metso automation Wafer-Sphere C Operating and maintenance manual

IMO - 308EN Issue Date: 10/06
INSTALLATION, MAINTENANCE, AND
OPERATING INSTRUCTIONS
MODEL C
WAFER-SPHERE®
Read entire instructions carefully before installation or servicing
TABLE OF CONTENTS
1GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3 Seat Replacement Standard Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4 Seat Replacement Fire-Tite® Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.5 Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.6 Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.7 Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4VALVE TESTING PROCEDURE (On-Site) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5MANUAL HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.1 Handle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.2 Change of Handle Quadrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.3 Setting Handle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6ACTUATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.2 Actuator Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.3 Direct Drive Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
7REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

WAFER-SPHERE BUTTERFLY VALVES
WAFER DESIGN
Figure 1
2
1GENERAL
This instruction manual contains important information
regarding the installation, maintenance, and operation of
Jamesbury® Model C Wafer-Sphere. Please read the
instructions carefully and save them for future reference.
The Jamesbury® Wafer-Sphere Valve is a high performance
butterfly valve design. Maximum shutoff pressure rating
depends on the materials chosen.
1.1 WARNING
SAFETY FIRST! FOR YOUR SAFETY, ASK THE FOLLOWING QUESTIONS
BEFORE REMOVING THE VALVE FROM THE LINE, AND BEFORE ANY
DISASSEMBLY:
1. WHAT’S IN THE LINE?
BE SURE YOU KNOW WHAT FLUID IS IN THE LINE. IF THERE IS ANY
DOUBT, DOUBLE-CHECK WITH THE PROPER SUPERVISOR.
2. ARE YOU PROTECTED?
WEAR ANY PROTECTIVE CLOTHING AND EQUIPMENT NORMALLY
REQUIRED TO AVOID INJURY FROM THE PARTICULAR FLUID IN
THE LINE.
3. IS THE LINE DEPRESSURIZED?
DEPRESSURIZE THE LINE AND DRAIN THE SYSTEM FLUID. THE
WAFER-SPHERE BUTTERFLY’S OFFSET SHAFT CREATES GREATER
DISC AREA ON ONE SIDE OF THE SHAFT. THIS MEANS THAT A
WAFER-SPHERE VALVE TENDS TO OPEN WHEN PRESSURIZED ON
THE INSERT SIDE WITHOUT A HANDLE OR AN ACTUATOR ON THE
VALVE.
4. IS THE VALVE CLOSED?
BEFORE YOU INSTALL A WAFER-SPHERE VALVE IN, OR REMOVE IT
FROM THE LINE, FULLY CLOSE THE VALVE. THE WAFER-SPHERE
BUTTERFLY VALVE MUST BE REMOVED FROM THE LINE IN THE
CLOSED POSITION. THIS WILL PREVENT MECHANICAL DAMAGE
TO THE DISC SEALING EDGE.THE BLADE DRIVE FLATS OR LINE ON
TOP OF THE SHAFT WILL INDICATE THE POSITION OF THE DISC.
(SEE FIGURES 1 AND 2 )
1.2 Description
Refer to the tag attached to each valve for this rating. Do
not use a valve at service conditions that exceed the rating
on the name plate.
Offset Shaft Design
One of the design features of the Wafer-Sphere valve that
is responsible for its superior performance is the valve’s
offset shaft design. The shaft is offset in two planes: (1)
away from the valve disc centerline and (2) behind the disc
sealing plane (See Figure 3). Offset shaft design makes
the rotating disc “cam” back and away from the seat,
completely eliminating the usual wear points at the top
and bottom of the seat. Because the disc rotates off the
seat in an eccentric arc, it operates in one quadrant only
(See Figure 3).
Square drive in disc
closed position.
Blade drive in disc
closed position.
WAFER-SPHERE BUTTERFLY VALVES
SINGLE FLANGE LUGGED DESIGN
Figure 2
Square drive in disc
closed position
Blade drive in disc
closed position.
Positive Stop Feature
To prevent seat damage from over-travel of the disc
beyond the closed position (usually during field mounting
of a handle or actuator), a “positive stop” feature has been
designed into the Wafer-Sphere butterfly valve. The “posi-
tivestop” feature also makes it possible to adjust the actu-
ator travel stops in-line. The location of this feature is
shown in (Figure 3).
Actuation
High line pressure may create high enough forces to pull a
manual handle out of an operator’s hand. With Types
815W,815L, 830W, and 830L valves, either a manual gear

3
operator, a pneumatic or an electric actuator should be used
in place of a detent handle on 2-1/2," 3" and 4" (DN 65, 80
and 100) valves when differential pressure exceeds 300 psi
(20.7 bar), on 5", 6" and 8" (DN 125, 150 and 200) valves
when differential pressure exceeds 150 psi (10.35 bar), and
on 10" and 12" (DN 250 and 300) valves when differential
pressure exceeds 50 psi (3.45 bar).
Wafer Body Design
Some wafer designs (See Figure 1) contain flange bolt
holes or slots in the body to hold the valve and assist with
correct alignment during installation in the line.The centering
holes or slots in wafer bodies alone are not suitable, or
intended for containing line pressure, and are only for use
in conjunction with a fully bolted pipeline flange.
2INSTALLATION
For lowest torque, Wafer-Sphere butterfly valves should be
installed with the body insert toward the higher pressure,
(shaft downstream).
1. Read the WARNING Section on Page 2 carefully.
2. IMPORTANT: Only operating handle stops or actuator
stop set screws must be used to stop the disc in position.
DO NOT use the “positive stop” by itself to limit travel.
3. Visually check the position of the disc when the valve is
in the closed position and the insert is fully compressed.
The disc should be parallel to the flanges within 1/32 “
(.79 mm).
4. Before installing a closed valve in the pipeline, be sure
that the handle or actuator is attached so that a counter-
clockwise rotation, viewed from above, opens the
valve (See Figure 3). Fully close the valve again before
installing it in the pipeline.
TABLE 1
Insert Screw Torque Table
(FT•LBS Unless Otherwise Specified)
Screw Torque Torque
Size Carbon Steel Stainless Steel
FT•LBS (N•m) FT•LBS (N•m)
#10 50 IN•LBS (6) 23 IN•LBS (3)
1/4" 14 (19) 6 (8)
5/16" 30 (41) 11 (15)
3/8" 50 (68) 20 (27)
7/16" 80 (109) 30 (41)
1/2" 120 (163) 40 (55)
TABLE 2
Cover Plate Screw Torque Table
Screw Torque – FT•LBS (N•m)
size
3/8" 35 (48)
1/2" 80 (109)
9/16" 110 (149)
5/8" 180 (244)
3/4" 270 (366)
Figure 3
Positive Stop
HANDLE DIRECTION
VALVE OPEN
HANDLE
DIRECTION
VALVE
CLOSED
Open Always
Counterclockwise
5. THE PIPELINE: The Wafer-Sphere butterfly valve must
be centered between flanges to avoid disc-pipe contact
which could damage the disc and shaft. Any flange or
pipeline welding should be done prior to installation of
the valves. If this is impossible, protective covering or
shields must be placed in the pipeline between the
valve and the area being welded prior to welding. Not
only must the valve be protected against weld slag,
but also against any excessive heat, which could cause
seat damage. It is essential that all weld slag, rods,
debris, tools, etc., be removed from the pipeline before
valves are installed or cycled.
6. Secure the valve between flanges. Compress the
flange gasket EVENLY by tightening the fasteners in
an alternating sequence.
IMPORTANT: The valve should be tightened between
flanges using appropriate gaskets and fasteners for the
service, in compliance with applicable piping codes and
standards. Recommended fastener lengths are listed in
Bulletin T104-1.
7. If there is seapage past the shaft seal upon installation,
the valve may have been subject to wide temperature
variations in shipment. Leak tight performance will be
restored by a simple packing adjustment described in
the MAINTENANCE Section.
Close Always
Clockwise

4
Removing Insert
Placing Spring Into Groove
Tapping End Of Spring Into Body
Installing Seat And Insert Assembly Into Body.
Angled As To Engage Insert Spring
Tapping Insert Assembly Into Body
Figure4
3MAINTENANCE
3.1 General
Routine maintenance consists of periodically tightening
down the compression plate to compensate for shaft seal
wear. The compression plate, however, should not be
tightened down too tight, since this will shorten the life of
the seals. More extensive maintenance such as seat, seal
and bearing replacement is described below.
3.2 Valve Removal
1. Read the WARNING Section on Page 2 carefully.
2. Valve must be fully closed before removing it from the
pipeline.
3. CAUTION: Valves equipped with spring-to-open
(air-to-close) actuators must be disconnected from the
actuators and then closed.Valves must be closed while
removing them from the pipeline.
3.3 Seat Replacement Standard Valves
Numbers in ( ) refer to items shown in (Figure 5).
1. After removing the valve from the line, place it on a
bench. Take care not to damage the sealing edge of
the valve disc.
2. Insert Styles:
A. Bolted Insert:
Remove the insert screws (21) and the insert (2).
If the insert does not lift out easily,tap it out from
the shaft side using a wooden or plastic rod and
a hammer. Do not strike the valve directly with a
hammer.
B. Snap-In Insert (See Figure 4):
Using a wooden or plastic rod and hammer,drive
the insert out of the body from the shaft side.
The rod should be placed on either side of the
positive stop in the body. Do not strike the valve
directly with a hammer. (NOTE: Removal of the
insert often results in damage to the seat being
replaced.)
3. Remove the seat (5) and discard it.
4. Remove the body seal (40) when applicable, (2-1/2”,3”
and 4” [DN 65, 80 and 100] Series 815L and 830L
valves).
5. Clean the valve, and deburr the insert.
6. Carefully clean and polish the disc sealing surface. It
should be free of all grooves and scratches.

5
Figure 5
EXPLODED VIEW
Valves Without Cover Plates
DIRECTION OF SEALS (8)
47
9
10
15
6
40
7
8
4
Graphite
(FIRE-TITE)
Chamfer
side down
TEFLON®
(Standard)
18
13
5
6
64
1
14
17
44
64
3
77
2
Direction of Installation
Toward Stop
2
21
5
1
PARTS LIST
ITEM PART NAME QTY
1Body 1
2 Insert 1
3 Disc 1
4 Shaft 1
5+Seat 1
6 Shaft Bearing 2
7 Spacer 1
8+Shaft Seal 1
9 Compression Ring 1
10 Compression Plate 1
13 Disc Pin 2
14 Stud 2
15 Nut 2
17 Nameplate 1
18 Drive Screw 2
21 Cap Screw **
40+Body Seal
(2.5", 3", 4" [DN 65, 80, 100]
815L & 830L Only) 1
41 Top Bearing Spacer 1
44 Paper Tag 1
47+Retaining Ring 1
64 Thrust Bearing 2
77+Insert Spring (3" - 12"
[DN 80 - 300] Wafer Style Only) 1
** Cap Screw quantities vary by valve, size
and style
+Parts contained in service kit

6
Figure5A
EXPLODED VIEW
Valves With Cover Plates
DIRECTION OF SEALS (8)
47
9
10
15
6
7
8
4
Graphite
(FIRE-TITE)
Chamfer side
down
TEFLON
(Standard)
18
13
5
6
64
1
14
17
44
64
3
54
2
Direction of
Installation
Toward Stop
2
21
5
1
PARTS LIST
ITEM PART NAME QTY
1Body 1
2 Insert 1
3 Disc 1
4 Shaft 1
5+Seat 1
6 Shaft Bearing 2
7 Spacer 1
8+Shaft Seal 1
9 Compression Ring 1
10 Compression Plate 1
13 Disc Pin #
14 Stud 2
15 Nut 2
17 Nameplate 1
18 Drive Screw 2
21 Cap Screw **
29 Indicator Pointer (Sqare
Drives Only) 1
41 Top Bearing Spacer 1
44 Paper Tag 1
47+Retaining Ring 1
53 Cover Plate 1
54 Gasket 1
55 Hex Head Cap Screw #
56 Lockwasher #
64 Thrust Bearing 2
** Cap Screw quantities vary by valve, size
and style
+Parts contained in service kit
# Quantities vary by valve size
55
56
21
53

7
7. If the disc is slightly damaged, it may be possible to
smooth the sealing surface with crocus cloth, a fine
stone, or the equivalent. If deep scratches are present,
replace disc or return the valve to the factory for service.
8. Place the new body seal (40) into the groove in the
body (when applicable).
9. Install the seat (5) into the insert (2).
10. Insert Styles:
A. Bolted Insert:
With the valve in the closed position, replace the
insert and seat together, using the insert screws.
Tighten the screws uniformly. Torque valves are
given in (Table 1). Open the valve and retorque
the insert screws per (Table 1). Take care not to
damage the sealing edge of the disc. Close the
valve.
B. Snap-In Insert:
Place the insert spring (77) into the groove in the
body, opposite the positive stop (See Figure 5).
Lightly tap one end of the spring into the body
groove. Be sure the spring is positioned snugly
into the groove. Lightly tap the other end of the
spring into the groove. Make sure that the ends
of the spring are embedded into the body
groove to prevent spring movement. With the
seat assembled into the insert and the disc
slightly open, install the assembly into the body
such that it is angled into the body to engage
the insert spring. Once the insert spring is
engaged, “pop” the opposite side of the insert
into the body by lightly tapping the insert with a
block of wood and a hammer. Close the valve.
11. Set the handle or actuator stops as described in the
SETTING HANDLE STOP Section or ACTUATOR
MOUNTING INSTRUCTION Section. NOTE: After
installation of a new seat, torque will be higher for a
few cycles.
3.4 Seat Replacement Fire-Tite Valves
Numbers in ( ) refer to items shown in (Figure 6).
1. After removing the valve from the pipeline, place it on
a bench and cycle it open.Take care not to damage the
sealing edge of the valve disc.
2. Insert Styles:
A. Bolted Insert:
Remove the insert screws (21) and the insert (2).
If the insert does not lift out easily,tap it out from
the shaft side using a wooden or plastic rod and
a hammer.Do not strike the valve directly with a
hammer.
B. Snap-In Insert:
Using a wooden or plastic rod and hammer,drive
the insert out of the body from the shaft side.The
rod should be placed on either side of the positive
stop in the body. Do not strike the valve directly
with a hammer. (NOTE: Removal of the insert often
results in damage to the seat being replaced.)
3. Remove the seat (5) and discard.Remove the body seal
(40) from the insert and body.
4. Carefully clean the gasketing surfaces with a suitable
solvent.They should be free of all grooves and scratches.
If deep scratches are present, polish or repair is required.
5. Clean the valve and deburr the insert.
6. Carefully clean and polish the disc. It should be free
from all grooves and scratches.
7. If the disc is slightly damaged, it may be possible to
smooth the sealing surface with crocus cloth, a fine
stone, or the equivalent. If deep scratches are present,
replace disc or return the valve to the factory for service.
8. Cycle the valve closed.
9. A body seal (40) is required between the seat tail and
body as shown in (Figure 7). The valve uses a graphite
type gasket. This is installed in accordance with the
following steps:
a. IMPORTANT: Exercise care at all times not to
damage the gasket.A break may cause the gasket
to leak.
b. The bottom surface of the insert is to be free of
all foreign particles. Clean thoroughly with suitable
solvent.
c. Apply the gasket to the body, and if a lug style,
take care to align the holes in the gasket with the
insert screw holes.
Figure 6
SNAP-IN INSERT
BOLTED INSERT
77
2
21
2
5
40

8
CAUTION: Read the WARNING Section (Page 2) before
continuing.
1. Remove the handle or actuator coupling.
2. Remove the nuts (15) from above the compression
plate (10). Remove the compression plate (10). The
studs (14) do not have to be removed.
3. Remove C-shaped retainer ring (47) from the shaft.
4. Remove the compression ring (9).
5. Remove the old shaft seal (8) segments. Do not score
the shaft or body bore!
6. The spacer (7) need not be removed for shaft seal
replacement.
7. Replace the old shaft seal with a new shaft seal.
NOTE: If the seal is of the PTFE V-ring type, keep the
seal rings stacked in the same order as removed from
kit. Note the orientation in (Figure 5).This orientation
is preferred for all applications, including vacuum.
8. Reinstall the compression ring (9), the retainer ring
(47), the compression plate (10), the nuts (15).
*If the compression ring initially sits too high to install the
retainer ring it may be necessary to precompress the shaft
seals somewhat.In that case,install the compression plate and
tighten the nuts enough to accomplish the precompression.
Remove the compression plate to install the retainer ring
and then complete the reassembly.
9. Close the valve.
10. With the valve closed, tighten the nuts (15) on the
compression plate evenly until the packing is adequately
compressed to prevent leakage. This should require
tightening the nuts approximately 1-1/2 to 2 full turns
after they have both come into contact with the
compression plate.
3.6 Valve Disassembly
Numbers in ( ) refer to items shown in (Figure 5 & 5A).
NOTE: If complete disassembly becomes necessary,
replacement of seats and all seals is recommended.
1. Place the valve on a bench or other suitable working
space.
2. If the seat is to be replaced or removed, follow Steps 2,
3, 4 and 5 in the SEAT REPLACEMENT Section.
NOTE: It is good practice to replace the seat, shaft and
body seals and bearings any time a valve is disassembled.
Figure 7
REFER TO
(FIGURE 5) FOR
COMPLETE VALVE
Disc in
Level Position
Body
Seal
BOLTED INSERT
SNAP-IN INSERT
Seat
Insert
10. Verify that the disc is in the level position. Install new
seat and insert. (See Figure 6 & 7.) For bolted inserts,
install the insert screws, and tighten them uniformly.
Torque values are given in (Table 1).Whenever possible,
open the valve and retorque the insert screws per
(Table 1).Take care not to damage the sealing edge of
the disc. Close the valve. For snap-in inserts, place the
retaining spring into the groove in the body, opposite
the positive stop. (See Figure 4.) The tips of the spring
should be toward the insert side of the valve. Lightly
tap one end of the spring into the body groove. Be
sure the spring is positioned snugly into the groove.
Lightly tap the other end of the spring into the groove.
Make sure the tips of the spring are embedded into
the body groove to prevent spring movement. With
the seat assembled into the insert, and the disc slight-
ly open, install the assembly into the body, such that it
is angled into the body to engage the retaining spring.
Once the retaining spring is engaged, “pop” the
opposite side of the insert into the body by lightly
tapping the insert with a block of wood and a hammer.
11. Set the actuator stops as described in the ACTUATOR
MOUNTING INSTRUCTIONS Section. Do not install
and tighten flanges on a newly reseated valve until the
actuator stops are properly set and the valve is fully
closed.Incorrect disc positioning may cause damage
to a new seat when the valve is compressed between
flanges for the first time. NOTE: After installation of a
new seat, torque will be higher for a few cycles.
3.5 Shaft Seal Replacement
Numbers in ( ) refer to items shown in (Figure 5).
See IMO-317 for live loaded shaft seals.

9
3. Remove the shaft seal compression hardware as detailed
in Steps 1-4 in the SHAFT SEAL REPLACEMENT
Section. The seal material itself can be more easily
removed after the shaft has been removed from the
valve.
4. Remove the disc pin welds by grinding or machining
off the welds. Drive out the pins opposite the installation
direction shown in (Figure 5).
5. Remove screws (55) and cover plate (53), and remove
gasket (54).
6. Remove the shaft (4). NOTE: When removing the shaft
and freeing the disc,be careful not to scratch the sealing
surface of the disc.
7. Remove the disc (3) and upper and lower thrust
bearings (64).
8. Remove the top bearing (6) either through the top of
the valve or the waterway.
9. Remove the bottom bearing (6).
3.7 Valve Assembly
Numbers in ( ) refer to items shown in (Figure 5).
1. Clean all valve components.
2. Inspect all components for damage before assembling
the valve. Look for damage to the sealing areas on the
disc, shaft, and body, and for wear in the bearing areas.
3. Carefully clean and polish the disc sealing surface. It
should be free from all grooves and scratches.
4. If the disc is slightly damaged, it may be possible to
smooth the sealing surface with crocus cloth, a fine
stone,or the equivalent. If deep scratches are present,
replace the disc or return the valve to the factory for
service.
5. Install the bearings (6) into the body bores.
6. To ease assembly of the shaft into the disc, it may be
necessary to coat the shaft and the disc bore lightly
with a lubricant compatible with the media to be
handled by the valve.
7. Slide the shaft through the top bearing and engage
the top thrust bearing (64). With the two pin holes
toward the bonnet, place the disc in the waterway and
slide the shaft through the shaft bore in the disc.Place
the lower thrust bearing (64) below the disc, slide the
shaft through and into the lower shaft bearing (6). Use
caution to prevent damage to the shaft bearings and
disc sealing surface.
8. Insert the disc pins (13), as shown in (Figure 5), and
drive them into place. The pins must be driven so that
both pins are the same depth within 1/16” (1.56 mm).
When they are correctly installed the drive shaft will be
as shown in (Figures 1 and 2).Weld both ends of the
pins, small end first, grounding the shaft only (body on
blocks of wood).After the disc cools,clean the welds with
a wire brush.CAUTION: Use care to keep contamination
out of the valve.
9. Install the upper bearing spacer (41) when applicable,the
spacer (7) with chamfered side toward disc, the shaft
seal (8), the compression ring (9) and the retainer ring
(47). If the shaft seal is of the PTFE V-ring type, be certain
that it is installed in the orientation shown in (Figure 5).
10. If the studs (14) have been removed from the valve,
reinstall them in the holes shown in (Figure 5), using
Loctite® or other locking compound to prevent vibration
loosening. Stud protrusion should be 2” (50.8 mm) for
the 3”,4”,6” and 8” (DN 80, 100, 150 and 200) valves and
2-1/4”(57.15 mm) for the 10”and 12”(DN 250 and 300)
valves.
11. Install new gasket (54), and secure cover plate to valve
body using screws (55). To ensure even gasket loading
tighten screws, in an alternating sequence to torque in
(Table 2).
12. If the handle ratchet plate has been removed from the
valve, reinstall it in the orientation shown in (Figure 6).
Install lock washers and screws in the two bonnet
holes. Do not tighten the screws until the stops are set.
(See SETTING HANDLE STOP Section or ACTUATOR
MOUNTING INSTRUCTIONS Section.)
13. Place the compression plate (10) over the shaft (4) and
studs (14). Install the nuts (15), but do not tighten.
14. Cycle the valve fully closed. Install new unused seat and
body seal. See the SEAT REPLACEMENT Section for
details.
15. With the valve still closed, tighten the nuts (15) on the
compression plate evenly until the shaft seals are
adequately compressed to prevent leakage. This
should require tightening the nuts approximately 1-1/2
to 2 full turns after they have both come into contact
with the compression plate.
16. Set the handle or actuator stops as described in the
SETTING HANDLE STOP Section or ACTUATOR
MOUNTING INSTRUCTIONS Section. Tighten the
screws holding the ratchet plate.

10
11. Repressurize the valve and check the leakage. If valve
still leaks,repeat step 10.If leakage cannot be stopped,
adjust the actuator stop so that leakage is minimized.
12. Rebuilt valves may have some minor leakage due to
damage to the disc. With the valve still pressurized,
insert the free end of the tube/hose into a beaker of
water and check for bubbles. In the absence of other
test standards, observe leakage after it has reached a
stable condition. Because of the volume of air that
must be exhausted from a cycled valve, it may be
necessary to wait several minutes for the leakage to
stabilize or stop.One bubble per inch (25.4 mm) of valve
diameter per minute may be considered acceptable
for rebuilt soft seated or Fire-Tite valves.
5MANUAL HANDLES
5.1 Handle adjustment
1. Depressurize the line.
2. 2-1/2” thru 6” (DN 65 thru 150) Valves - To ensure proper
handle/shaft engagement,the handle must be mounted
on the shaft such that it rests on the bottom of the
shaft blade. (See Figure 8.)
3. 8”
,10” and 12” (DN 200, 250, and 300) Valves - Handles
for these valves are of solid cast construction.
Adjusting these handles along the blade to assure
proper ratchet plate engagement is permitted.
NOTE: Handles not available on square drives.
4VALVE TESTING PROCEDURE
Should it become necessary to perform a leak test of the
valve prior to its installation in the pipeline, follow the
procedure outlined below.
1. In the following test, suitable gaskets are required
between the faces of the valve and the test hardware.
2. Before pressurizing the valve be sure all actuator link-
age fasteners are tight, and that the power or pressure
is applied to the actuator to maintain the valve in the
closed position. The offset design on the valve may
cause it to rotate when the test pressure is applied to
one side of the disc.
3. The valve should be installed between flanges or in a
testing apparatus. If flanges are used, refer to
INSTALLATION Section, part 6. If a testing device other
than flanges is used, the clamping force of the device
must be comparable with flange bolt loads on the
valve.
4. Slightly open the valve. Verify that you do not have a
seal between the seat and the disc. Exercise caution
when cycling a valve in the test apparatus to avoid
possible disc damage from the disc striking the test
fixture.
5. Cap the downstream vent and apply 100 psi (6.9 bar)
to the valve. Check the shaft seals, and flange gaskets
for leakage.This can be done by applying a liquid mixture
of soap and water at all seal joints and watching for
bubbles.
IMPORTANT: If leakage is detected between the valve and
flanges STOP IMMEDIATELY. Mark the area of leakage.
Vent the valve, and when it has returned to 0 psi (0 bar),
retighten the flange bolts in the area. Repressurize the
valve checking the gasket again. If leakage persists, disas-
semble and inspect for damage.
6. If leakage is detected at the shaft seals, tighten the
bonnet nuts only enough to stop the leak.
7. Vent the valve, and when it has returned to 0 psi (0
bar), cycle the valve closed.
8. Attach a small tube or hose to the downstream flange
(shaft side of the valve).
9. Be sure power/pressure is still applied to the actuator.
Pressurize the upstream flange (insert side of valve) to
100 psi (6.9 bar). Check for leakage passing through
the free end of the tube/hose.
10. If leakage is detected, vent the valve and make an
actuator close-stop adjustment as described in the
appropriate Jamesbury actuator IMO, listed on Page 11.
Figure 8
H1
H6
H2
H7
H3
HANDLE SUBASSEMBLY

11
5.2 Change of Handle Quadrant
If it is necessary to remount the handle 180 degrees from
its standard direction (Figure 8-1).
1. Depressurize the line.Remove the handle, hex head cap
screws (H6) and lockwashers (H7). Do not remove the
studs (14), nuts (15), or compression plate (10).
2. Lift the ratchet plate up and rotate it 180 degrees. Do
not turn it upside down.
3. Reinstall all the components which were just removed.
Do not tighten the ratchet plate fasteners until the
plate has been properly adjusted as described below
in the SETTING HANDLE STOP Section. If the valve is
not installed in the line,do not install it until the ratchet
plate is properly adjusted.
5.3 Setting Handle Stop
1. It is recommended that the valve be out of the
pipeline for proper adjustment. If this is not possible,
valve must be depressurized before adjustment is
made.
2. Loosen the two hex head cap screws (H6) clamping
the ratchet plate to the valve.
3. Close the valve until the disc is parallel with the flange
faces within 1/32” (.79 mm). Do not over close the
valve, so that the disc is in contact with the positive
stop in the body.
4. If the handle (H1 in Figure 8-1) has been removed
from the valve, reinstall it on the shaft drive blade and
tighten. Cast handles use a screw (H3) and nut (H5).
Fabricated handles use only a set screw (H3). With the
handle locking tab in the last (closed) notch of the
ratchet plate, rotate the ratchet plate clockwise (when
viewed from above the handle) until it is stopped by
the locking tab. The disc/handle assembly is now
trapped between the disc stop in the body and the
ratchet plate.
5. Tighten the two screws (H6) holding the ratchet plate.
TABLE 4
Actuator IMO
QUADRA-POWR IMO-31, 32
ST-50 IMO-22
ST-60, 90, 115, 175MS IMO-23
ST-200/400 IMO-26
ST-600/1200 IMO-24, 38
ST-160, 240, 290, 440MS IMO-27, 39
ST-1800 IMO-506
Manual Gears IMO-63
SP IMO-512
BC, B1C 5 BC 70-A
BJ, B1J 5 BJ 70-A
EU Series IMO-515
ER Series IMO-516
6ACTUATOR MOUNTING
6.2 Actuator Mounting Instructions
1. When a spring-return actuator is being mounted, the
valve should be in the closed position for spring-to-close
operation or in the open position for the spring-to-open
operation.When an electric or double-acting pneumatic
actuator is being mounted, the valve position should
correspond to the indicated actuator position.
Figure 8-1
6.1 WARNING
BEFORE INSTALLING THE VALVE AND ACTUATOR, BE SURE THAT THE
INDICATOR POINTER ON TOP OF THE ACTUATOR IS CORRECTLY
INDICATING THE VALVE POSITION. FAILURE TO ASSEMBLE THESE
PRODUCTS TO INDICATE CORRECT VALVE POSITION COULD RESULT
IN PERSONAL INJURY.
CAUTION: WHEN INSTALLING A LINKAGE OR SERVICING A
VALVE/ACTUATOR ASSEMBLY,THE BEST PRACTICE IS TO REMOVE THE
ENTIRE ASSEMBLY FROM SERVICE.
CAUTION: AN ACTUATOR SHOULD BE REMOUNTED ONTHE VALVE FROM
WHICH IT WAS REMOVED.THE ACTUATOR MUST BE READJUSTED FOR
PROPER OPEN AND CLOSE POSITION EACH TIME IT IS REMOUNTED.
CAUTION: THE LINKAGE HAS BEEN DESIGNED TO SUPPORT THE
WEIGHT OF THE JAMESBURYACTUATORS AND RECOMMENDED
ACCESSORIES. USE OF THIS LINKAGE TO SUPPORT ADDITIONAL
EQUIPMENT SUCH AS PEOPLE, LADDERS, ETC. MAY RESULT IN THE
FAILURE OF THE LINKAGE, VALVE OR ACTUATOR AND MAY CAUSE
PERSONAL INJURY.
WARNING: WHEN MOUNTING THE ACTUATOR MAKE SURE THAT THE
VALVE AND ACTUATOR ARE BOTH IN THE SAME POSITION. MOUNTING
AN OPEN ACTUATOR TO A CLOSED VALVE MAY RESULT IN VALVE STEM
DAMAGE.
NOTE: WHEN A SINGLE-ACTING STMS PNEUMATIC SPRING-RETURN
ACTUATOR IS MOUNTED TO A WAFER-SPHERE VALVE, IT CAN BE
MOUNTED ONLY IN THE SPRING-TO-CLOSE MODE (AIR-TO-OPEN).

12
Figure9-1 Figure 9-2
Place Coupling On Stem.
Screws of no-play
coupling to face in line
with pipe with the valve
closed.
Tighten sequentially.
Tighten per
(Table 4)
2. Assemble bracket to actuator as shown in (Figure 9-1).
Tighten to torque listed in (Table 4).
3. Place the coupling onto the valve stem.If the valve has
a two-piece “no-play” bolted coupling, assemble the
coupling loosely on the valve stem. Use socket head
cap screws and lock nuts. (See Figure 9-2.)
4. Lower actuator and bracket onto valve while engaging
actuator stem driver into coupling.Tighten screws just
enough to firmly mate bracket to valve. This should
allow bracket to shift, allowing the coupling to align the
valve and actuator shafts. (See Figure 9-3, Step 3A.)
5. Tighten the no-play coupling screws to torques shown
in (Figure 9-3, Step 3B).Use alternating sequence
shown.
6. Cycle actuator. See actuator instructions.
7. Fully tighten the screws holding the bracket to the
valve, as shown in (Figure 9-3, Step 3C).
8. Recheck no-play coupling screw torques, using the
torques in (Figure 9-3, Step 3B). Use alternating
sequence shown.
9. Adjust the actuator travel stops as described in the
actuator instructions to these proper valve open and
closed positions:
Valve Open: Disc face (or shaft blade)
perpendicular with the flange face.
Valve Closed: Disc face parallel to
flange face within 1/32" (.79 mm).
6.3 Direct Drive Mounting
Follow instructions per Paragraph 6.2 except for coupling
assembly.(See Figure 9-4.)

Figure 9-3 Figure 9-4
STEP 3B
Tighten these to
Screw Size Torque FT•LBS (N•m)
5/16" 25 (34)
3/8" 40 (54)
1/2" 90 (122)
5/8" 165 (224)
STEP 3A
Tighten these until bracket
sits firmly on valve
STEP 3C
Tighten these to
Screw Size Torque FT•LBS (N•m)
3/8" 30 (41)
1/2" 75 (102)
3/4" 230 (312)
NO PLAY COUPLING
7REPAIR KITS/SPARE PARTS
Service kits include one seat (seat assembly for Fire-Tite
valves), and a set of shaft seals.When ordering service kits,
seat and shaft seal materials must be specified.For example,
a kit for a 10” (DN 250) type 815L valve with filled PTFE(M)
seat and PTFE(T) seals is ordered as RKW-362MT. Wafer
style valves will also include insert springs. 2-1/2”,3”, and 4”
(DN 65, 80 and 100) lug style only will also include body
seals.
For further information on spare parts and service or
assistance visit our web-site at www.jamesbury.com.
13
1/8 NPT
Monitoring Port
Figure 10
DOUBLE PACKING
WITH MONITORING PORT
DOUBLE PACKING

14
TABLE 4
Bracket Bolting Torques for GR.5 Hex Cap Screws
Torque to Aluminum Body Actuators Torque to Cast/Ductile Body Actuators
No Lubrication to Screws
FT•LBS N•m FT•LBS N•m
1/4 6 - 8 -
5/16 12 - 16 -
3/8 20 - 27 -
7/16 30 - 45 -
1/2 50 - 67 -
9/16 70 - 100 -
5/8 90 - 135 -
3/4 160 - 225 -
7/8 250 - 335 -
1360 - 520 -
1-1/8 520 - 700 -
1-1/4 700 - 990 -
M6 - 6.8 - 9.5
M8 - 14.9 - 19.0
M10 - 30 - 38
M12 - 52 - 65
M16 - 122 - 156
M20 - 230 - 305
M30 - 773 - 1062
M36 - 1288 - 1826
Bolt Size
inches

WAFER-SPHERE REPAIR KITS
MODEL C
Size Soft Seat FIRE-TITE
Wafer Lug Wafer Lug
2-1/2" (DN 65) 815 RKW-470 RKW-471 O/A O/A
2-1/2" (DN 65) 830 RKW-470 RKW-471 O/A O/A
3" (DN 80) 815 RKW-352 RKW-358 RKW-364 RKW-370
3" (DN 80) 830 RKW-352 RKW-358 RKW-364 RKW-370
4" (DN 100) 815 RKW-353 RKW-359 RKW-365 RKW-371
4" (DN 100) 830 RKW-353 RKW-359 RKW-365 RKW-371
5" (DN 125) 815 RKW-468 RKW-469 RKW-472 RKW-473
6" (DN 150) 815 RKW-354 RKW-360 RKW-366 RKW-372
6" (DN 150) 830 RKW-405 RKW-409 RKW-413 RKW-417
8" (DN 200) 815 RKW-355 RKW-361 RKW-367 RKW-373
8" (DN 200) 830 RKW-406 RKW-410 RKW-414 RKW-418
10" (DN 250) 815 RKW-356 RKW-362 RKW-368 RKW-374
10" (DN 250) 830 RKW-407 RKW-411 RKW-415 RKW-419
12" (DN 300) 815 RKW-357 RKW-363 RKW-369 RKW-375
12" (DN 300) 830 RKW-408 RKW-412 RKW-416 RKW-420
14" (DN 350) 815 RKW-678 RKW-678 RKW-663 RKW-663
14" (DN 350) 830 RKW-673 RKW-673 RKW-668 RKW-668
16" (DN 400) 815 RKW-660 RKW-660 RKW-664 RKW-664
16" (DN 400) 830 RKW-674 RKW-674 RKW-669 RKW-669
18" (DN 450) 815 RKW-661 RKW-661 RKW-665 RKW-665
18" (DN 450) 830 RKW-675 RKW-675 RKW-670 RKW-670
20" (DN 500) 815 RKW-662 RKW-662 RKW-666 RKW-666
20" (DN 500) 830 RKW-676 RKW-676 RKW-671 RKW-671
24" (DN 600) 815 RKW-334 RKW-334 RKW-667 RKW-667
24" (DN 600) 830 RKW-677 RKW-677 RKW-672 RKW-672
OA = ON APPLICATION
15

16
Metso Automation, Field Systems Division
Europe, Levytie 6, P.O.Box 310, 00811 Helsinki, Finland. Tel. int. [phone]. Fax int. [phone]
Europe (UK), 2 Lindenwood, Crockford Lane, Chineham Business Park, Basingstoke, RG24 8QY UK.Tel. int. [phone]. Fax int. [phone]
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www.jamesbury.com
IMO-308EN-10/06 © 2006 Metso Automation Printed in U.S.A.-R-J