Honeywell 9410 Series Instruction manual

Revision: 1.1
Series 9410
Ball Valve
70-16-45-06-EN
INSTALLATION, OPERATION, MAINTENANCE MANUAL

Contents
1. General....................................................................................................... 1
1.1 Introduction to Valves.......................................................................................................... 1
2. Storage....................................................................................................... 1
3. Installation ................................................................................................. 2
4. Operation ................................................................................................... 7
4.1 Inspections before Operation ............................................................................................. 7
5. Maintenance and Repair........................................................................... 8
5.1 General .................................................................................................................................. 9
5.2 Body Disassembly and Assembly (See Fig 5.1) ................................................................ 9
5.2.1 Disassembly ......................................................................................................................9
5.2.2 Assembly ........................................................................................................................ 10
6. Preventive Maintenance and Troubleshooting......................................11
6.1 Troubleshooting ..................................................................................................................11
7. Others ...................................................................................................... 12
7.1 Procedure for Switching Action (Reverse Action ↔Direct Action) ............................. 12

- 1 -
1. General
1.1 Introduction to Valves
A) The ball valve has been designed for the requirements and applications of piping.
B) The most important feature of the Honeywell angle valve is its body that has been manufactured in
appropriate sizes to meet the requirements of piping. It consists of a body that includes a cage to
control flow speed, a seat ring, a bonnet, and an actuator.
C) The ball Valve is designed for easy maintenance.
D) The ball valve trim boasts a long life span and has few faults. To use the system to its full life span,
you should install it correctly according to the manual and maintain it according to the prescribed
procedures while using it.
♣RECOMMENDATIONS
Engineers who have professional assembly capabilities are required to maintain Ball valves. Therefore,
it is more economical to request repairs of the valves to Honeywell. As the valves repaired by
Honeywell are thoroughly tested and warranted, you are recommended to entrust Honeywell with
repairs.
2. Storage
A) Do not throw, drop, trip or drag ball valves when transporting them.
B) Keep all parts of the ball valve in a well-ventilated place protected from fire, rain and wind.
Store the valve at a temperature between - 29℃(-20℉) and 48℃(120℉).
The storage area must be protected from flooding.
To avoid possible injury to personnel or damage to valve parts, WARNING
and CAUTION notes must be strictly followed. Modifying this product,
substituting non-factory parts or using maintenance procedures other than
outlined could drastically affect performance, be hazardous to personnel
and equipment and may void existing warranties.

- 2 -
C) Operate the elastomer (O-ring type) of pneumatic actuator at least once every six months to
prevent their functional degeneration. Operate it to the full stroke even under general operation
conditions at least three times a month.
D) Do not remove the flange cap attached to the flange surface to prevent foreign substances from
penetrating into the system until ball valves are installed on the line.
3. Installation
Like any other valves, the Honeywell control valve must be installed carefully at first according to the
following cautions to use it for many years without malfunction.
A) Remove the flange cap and check whether there are any foreign substances in the body. If you find
foreign substances, remove them before starting installation.
B) As cast steel products are processed with rust preventive oil before shipping to prevent corrosion,
remove the rust preventive oil from the pipes before installing them on the line.
C) Blow off all foreign substances including welding chips in the pipes before starting installation.
D) Install valves in the direction of arrow marked on the body.
♣CAUTIONS
When moving control valves, you should handle them carefully so that the components and air piping
will not be damaged. Otherwise, the electronic and electric parts such as solenoid valve, positioner, and
limit switch may get damaged or the valve travel may change.
Be careful not to damage the sealing surface of valve flange.
Apply thermal insulation as needed, but do not apply thermal insulation to the cooling fin and extensions.
- WARNING -
To prevent damages to plugs and seats, you must blow out (flashing) foreign
substances such as weld beads, scales and chips from the pipeline
according to the prescriptions before installing the ball valve.

- 3 -
E) When assembling the valve, you should use a specified gasket, and install it in parallel with the other
flange. Also, you are recommended to fasten the bolts in several parts in a balanced manner
sequentially in diagonal direction. (See Fig 3.1)
Fig 3.1 Procedure for Fastening Flange Bolts
F) Install the valve at right angle to the ground as much as possible. If this is impossible, attach a support to
the valve before installing it. (See Fig 3.2 and 3.3)
Fig 3.2 Installing Support Fig 3.3 Installation Location of Actuator
16
4
8
2
5
3
7

- 4 -
G) A minimum space is required for maintenance of the valve installation area. (See Fig 3.4) In addition, a
space for manual operation is required if a manual hand wheel has been installed.
Fig 3.4 Space required for control valve installation
☞ A: Face-to-Face Dimension
B: Minimum distance from obstacles (Approx. 30 cm)
C: Space for removing the actuator (Approx. 40 cm)

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H) Install a bypass line for valve maintenance. (See Fig 3.5)
Fig 3.5 Example of Control Valve Installation
♣NOTE
When the control valve has a problem, you may have to close the block valve and open the bypass valve to
control flow. Therefore, use a control valve that has the feature to control flow by opening the bypass valve.
Moreover, it is ideal to choose the same flow characteristics and size as those of control valve. Fig 3.6
shows an example of ideal control valve installation recommended by Honeywell.
Fig 3.6 Example of Control
Valve Installation Recommended by
Honeywell
Block Valves
Pressure gauges
응축수 회수관
6
Steam trap (Drain Valve)6
Bypass Valve
Control Valve
3
5
1
Strainer
3
2
4
4
5
2
Main steam line
124
Return line of Condensation Water

- 6 -
♣NOTE
To maintain a constant pressure at the entrance for all tracks of the valve, the straight pipe length at the
valve entrance must be at least 10 to 20 times the pipe diameter. For the fluid to maintain the specified
pressure after passing the valve and to prevent noise or vibration by turbulent flow, the straight pipe length
at the valve exit must be at least 3 to 5 times the pipe diameter. Straight piping at the entrance and exit
allows the preservation of accurate operation status by enabling accurate measurement of the pressure at
the entrance and exit. (See Fig 3.7)
Fig 3.7 Minimum straight pipe length for valve performance and pressure measurement
배관구경 x 13
배관구경 x 16
배관구경 x 4
배관구경 x 5
Pi
p
e Dia. x 13
Pi
p
e Dia. x 16
Pipe Dia. x 4
Pipe Dia. x 5

- 7 -
4. Operation
4.1 Inspections before Operation
①Check whether there is any leak from all connections including the air pipe connections.
②To check whether there is any leak from gland packing and gaskets, apply a pressure to the pipeline. If
any leak is detected, remove pressure from the pipeline and fasten the gland flange nut.
③Check the bolts and nuts of the actuator and the yoke for any looseness.
④Check whether there is any short circuit in the electric signal system.
⑤Check whether the attached manual hand wheel is at the Neutral position.
⑥Check whether the system operates accurately and flexibly according to the signals from the controller.
⑦When raising the temperature or pressure, do it slowly. Never raise the temperature or pressure quickly.
⑧Check whether the air pressure required for valve operation is accurately set. (Cylinder Actuator:
5.0kgf/cm2-> Specified in the name plate)
⑨Electrical devices such as limit switch or solenoid valve are attached to an control valve. Even if the
manufacturer has adjusted them, the tubing may be bent or the valve stem’s position becomes incorrect
due to a shock during transportation or careless handling during assembly. Therefore, it is
recommended to readjust the valve during the test run.
- WARNING -
①Remove air pressure from the actuator before using the manual hand wheel. If you use the
hand wheel without removing air pressure, it may not work normally and its weak part may
get damaged by overstrain.
②If the manual hand wheel is not at the Neutral position during control operation, it may not
work normally and its weak part may get damaged.
③If you use a pressure higher than the specified pressure on the name plate, the rubber and
O-rings of the actuator may be damaged and cause operation problems.

- 8 -
5. Maintenance and Repair
REGULAR INSPECTION
Repair and inspect as described below. If any malfunction occurs, take appropriate measures according to
the preventive maintenance procedures and troubleshooting in Chapter 6. Also, disassemble and inspect the
valve body and actuator during the regular overhaul period, and replace parts if necessary.
♣RECOMMENDATIONS
The life span of the valve can increase if you replace parts according to their replacement cycles. Refer
to the Part Replacement Cycle Sheet shown below.
Part Replacement Cycle Sheet
Item Name Replacement Cycle Others
Packing 2 years
Gasket 2 years
Ball 2 years
Replace after inspection according to the fluid
conditions and used environment.
Seat 2 years
Replace after inspection according to the fluid
conditions and used environment.
IRREGULAR INSPECTIONS
①Are there abnormal noise, vibration or hunting?
②Is there any leak from the seat?
③Are there any loose bolts and nuts?

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5.1 General
♣Prepare gland packing and gaskets as required. (Do not reuse parts that have been used.)
5.2 Body Disassembly and Assembly (See Fig 5.1)
5.2.1 Disassembly
①Pull out the valve from the component while taking care not to damage the accessories and pipes.
②Remove the valve from the actuator.
③Unfasten the gland bolt (9) from the valve and remove the gland flange (8).
④ Unfasten the cover nut (20) and remove the body (1) and body cap (2).
⑤Remove the ball (3), and push the stem (5) to the inside of the body (1) to remove it.
⑥Remove the seat ring (4) and gasket (31) from the body (1) and the body cap (2).
- Clean each part and check them for any damage. Prepare available parts for future repair.
- WARNING -
To prevent human injuries and damages to control system, close the block valve, remove
instrument air and signals from the valve and open the bypass valve to switch over the
pressure from the line to the bypass. Then slowly unfasten the bolts from the pipe until the
internal pressure of the body is completely released and remove the valve before
disassembling the actuator.
- WARINING -
To prevent injuries or damages to the system, remove the line pressure and remove the valve
from the line before starting disassembly.
- Warning -
Take special care not to damage the surface of ball and seat during assembly.

- 10 -
INSPECTION AFTER DISASSEMBLY
①Are there any damages to the seat ring and ball?
②Are there any damages to the gasket and gland packing?
♣RECOMMENDATIONS
①Be sure to inspect and replace worn out parts before reassembling them.
②You are recommended to replace soft products such as packing, gasket and seat always before
reassembling.
5.2.2 Assembly
Assemble in the reverse sequence of the disassembly.
Fig 5.1 Body Assembly Diagram

- 11 -
6. Preventive Maintenance and Troubleshooting
♣NOTE
Replace parts after inspection by referring to the Part Replacement Cycle Sheet in Section 5. For other parts,
replace them to prevent damages to other devices when they show a wearing sign.
6.1 Troubleshooting
Table 6.1 shows some remedies to general problems that may occur at the site while using ball valves. For
more serious problems, transport the system to the factory.
Table 6.1
Problem Solution
Leak from Stem Packing
1. Fasten the packing flange. Check for leaking.
2. If you suspect any damage to the stem, go to item #3. Otherwise, replace
packing after taking all safety precautions at the site.
3. Disassemble the valve. Visually inspect the stem. Check whether the plug
components are damaged, and replace them if necessary. Also, replace
the gland packing.
Excessive internal leak
when the valve is blocked
(Seat)
1. Check the air pressure supplied to the valve.
2. If you suspect any damage to ball or seat, go to item #3
3. Disassemble the valve. Visually check ball and seat for damages. Replace
them if any damage is found.
The stroke time is delayed.
1. Check the air pressure supplied to the valve.
2. Check the pressure of the filter regulator.
3. Check the adjustment of accessories such as booster solenoid.
Leak from the connection
between body and body
cap
1. Remove pressure from the line and fasten the bolts connecting the body
and body cap.
2. Disassemble the valve and check the gasket.

- 12 -
7. Others
7.1 Procedure for Switching Action (Reverse Action ↔Direct Action)
Disassemble the valve body and actuator by referring to the procedure described in Section 5.2. Change the
ball direction to the desired action, and connect the solenoid valve and accessories. Then perform a
recalibration.
Problem Solution
Ball does not move.
1. Check the air pressure supplied to the valve and then check the condition
of the filter regulator.
2. Check the operations of parts such as solenoid valve and air operated
valve.
3. Disassemble the valve and check whether there are any foreign
substances in the ball and seat.
4. Check the design temperature and actual line temperature.
5. Remove the actuator and try to operate the actuator only.
The valve does not respond
to input signals.
1. Check the air pressure supplied to the valve.
2. Check the voltage of the solenoid valve.
3. Apply the correct air pressure to the actuator to see whether it works
properly or leaks. (If it leaks, fasten the cylinder cover bolts.)
The valve flow is low.
1. Check pressure at the entrance and exit of the valve.
2. Visually check whether the valve responds to signals.
3. Check whether the valve operates with the maximum stroke.

- 13 -
Sales and Service
For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor,
contact one of the offices below.
ASIA PACIFIC
Honeywell Process Solutions,
(TAC)hfs-tac-
[email protected]
Australia
Honeywell Limited
Phone: +(61) 7-3846 1255
FAX: +(61) 7-3840 6481
Toll Free 1300-36-39-36
Toll Free Fax:
1300-36-04-70
China – PRC - Shanghai
Honeywell China Inc.
Phone: [phone]
Fax: [phone]
Singapore
Honeywell Pte Ltd.
Phone: +(65) 6580 3278
Fax: +(65) 6445-3033
South Korea
Honeywell Korea Co., Ltd.
Phone: +[phone]
Fax: +[phone]

70-16-45-06-EN
September 2014
ⓒ2014 Honeywell International Inc.
For more information
To learn more about Honeywell Control valves,
Visit www.honeywellprocess.com
Or contact your Honeywell Account Manager
Process Solutions
Honeywell
1250 W Sam Houston Pkwy S
Houston, TX 77042
Honeywell Control Systems Ltd
Honeywell House, Skimped Hill Lane
Bracknell, England, RG12 1EB
Shanghai City Center, 100 Jungi Road
Shanghai, China 20061
www.honeywellprocess.com
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