Dresser Masoneilan VariPak 28000 Series User manual

Instruction No.
EH 45004 E
05/2004
Masoneilan®
Instruction Manual
for VariPak 28000 Series
Adjustable-CvMicroflow Valve with Actuator

Instruction No. EH 45004 E
05/2004
2

Instruction No. EH 45004 E
05/2004
3
1. - GENERAL ....................................................... 4
1.1 - SPARE PARTS......................................................... 4
1.2 - AFTER SALES DEPARTMENT ............................... 4
1.3 - TRAINING................................................................. 4
2. - OPERATION.................................................... 5
2.1 - PRECISE ADJUSTMENT OF THE VARIPAK
28002 ADJUSTABLE-CvVALVE............................. 5
2.2 - FLOW COEFFICIENT OF VARIPAK 28001
SINGLE-LEVER AND 28002 ADJUSTABLE-Cv
VALVES.................................................................... 5
2.3 - ACTUATOR .............................................................. 7
2.4 - HANDWHEEL ........................................................... 7
2.5 - REVERSING THE VALVE ACTION ......................... 8
3. - INSTALLATION............................................. 10
3.1 - PRELIMINARY STEPS........................................... 10
3.2 - VALVE INSTALLATION......................................... 10
3.3 - PNEUMATIC AND ELECTRICAL CIRCUIT........... 11
3.4 - LIMIT SWITCHES................................................... 11
4. - CALIBRATION .............................................. 12
4.1 - PISTON ROD CLEVIS ADJUSTMENT .................. 12
4.2 - PLUG STEM ADJUSTMENT.................................. 12
4.3 - LIMIT STOP ADJUSTMENT .................................. 13
4.4 - VARIPAK 28002 CvADJUSTMENT ...................... 14
4.5 - POSITIONER START-UP PRESSURE
ADJUSTMENT........................................................ 14
5. - MAINTENANCE ............................................ 14
5.1 - ACTUATOR DIAPHRAGM REMOVAL .................. 14
5.2 - ADDING PACKING RING ...................................... 14
5.3 - DISASSEMBLY ...................................................... 15
5.4 - REASSEMBLY ....................................................... 16
5.5 - PACKING QUICK CHANGE METHOD (ONLY FOR
VALVES WITH MAX. CvOF 0.6 TO 3.8) ............... 18
5.6 - 7700P OR 7700E POSITIONER
MAINTENANCE...................................................... 18
5.7 - MAINTENANCE OPERATIONS SPECIFIC
TO THE 7700E POSITIONER ................................ 19
5.8 - CONVERTING A 7700P POSITIONER
(PNEUMATIC) INTO A 7700E POSITIONER
(ELECTRO-PNEUMATIC) ...................................... 20
Contents

Instruction No. EH 45004 E
05/2004
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These installation, operation, and maintenance instructions apply to Masoneilan VariPak* 28000 series control
valves. They also include a parts reference list with recommended spare parts (see page 21).
* Registered patent
1.1 SPARE PARTS
For maintenance purposes, always use original
spare parts obtained through your local Masoneilan
representative or Spare Parts Department. When
ordering, always give the references of the original
order for the equipment concerned and, in particular,
the number indicated on the serial plate. (135).
1.2 AFTER SALES DEPARTMENT
Masoneilan has a highly skilled After Sales
Department to assist customers with start-up,
maintenance, and repair of valves and instruments.
Contact your nearest Masoneilan Sales Office or
Representative, or the After Sales Department at the
Condé-sur-Noireau plant.
1.3 TRAINING
Masoneilan organizes regular training courses in the
operation, maintenance, and application of its
control valves and instruments for customer service
and instrumentation personnel at its Condé-sur-
Noireau plant. For further details, contact your local
Masoneilan representative or the Training
Department at the Condé-sur-Noireau plant.
IMPORTANT REMARKS
Before installing, operating, or performing maintenance on this equipment, you should read these
instructions carefully and make sure you have understood them.
Work on this equipment should only be carried out by qualified personnel.
Failure to follow the instructions and precautions given in this document could lead to a malfunction
and seriously damage the equipment.
1. General

Instruction No. EH 45004 E
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The VariPak microflow control valve features a very
wide range of rated flow coefficients (Cv), from 0.004
to 3.8.
Two types of actuators are available:
-The VariPak 28001 with a single lever, designed
for just one rated Cv. This version is used when
enough is known about the operating conditions
when sizing the valve.
- The VariPak 28002 with an adjustable rated Cv .
This valve uses a patented lever system to adjust
the rated C
v
on site to suit the actual operating
conditions, thereby avoiding any oversizing in flow
capacity. Each plug and seat ring combination can
be adjusted without changing the control signal.
2.1 PRECISE ADJUSTMENT OF THE
VARIPAK 28002 ADJUSTABLE-Cv
VALVE
The valve is adjusted using a simple, but robust,
crossed-lever system with an adjustable fulcrum.
This can be done easily by hand, either before
installation or during operation.
For example, an application requiring a theoretical
Cvof 0.006 could be handled using a VariPak 28002
with a maximum Cvof 0.010, that can subsequently
be calibrated on site between 0.004 and 0.010.
2.2 FLOW COEFFICIENT OF VARIPAK
28001 SINGLE-LEVER AND 28002
ADJUSTABLE-CvVALVES
2.2.1 Plug/seat ring combinations (trim)
Eight plugs and five seat rings are used to make up
the ten available plug and seat ring combinations,
identified by codes from 0 to 9 (see figure 2).
The shape of each plug and the port diameter of the
seat ring can be used to match parts with the table in
figure 2.
The difference between the four plugs in trim Nos. 6
to 9 lies in the angle of the flat machined on the tip.
The same seat ring (3e) and the same spacer (3f)
are used in all four cases (see figure 2).
Use the table in figure 1 to select the plug and seat
ring combination to obtain the Cvvalue or range of
Cvvalues you require.
2. Operation
Trim
No.
FLOW COEFFICIENT Cv
VARIPAK
28001
VARIPAK 28002
MIN. RISK
FREE MAX.
90.0040 0.0016 0.0020 0.0024 0.0028 0.0032 0.0036 0.0040
80.010 0.004 0.005 0.006 0.007 0.008 0.009 0.010
70.025 0.010 0.013 0.016 0.019 0.021 0.023 0.025
60.050 0.020 0.025 0.030 0.035 0.040 0.045 0.050
50.10 0.04 0.05 0.06 0.07 0.08 0.09 0.10
40.25 0.10 0.13 0.16 0.19 0.21 0.23 0.25
30.6 0.25 0.30 0.35 0.4 0.45 0.5 0.55 0.6
21.2 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
12.3 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3
03.8 1.5 1.9 2.3 2.6 2.9 3.2 3.5 3.8
Figure 1

Instruction No. EH 45004 E
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2.2.2 Changing the plug and seat ring
combination
The plug and seat ring combination can be changed
very easily for trim Nos. 1 to 9 inclusive. Simply replace
the following parts:
-The plug and seat ring (see figures 1 and 2 to
select the combination required for the new Cv).
-The Cvadjustment plate (25) in the case of the
VariPak 28002 adjustable-Cvvalve.
-If necessary, the actuator spring (134) (see
figure 3 to check the spring range corresponding
to the new Cv.
VariPack
28001
VariPack
28002 Cv
Cv
Clapet/siŁge
N9
Clapet/siŁge
N8
Clapet/siŁge
N7
Clapet/siŁge
N6
Clapet/siŁge
N5
Clapet/siŁge
N 4
Clapet/siŁge
N3
Clapet/siŁge
N 2
Clapet/siŁge
N1
Clapet/siŁge
N0
Orifice
ł2
mm
Orifice
ł1,6
mm
Orifice
ł4,5
mm
Orifice
ł9,5
mm
Orifice
ł14,3mm
0,004

0,0016
0,004 Cv0,010 Cv0,025 Cv0,050 Cv0,10 Cv0,25 Cv0,60
Cv
0,010

0,004
Cv
0,025

0,010
Cv
0,050

0,020
Cv
0,10

0,04
Cv
0,25

0,10
Cv
0,60

0,25
Cv
1,2

0,5
Cv
2,5

0,9
Cv
3,8

1,5
Cv1,2 Cv2,5 Cv3,8
182
183
3f
3e
12d
3d 3c 3b 3a
12c 12b 12a
Figure 2 - Ten plug and seat ring combinations (trim)
Plug and
seat ring
No. 9
Plug and
seat ring
No. 8
Plug and
seat ring
No. 7
Plug and
seat ring
No. 6
Plug and
seat ring
No. 5
Plug and
seat ring
No. 4
Plug and
seat ring
No. 3
Plug and
seat ring
No. 2
Plug and
seat ring
No. 1
Plug and
seat ring
No. 0
Orifice
Dia. 2 mm
Orifice
Dia. 1.6 mm
Orifice
Dia. 4.5 mm
Orifice
Dia. 9.5 mm
Orifice
Dia. 14.3 mm
0.004 0.010 0.025 0.050 0.10 0.25 0.60 .22.5 3.8
0.004
to
0.0016
0.010
to
0.004
0.025
to
0.010
0.050
to
0.010
0.10
to
0.04
0.25
to
0.10
0.60
to
0.25
1.2
to
0.5
2.5
to
0.9
3.8
to
1.5
Plug/Seat No. Flow Coefficient
Cv
Spring Range (134)
Max. Pressure Supply
Adjustable CvSingle Lever
Cl. IV Cl. V Cl. IV Cl. V
m.bar Psi Color Code bar (Psi) bar (Psi) bar (Psi) ATO ATC
03.8 to 1.5
414
-
1660
6-24 Red 2.1
(30)
2.1
(30)
2.1
(30)
2.8
(40)
12.3 to 0.9
21.2 to 0.5
30.6 to 0.25
40.25 to 0.10
207
-
1035
3-15 Green 1.4
(20)
1.4
(20)
1.4
(20)
1.7
(25)
50.10 to 0.04
60.050 to 0.020
70.025 to 0.010
80.010 to 0.004
90.004 to 0.0016
Figure 3 - Actuator spring ranges and supply pressures

Instruction No. EH 45004 E
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Follow the procedure described in the
"Disassembly/Reassembly" section of the
"Maintenance" chapter on pages 14 to 18.
-Also change the serial plate (135) or correct the
information on the existing plate.
2.2.3 Adjusting the Cv of a Varipak 28002 valve for
each plug and seat ring combination
This is done by moving adjustment knob (24) along
adjustment plate (25) fastened to the top of lever No.
1 (21).
The adjustment plate (25) gives the range of Cv
values offered by the selected plug and seat ring
combination. Carry out this adjustment operation as
follows:
-Loosen adjustment knob (24) and slide it along
the lever to the required value. Tighten the
adjustment knob again firmly.
Note:
- This operation entails moving lever No. 2, either
pneumatically (by allowing air into the actuator),
or manually (by pressing piston clevis (140b)
with a screwdriver or similar tool) so that the
slides of the two levers are perfectly parallel.
- It may be necessary to reset the zero to
calibrate the closure point after changing the Cv.
2.3 ACTUATOR
A single actuator allows VariPak valves to act in
direct Air-to-Close (ATC), or reverse Air-to-Open
(ATO).
Valve action can be changed with no additional part
by simply shifting:
-the pivot pin and the attachment hole of the
positioner balance spring clamp for the single-
lever VariPak 28001 valve,
-the two pivot pins for the adjustable-cv VariPak
28002 valve,
then calibrating as required.
Follow the instructions given under "Reversing the
valve action" on page 8.
2.4 HANDWHEEL(Figure 5)
The handwheel is an optional feature located on top
of the cover and fitted with a locking lever. Access
can be gained to it directly without removing any
other parts. It consists of a threaded rod, equipped
with a handwheel (120) and a lever arm stop (122).
The threaded rod rests freely on the actuator bracket
(108) and is guided through the cover (110) by
handwheel bushing (119). The stop consists of a
block screwed onto the threaded rod. The block is
guided by the actuator bracket (108).
Caution: If the valve in question includes a
1/2" or 3/4" NPT threaded end, the maximum
capacity of the body is respectively limited to
trim Nos. 9 to 3 inclusive or 9 to 2 inclusive.
A trim No. 9 cannot be installed in a VariPak
valve body designed for a trim No. 0.
Likewise, a trim No. 0 cannot be installed in
valve bodies designed for other trim
numbers.
Figure 4 - Adjusting the Cvof VariPak 28002 valve
for each plug/seat ring combination
120
121 22 21
119
118
122
108
181
125
180
131
108
134
110
Figure 5
VariPak handwheel Limit stop

Instruction No. EH 45004 E
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When the handwheel (120) is turned clockwise, the
stop (122) moves up the threaded rod, compressing
the spring (134) and raising lever No. 2 (22) (VariPak
28002) or (113) (VariPak 28001). This closes the
valve if the valve is equipped with a direct-action
actuator (Air-to-Close) and opens the valve if it is
equipped with a reverse-action actuator (Air-to-
Open).
The valve can be returned to automatic mode
(neutral position), by turning the handwheel counter-
clockwise until the stop (122) comes into contact with
the bracket (108).
Note: During this operation, the compression is
released when the stop (122) moves away from the
lever (22) (VariPak 28002) or (113) (VariPak 28001).
Continue the operation until a slight tension
reappears, then tighten the handwheel lock (121).
VariPak actuators are equipped with a limit stop.
This consists of parts (180) and (181), and is
designed to prevent damage to the plug and seat
ring assembly and/or the plug stem in the event of
handwheel or actuator overstroke.
Note: The limit stop is not used with air-to-open
valves fitted with a handwheel, and must be screwed
down at the bottom of the piston.
2.5 REVERSING THE VALVE ACTION
(Figures 5, 6, 26, 27 and 29)
A. Loosen and remove cover (110). On valves
equipped with a handwheel, loosen cover screw
(109), back off handwheel lock (121), and turn
handwheel (120) counter-clockwise to release
cover (110).
B. Adjust the signal so that the valve closes.
Change the signal slightly so that the plug just
moves off the seat ring. On the VariPak 28002
adjustable-Cvvalve, set the adjustment knob
(24) to the minimum Cvsetting.
C. Loosen locknut (103) and, using a screwdriver,
turn the plug stem one and three-quarter turns
counter-clockwise. Shut off the signal and the
supply pressure. Slightly tighten locknut (103)
against the clevis.
D. Unlock nut (117) and completely loosen screw
(116). Unhook spring (114) from spring clamp
(115).
2.5.1 VariPak 28001 single-lever valve
E. Remove retainer clips (112b) from pin (18), and
remove the pin from lever (113) and plug clevis
(104a).
Note: This operation will be simplified by
relieving the load exerted on the plug clevis by
the conical compression spring (106). To do this
push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from the
pin (105) and disengage it to uncouple the lever
(113) from the bracket (108).
G. Refit the levers (113) making sure that the pin
(105) is fitted into the correct holes in the lever
and bracket for the new action of the actuator
(see figure 6). Fit the spring clamp (115) into the
corresponding lever hole.
Note: Ensure that the clevis is correctly
positioned before fitting the lever on the bracket.
H. Couple the plug stem clevis (104a) to the lever
(113) following the normal reassembly
procedure (step I. in the "Reassembly" section
on page 17). Then follow the same procedure as
for the VariPak 28002 adjustable-Cvvalve as
from step L.
2.5.2 VariPak 28002 adjustable-Cvvalve
(2 levers)
E. Remove retainer clips (112b) from each of the
two pins (184) and remove pins from lever (113)
and plug clevis (104a).
Note: This operation will be simplified by
relieving the load exerted on the plug clevis by
the conical compression spring (106). To do this
push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from pin
No. 1 (105) and disengage it to uncouple lever
No. 1 from bracket (108). Loosen adjustment
knob (24) and slide it to the maximum Cvsetting.
Disengage the smooth end of the adjustment pin
(23) from the groove in lever No. 2 while
removing lever No. 1.
G. Drive out pin No. 3 (18) and remove lever No. 2
(22) from the bracket.
H. Remove the two screws (26) and refit Cv
adjustment plate (25) after turning it round to
comply with the new action.
I. Refit levers No. 1 and 2 in sequence, making
sure that pins (105) and (108) are fitted into the
correct holes in the levers and bracket for the
new action of the actuator (see figure 6).
Caution: The valve must be isolated and
pressure vented before disassembly.

Instruction No. EH 45004 E
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Note: Ensure that the clevis is correctly
positioned before fitting the lever No. 1 on the
bracket (108).
J. Reset adjustment knob (24) to the minimum Cv
position.
K. Couple plug stem clevis (104a) to lever No. 1
following the normal reassembly procedure (step
L. in the "Reassembly" section on page 17).
L. Hook spring (114) in the appropriate hole in
spring clamp (115) (see figure 6).
M. Admit supply and signal pressures and complete
calibration. Refit cover (110) using the two
screws (109). If the valve is equipped with a
handwheel, refit the cover and turn the
handwheel clockwise so that it engages in lever
arm stop (122). Tighten cover screws (109).
N. Put the valve back into service.
Note:
- When replacing an Air-to-Close actuator with an
Air-to-Open actuator, do not forget to neutralize the
limit stop by screwing it down at the bottom of the
piston.
- When replacing an Air-to-Open actuator with an
Air-to-Close actuator, set the limit stop to the
opening position.
AIR-TO-CLOSE ACTUATOR AIR-TO-OPEN ACTUATOR
VariPak 28001
with
single lever
VariPak 28002
with
adjustable Cv
(2 levers)
* Only with type 7700 positioner
Figure 6 - Identification of lever pivot pin holes
115
114
113
105
104a
*
*
115
114
113
105
104a
*
*
115
114
18
105
104a
*
*
No. 1
No. 2
115
114
18
105
104a
*
*
No. 1
No. 2

Instruction No. EH 45004 E
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3.1 PRELIMINARY STEPS
A. Before installing the valve in the line, remove all
traces of foreign material from the piping such as
welding chips, scale, oil, grease, etc.
B. Note down all the data given on the serial plate.
C. For valve inspection without interrupting process
operation, a hand-operated stop valve will be
required on either side of the VariPak, together
with a hand-operated throttling valve mounted on
a bypass line.
3.2 VALVE INSTALLATION (Figures 7, 8
and 9)
Connections: The body of the ANSI Class 1500*
rated VariPak valve can be:
- Bolted between 25 mm (1") pipe flanges
machined to standards ISO-PN 10 to PN 250
(ANSI 150 - 300 - 600 - 900 and 1500 lb).
Use ASTM A 193 Gr B 7 (or equivalent) carbon
steel bolting for temperatures between -29° and
+350 °C. For corrosive or cryogenic service, use
ASTM A 193 Gr B8 strain-hardened stainless
steel. All the line bolting required for installation
can be supplied by Masoneilan on request.
- Connected by 25 mm flanges machined to
standards ISO-PN 20, 50 and 100 (ANSI 150,
300 and 600 lb).
Fit gaskets compatible with service conditions
between the valve body and the pipe flanges.
The VariPak valve body can be supplied on
request with 1/2", 3/4", or 1" NPT threaded ends.
Apply PTFE tape or a sealing compound
compatible with the process to the threaded pipe
ends.
Alignment: This valve is small and light, making it
easy to install on the piping. Support the valve body
when fitting studs. Suitably shaped bosses are
provided to center the valve in the line and prevent
rotation before the studs are finally tightened.
The valve must always be installed with "flow
tending to open". The flow arrow on the valve body
must be pointing in the direction of flow. Fit the bolts
and tighten in criss-cross fashion.
3. Installation
* Except in the case of valve bodies designed for maximum Cvof 3.8: ANSI class
Figure 7 - VariPak flanged connection
Figure 8 - VariPak flanged body
Figure 9 - VariPak screwed connection (option)