and packing flange, and tighten the nuts.
For the tightening torques, see Table 2-2.
Table 4-1 HPC Seated Ring Tightening Torques
Size (in.) ANSI Class Torque (N.m{kgf-cm})
1-1/2 900-2,500 310 {3,100}
2 900-2,500 570 {5,700}
3 900-1,500 1,000 {11,000}
4 900-1,500 1,800 {18,000}
6 900-1,500 3,750 {37,500}
8 900-1,500 5,500 {55,000}
3 2,500 700 {7,000}
4 2,500 1,550 {15,500}
6 2,500 3,000 {30,000}
8 2,500 4,000 {40,000}

10
Table 4-2 HCB/HCU/HCN Seated Ring Tightening Torques
Size (in.) Torque (N.m{kgf-cm})
3 650 {6,500}
4 800 {8,000}
6 1,200 {12,000}
8 1,500 {15,000}
Table 4-3 Tightening Torques of Bonnet Stud Bolts
Bolt Torque (N.m{kgf-cm})
M12 60 {600}
M16 100 {1,000}
M20 150 {1,500}
M22 200 {2,000}
M24 250 {2,500}
M27 350 {3,500}
M30 500 {5,000}
M33 660 {6,600}
M36 850 {8,500}
M39 1,000 {10,000}
M42 1,200 {12,000}
M45 1,400 {14,000}

11
Figure 4-1-1 Normal Temperature Type
Packing Flange
Packing Flange Nut
Packing Follower
Gland Packing
Bonnet
Stud Bolt
Hex Nut (1)
Gasket (1)
Stud Bolt
Va lve Body
Combination of Trim Parts
Model HCB
Integral Cage Type
Model HCB
Integral Cage Type,
Plug with Piston Ring
Model HCN
Integral Cage Type
Model HCU
Integral Cage Type
Combination of Trim Parts
Valve Stem
Valve Plug
Cage
Gasket (2)
Spiral
Gasket
Piston
Ring
Piston Ring

12
Figure 4-1-2 High Temperature Type (Extended Bonnet Type)
Figure 4-1 Model HCB, HCN, HCU Control Valves
Lubricator
Extension Bonnet
Combination of Trim Parts
Combination of Trim Parts
Model HCB
Split Cage Type
Model HCB
Plug with Piston Ring
Model HCN
Split Cage Type
Model HCU
Split Cage Type
Gasket (2)
Seat Ring

13
Figure 4-2 Model HPC Control Valves

14
4-3. Disassembly and assembly of actuator
Normally the actuator requires no adjustment. However, it should be disassembled and
assembled when installing it on a valve body, when modifying its specifications, or when
replacing damaged parts. The disassembly and assembly procedure of the actuator for such
purposes are covered in Sections 4-4 and 4-5.
To disassemble the actuator, refer to fig.4-3 to Fig.4-17.
Pointer
Hex Bolt
Lock Nut
Stem Connector
Yoke Clamping Nut
Figure 4-3
When disassembling or assembling the actuator, keep it in the vertical attitude. For the
tightening torques of bolts and nuts, see Tables 4-4,4-5.
For the names of the parts, see Figs.4-9 and 4-17.

15
Notes for Disassembly
(1) The nuts for the eyebolts are made of stainless steel. Discriminate these nuts from other
nuts when assembling the diaphragm case.
(2) It is recommendable to make locating marks on the top and bottom diaphragm cases
before disassembly. This will help you to find easily the air piping connector location.
(3) Store the removed parts in a clean place.
CAUTION
Never loosen or remove carelessly the bolts and nuts of the actuator. The actuator
employs powerful compressed springs and if you remove the bolts and nuts carelessly,
the springs may leap out causing hazards. When removing the bolts and nuts, be sure
to observe the instructions given for disassembly and assembly procedures of the
actuator and top handwheel.
4-4. Disassembly and assembly of model PSA 1
Disassembly procedure
A. Direct action model (see Figure 4-4)
(1) Disconnect the air piping and detach the accessories from the actuator.
(2) Remove the stem connector.
(3) Remove the clamping bolts (except the pair of eyebolts) from the diaphragm case.
(4) Alternatively and evenly loosen the pair of eyebolts. The initial setting of the springs is
achieved using these eyebolts.
(5) Removing the diaphragm case. Pull the actuator rod upward and out together with the
diaphragm.
(6) Take out the springs.
B. Reverse action model (see Figure 4-5)
(1) Disconnect the air piping and detach the accessories from the actuator.
(2) Remove the stem connector.
(3) Remove the clamping bolts (except the pair of eyebolts) from the diaphragm case.
(4) Alternately and evenly loosen the pair of eyebolts. The initial setting of the springs is
achieved using the eyebolts.
(5) Remove the diaphragm case. Take on the springs.
(6) Pull the actuator rod upward and out together with the diaphragm.