Badger Meter 9000 Valve User Manual

Model 9000

Series 9000 Control Valves

(for valves with model

9050 reversible actuator)

Instruction

Manual

GENERAL

This manual provides installation, operation and mainte­nance instructions for the Model 9000 control valve. To
insure operator safety and optimum performance, these
instructions should be read, understood and followed. The
Model 9000 technical brochure or appropriate engineering
drawings, should be used in conduction with this manual.

UNPACKING

To minimize damage during transit, most Badger® products
are shipped in heavy double wall boxes and packed in high
density Insta-Pak foam.
> If the container is damaged, the carrier should be
notified immediately and appropriate claims filed by your
company.
> Inspect each item for possible damage and verify item
quantity with the packing list.
> Leave all products in their protective packaging until
ready for installation.
> Leave flange surface protectors in place until ready for
installation.

INSTALLATION

> Clear pipeline of debris before installing the valve.
> Remove protective plugs or coverings from the body and
instrument air connections. Note: Leave the black “vent
plug” in place [in spring case opposite the air connection].

!

CAUTION

Do Not use the “cork” flange face protector as a gasket.
Use only gaskets approved by your company.
> The standard “flangeless/NPT” body can be piped with
NPT fittings or clamped between companion flanges.
Note: The 2" size valve cannot be clamped between Class
300 flanges due to the flange having eight [8] bolts.
> When installing with NPT fittings, use a thread sealant to
preclude galling and decrease leakage.
> Be sure to install the valve [with] the flow direction arrow
on the body unless instructed by the factory to do other­wise.
> If clamping between flanges, make sure the I.D. of the
gasket does not restrict the inlet or outlet openings of the
valve.
> Flange bolts or studs, should be applied in accordance
with ASME or your company standards.

> If vibration or shock is anticipated, a support bracket
should be attached to the actuator rim screws and attached
to a strong support structure. [Brackets are available from
the factory]

AIR CONNECTION

> The air signal to the diaphragm should not exceed the
pressure range stamped on the nameplate.
If used in conjunction with a positioner, the positioner supply
pressure should be set at no more than 60 psig, although the
diaphragm is capable of withstanding 90 psig.
> All instrument and supply air should be: clean, dry and
free of oil and debris. Any deviation can cause malfunction
or shorten the life of the valve.
> The standard air connection is 1/4" NPT.
Note: If the unit has been special ordered with a BSP Gl/4
fitting, it will be marked accordingly.
> Although conditions can vary, normally 1/4" O.D. tubing is
appropriate for air signal lines of 30' or less. If the distance
is longer, or if response is slow, larger air lines may be
required.

UNITS WITH POSITIONERS

> Connect instrument signal and supply air line to the
positoner input and supply port using a small amount of
paste type thread sealant. Do Not use TFE tape.
NOTE: Normally 25-35 psi supply air pressure is appropri­ate. If the valve does not achieve the required travel, the
supply pressure can be raised until the travel is achieved.

TESTING

> The test tag [attached to the yoke] indicates the types of
tests that were performed on the valve by the factory.
> Should the packing require adjustment, do so by turning
the gland in a clockwise direction, until the leakage stops.
DO NOT overtighten the packing as it can unnecessarily
increase stem drag and reduce performance.
> DO NOT re-orient the actuator without raising the
innervalve off the seat. Rotation of the innervalve while
under spring or air tension, will damage the seating surface.

NOTE: Although the valve will operate in any orientation,
vertical is normally recommended.
NOTE: If the valve is used in a particularly hot or cold
service, do not insulate the bonnet area. The length of
bonnet material provides protection from hot and cold, for
the stem packing.

BadgerMeter, Inc.

®

941152

12-05

ADJUSTMENTS

[Stem Packing]
> Standard stem packing is PTFE chevron rings, which are
designed to energize under pressure.
If adjustments are necessary, tighten the gland 1/8th turn
and check for leaks. Repeat if necessary.
> If equipped with graphite packing, the gland should be
tightened only enough to stop the leak. Overtightening can
cause excess stem drag. Note: Graphite packing normally
requires a “break-in” period.

[Body-Bonnet Gasket]
> The bonnet flange bolts should not need re-tightening.
However, if leakage does occur, tighten [in a criss-cross
pattern] to the following values:
1” Valve: (5/16” bolt thread] = 17-20 ft-lbs

1.5" Valve: (3/8" bolt thread] = 30-35 ft-lbs
2" Valve: [7/16" bolt thread] = 50-55 ft-lbs.

[Bench Setting] [ATO-Without Positioner]
> Best done on a workbench with an air station and
guages. If attempting to adjust spring loading while the
valve is in line, it is recommended to shut off the upstream
pressure to the valve while making adjustments.
> The point at which the instrument signal lifts the
innervalve off the seat is pre-adjusted at the factory. If the
incoming pressure is higher than the unit is adjusted to
handle, additional spring loading can be attained by
adjusting the stem length with the stem connector.
> To increase spring tension [bench setting], stroke the
valve off the seat, using a manually operated air signal, to
the desired bench setting. (Positioners must be by-passed.)

NOTE: The 3-15psi [3 spring] version, can be adjusted to
8-20 psi. The 6-30psi [6 spring] version, can be adjusted to
16-40psi.
> Loosen the jam nut on the stem connector [against the
bottom of the actuator stem].
> Turn the stem connector [unscrewing it out of the
actuator stem] until the innervalve touches the seat.
DO NOT attempt to increase spring tension only by turning
the innervalve. Turning the innervalve while seated will
damage the innervalve, causing galling and/or seat
leakage.
> Re-Tighten the jam nut and reduce the air signal
pressure to see if the valve now shuts off. If the anticipated
[psi air] increase is not enough, repeat the above until the
proper setting is achieved.
> Once the proper setting is achieved, the valve can be
put back into service.

ZERO ADJUSTMENT [Positioner]
Details of the positioner are not included in this manual.
However, zero adjustment is a simple matter.
Most positioners have the zero adjustment clearly marked
or indicated in the manual accompanying the positioner. >
Simply set the instrument signal to the positioner at
aproximately 3.1 psi [if 3-15psi signal].
> Adjust the zero adjusting mechanism until the valve
touches the seat [going closed].
> Check the zero point by raising and lowering the air
signal to verify the setting.

DISASSEMBLY [Valve body assembly from actuator]
Although adjustments or some repairs can be performed
with the valve in line, they are best done in a properly
equipped workshop.

!

CAUTION

DO NOT attempt any repairs or disassembly, other than
packing adjustment, while the valve is under pressure.

> If the unit is Air to open, using a manual air station, raise
the innervalve to a position between 3/4 and full open.
> While holding the stem connector with a wrench, loosen
the innervalve stem jam nut and unscrew the innervalve
completely, from the stem connector.
> Using a wrench or a hammer and punch, loosen and
unscrew the yoke lock nut.
> Lift the actuator off the bonnet.
> If the actuator is not to be disassembled, you may want
to leave the air line connected and air on the diaphragm so
that it will not be forgotten during re-assembly.

DISASSEMBLY [Body/Bonnet assembly]
> Remove the innervalve jam nut
> Remove the bonnet flange screws [or studs]
NOTE: Keep these 4 screws apart from other hex screws,
as they are high strength screws and other types of screws
should not be substituted.
> Remove the bonnet from the body by slowly twisting and
pulling, by hand, until it pulls free. DO NOT pry the bonnet
out.
> Extract the seat (if so equipped] from inside the body.
> Loosen the packing gland 2-3 turns.
> Pull the innervalve out the bottom of the bonnet.
> Remove the packing gland.
> Insert a wood, plastic or soft metal [copper or brass] rod
[aprx. 0.4-0.5"ø into the bottom of the bonnet and push the
packing cavity components out the top of the bonnet.
> Carefully remove the graphite body-bonnet gasket from
both the body and bonnet. Clean both surfaces of graphite.
> Clean out the body with an appropriate solvent or soap
and water. Use a brush as necessary.

REASSEMBLY [Body/Bonnet assembly]
[Described as if installing a new innervalve, packing kit and
gasket]
> Carefully thread the new seat into the body [if so
equipped]
> Tighten the seat (with appropriate socket] to the torque
levels below:
1" Valve = 35-40 ft-lbs

1.5" Valve = 40-50 ft-lbs
2" Valve = 45-55 ft-lbs
> Lubricate innervalve stem and guide with Silicone
grease, Krytox® or other suitable lubricant. Do Not use
lubricants that contain metal particles.
> [Holding the bonnet upright] in the packing cavity end of
the bonnet, place [over the stem].

1. the SST metal ring [packing floor adapter), making sure
it reaches the bottom of the cavity.

2. the lower TFE packing adapter [flat side down]

3. 3 rings of chevron packing.

4. the upper TFE packing follower [flat side up].

5. the packing gland [tighten only hand tight for now].

Page 2

REASSEMBLY [continued]
> Install [into body] a new graphite gasket.
> Hold the bonnet in one hand and push the innervalve
into the bonnet until it stops.
> Insert the bonnet into the body until it seats firmly onto
the gasket.
> Place the bonnet flange over the bonnet.
NOTE: The 1" bonnet flange should have the screw head
recesses facing up. The 1.5” and 2" flanges are reversible.
> Install 4 flange screws [or studs] only hand tight
> Using a criss-cross pattern, tighten the four screws,
starting at 5 ft/lbs and progressing [in 5 or 10 ft/lb incre­ments) up to the following torque values:
1" Valves = 17-20 ft/lbs

1.5" Valves = 30-35 ft/lbs
2" Valves = 50-55 ft/lbs

> While holding the innervalve plug by hand, tighten the
1/4-28 jam nut onto the innervalve stem with a wrench.
Note: Later, you will use this nut to thread the innervalve
stem into the actuator stem.
DO NOT clamp innervalve in a vise or hold with pliers.
> By hand, move the innervalve up and down to check for
binding.
> Tighten the packing gland by hand, until you feel the
stem/packing friction as you stroke the innervalve by hand.

REINSTALLING ACTUATOR TO BODY ASSEMBLY

> Making sure the actuator stem is at the full travel
position, set the actuator onto the bonnet.
> Install and tighten the yoke lock nut.
> Pull the innervalve stem up to meet the actuator stem
and thread it into the stem until the jam nut contacts the
actuator stem. Use the innervalve jam nut as a wrenching
point.
> Lower the signal pressure until it reads 3.1 psi, [if a 3-15
signal is desired] or whatever calculated “bench setting” is
desired.
> Carefully unscrew the innervalve stem out of the actuator
stem until the innervalve contacts the seat.
> Tighten the innervalve jam nut against the actuator stem.
NOTE: Use a back-up wrench on the flats of the actuator
stem when tightening the innervalve jam nut, to preclude
rotation of the actuator stem.

DISASSEMBLY-ACTUATOR (Mod 9050]
[Air to Open configuration]
Note: To reverse the actuator from Air to open to Air to
close or vice-versa, see “REVERSING ACTUATOR
ACTION” later in this manual.

> With the actuator off the valve, remove the air signal line.
> Remove the 12 actuator rim screws/nuts.
> Separate the pressure cases and set the upper case
aside. [May require a screw driver to separate the cases,
as they may be stuck together.]
> Remove the springs from the piston.
> While holding the stem with a wrench on the flats of the
bottom end of the stem, remove the center [high strength]
hex screw from the upper side of the assembly (afixing the
diaphragm/piston to the stem].
> Remove the hardened thrust washer [under screw head]
> Remove the piston
> Remove the diaphragm and bottom retainer plate
> Push the stem out the bottom of the yoke.

> If replacing the stem seal, stem bushing guides or “O” ring.
> Remove 6 [six] ea [7/16" hex] screws, afixing the
bottom case to the yoke.
> Remove the bottom case from the yoke, noting the
orientation of the case on the yoke. Make a mark on each
so they can be oriented properly later.
> Remove the large composite gasket [between case and
yoke].
> Clean case and yoke surfaces of gasket material [if
damaged]. If not, leave alone.
> If gasket is not damaged, set aside to re-use.
> Remove black Nylatron

®

upper stem bushing.
> Remove “O” ring from under upper bushing.
> Remove lower bushing [if necessary or worn]. This
bushing does not necessarily need to be replaced as it
gets little wear. If it does need to be removed and
replaced, use a metal rod [aprx. 0.650-670"] Ø to press
the bushing out from the opposite side of the cavity.

REASSEMBLY

> Replace the lower stem bushing [only if necessary]
> Lubricate with Krytox® grease and install new “O” ring
into yoke cavity [atop lower stem bushing]
> Install new or old upper stem bushing [small turned end
facing up]
> Install gasket and align 6 holes with 6 holes in yoke
> Place lower pressure case onto yoke gasket
> Hand-Tight, install 6 grade 5 hex screws
> Push actuator stem up through the bushings from the
opposite side of the yoke and hold in place.
> Tighten 6 screws to 10 ft-lbs.
> Place the diaphragm retainer plate onto the stem.
> Then place the diaphragm onto the retainer plate [fabric
side up].
> Place the piston into the premolded portion of the
diaphragm.
> Install thrust washer and high strength hex screw
through the piston, diaphragm and retainer plate and into
the stem.
> While holding the stem with a 1/2" wrench, tighten the
high strength hex screw to 28-30 ft-lbs.
> Align the holes in the diaphragm with the holes in the
lower pressure case.
> Place the springs back into their pockets.
> Rest the upper case onto the springs and diaphragm.
> Re-install the 12 rim screw/nuts/washers and tighten
progressively to 6-8 ft-lbs or until the diaphragm just
starts to extrude from between the cases.

DISASSEMBLY AND REASSEMBLY [Air to close
version]
The procedures for disassembling the air to close version
are similar to the air to open version. However, the piston,
diaphragm, retainer plate and springs are turned upside
down. NOTE: As shown in the drawing, the thrust washer
that fits under the head of the high strength hex screw on
the Air to open version, fits between the actuator stem
and the piston, on the Air to close version.

NOTES:
If lapping of the innervalve is required, use 1000 grit
compound and lap for no more than 2 minutes before
cleaning both the plug and seat and checking for leakage.
Consult the factory for assistance if unsure how to
proceed.

Page 3

REVERSING ACTUATOR ACTION

Changing from Air to open to Air to close can be
accomplished without additional parts and with standard
tools.

> Start by removing the actuator from the valve according
to previous instructions.
> Remove the rim screws.
> Separate the pressure cases.
> Lift out the springs.
> Remove the Nylon inserted lock nut [up travel stop inside
the yoke] from the stem.
> Grasp the piston and remove the entire stem/diaphragm/
piston assembly from the yoke.
> Using a 1/2" open end wrench, hold the actuator stem [in
the yoke area] and loosen the high strength hex screw in
the center of the piston.
> Loosen and remove the screw. Note the hardened thrust
washer under the head of the screw.
> Grasp the Piston, Diaphragm and Retainer plate and lift
all three parts off the stem and turn them over.
> Place the high strength hex screw [WITHOUT THRUST
WASHER] through the retainer plate, diaphragm, piston
and thrust washer.
> Thread the hex screw into the end of the actuator stem
and tighten by hand.
> Holding the opposite end of the stem with a wrench,
torque the high strength hex screw to 28-30 ft-lbs.
> Set the yoke [with lower pressure case still attached]
upright on the workbench.
> Set the springs inside the pressure case
> Carefully slide the threaded [end that connects to the
innervalve] actuator stem down through the center stem
bushing. Make sure each spring enters its own pocket and
that they are evenly spaced in each pocket [if only 3
springs are used].
> Place the upper case onto the lower case, keeping the
rim screw holes aligned with the holes in the diaphragm
and lower case.
> Re-install the 12 rim screw/nuts/washers and tighten
progressively to 6-8 ft-lbs or until the diaphragm just starts
to extrude from between the cases.
> Replace the up travel stop nut [thin nylon inserted lock
nut] into the actuator stem.
> Move the black plastic vent plug from the upper housing
to the lower housing.

> Once mounted, connect air to the upper case and make
zero adjustments.
The stem length should be adjusted so that at aprx. 14.75
psi, the innervalve touches the seat.
> Reduce the signal to 3 psi
> Adjust the up travel stop nut where it just touches the
underside of the yoke, providing an up travel limit.

DO’S and DON’TS

• With air to open actuators, DO NOT attempt to adjust
spring tension without first raising the innervalve off the
seat.
ANY rotation of the innervalve while seated will damage the
seating surface.

• DO NOT use TFE tape on positioner supply air lines. Small
pieces of the tape can plug the positioner pilot and cause
malfunctions or improper response.

• To re-orient the actuator [to make piping the air line more
suitable].
> Raise the innervalve off the seat [if Air to open].
> Loosen the yoke lock nut.
> Orient the actuator as desired.
> Re-tighten the yoke lock nut.
> Lower the innervalve to the seated position.

Proceed with re-mounting the actuator to the valve
assembly.
NOTE: Since the springs are keeping the stem at full
travel, air does not need to be applied to the actuator at
this time.

Please see our website at

www.badgermeter.com

for specific contacts.

Copyright © Badger Meter, Inc. 2005. All rights reserved,

Badger® is a registered trademark of Badger Meter, Inc.
Krytox® is a registered trademark of E.I. du Pont de Nemours and Company.
Nylatron® is a registered trademark of The Polymer Corporation.

Due to continuous research, product improvements and enhancements,
Badger Meter reserves the right to change product or system specifica­tions without notice, except to the extent an outstanding contractual
obligation exists.

BadgerMeter, Inc.

6116 E. 15th Street, Tulsa, Oklahoma 74112
[phone] / Fax: [phone]

®

www.badgermeter.com