Jordan Valve Mark 78 User Manual

I & M Mark 78 Series

3170 Wasson Road • Cincinnati, OH 45209 USA

Phone [phone] • Fax [phone]

[e-mail] • www.jordanvalve.com

Installation & Maintenance Instructions for

Mark 78 Control Valves (1/2” - 1”)

Warning: Jordan Valve Control Valves must only be used, installed and repaired in accordance with these Installa­tion & Maintenance Instructions. Observe all applicable public and company codes and regulations. In the event
of leakage or other malfunction, call a qualified service person; continued operation may cause system failure or a
general hazard. Before servicing any valve, disconnect, shut off, or bypass all pressurized fluid. Before disassembling
a valve, be sure to release all spring tension.

Please read these instructions carefully!

shipment from Jordan Valve.

5. Install the valve in the highest horizontal line of pip­Your Jordan Valve product will provide you with long, trou­ble-free service if it is correctly installed and maintained.
Spending a few minutes now reading these instructions
can save hours of trouble and downtime later. When mak­ing repairs, use only genuine Jordan Valve parts, available
for immediate shipment from the factory.

ing to provide drainage for inlet and outlet piping, to
prevent water hammer and to obtain faster response.

6. The flow arrow on the regulator body must be pointed

in the direction of flow. The valve may be installed ver­tically or horizontally without affecting its operation.

7. For best control, 3’ 0” straight sections of pipe should

be installed on either side of the valve.

Ideal Installation

8. In hot vapor lines, upstream and downstream piping

near the valve should be insulated to minimize con­densation.

Main Line

3

4

1

Condensate Return

Control Valve

4

1

1

5

2

Bypass Line

1

2

1. Shut off Valve

2. Pipe Union

3. Strainer and Drain Valve

4. Pressure Gauge

5. Control Valve

6. Relief Valve

6

R

9. If possible, install a relief valve downstream from the

valve. Set at 15 psi above the control point of the valve.

10. Expand the outlet piping at least one pipe size if the

controlled pressure (downstream) is 25% of the inlet
pressure or less. A standard tapered expander con­nected to the outlet of the valve is recommended.

11. Where surges are severe, a piping accumulator is rec-

ommended.

Start-Up

1. Be sure that the action of the control valve and the

controller are such as to give the desired results. See
“Reversing Action” to change the valve action if nec­essary.

1. To protect the valve from grit, scale, thread chips, and

other foreign matter, all pipe lines and piping compo­nents should be blown out and thoroughly cleaned
before the valve is installed.

2. Shutoff valves, pressure gauges, and bypass piping

should be installed as indicated in the diagram to pro­vide easier adjustment, operation, and testing.

3. In preparing threaded pipe connections, care should

be exercised to prevent pipe sealing compound
from getting into the pipe lines. Pipe sealing com­pound should be used sparingly, leaving the two lead
threads clean.

4. A line strainer should be installed on the inlet side of

the regulator to protect it from grit, scale and other
foreign matter. A 0.033 perforated screen is usually
suitable. Line strainers are available for immediate

If an increase

in pressure or

temperature must:

And the

action of the

valve is:

Then the action

of the controller

must be:

Close Valve Air to Close Direct

Close Valve Air to Open Reverse

Open Valve Air to Close Reverse

Open Valve Air to Open Direct

2. The control valve has been pre-set by Jordan Valve.

However, finer adjustments may be required to com­pensate for pressure drop conditions of the applica­tion.

3. With the inlet, outlet and bypass shutoff valves closed,

and no pressure in the downstream line, fully open the
shutoff valve. Slowly open the inlet valve just enough

to start flow through the control valve. Increase flow
gradually by slowly opening the inlet shutoff valve. Do
not fully open the inlet valve until you are sure that
the controller and control valve have control of the
system. Usually, the handwheel on the inlet valve will
turn freely when this point is reached.

4. To shut off the line fluid, close the inlet shut-off valve

first, then the outlet shut-off valves.

Maintenance

To reduce maintenance time, refer to proper figure
and follow steps indicated below for applicable main­tenance operation.

Proposed Maintenance

Procedure

Renewing stem packing Packing Replacement

Valve disassembly, inspecting

parts, replacing plug or seat ring

Valve Reassembly Valve Reassembly

Actuator spring preload

adjustment

Actuator maintenance Actuator Maintenance

Changing valve action Reversing Action

Routine maintenance should be expected due to nor­mal wear and tear, damage from external sources or de­bris. The regulator components, especially the moving
and sealing parts, should be inspected periodically and
replaced as necessary. Frequency of inspection/replace­ment depends upon severity of conditions, but may also
be required by local/state/federal law or industry stan­dards.

Follow Steps...

Valve Disassembly

Actuator Spring

Preload Adjustment

Packing Replacement

Renew valve plug stem packing if control valve has been
in service beyond normal maintenance, and packing
shows signs of wear. Wear will be indicated by leakage
which cannot be corrected by minor tightening of pack­ing flange.

An additional packing ring can be installed to overcome
minor leakage without dismantling the control valve or
breaking valve plug connection.

1. Disassemble control valve as far as necessary for the

work required (see “Valve Disassembly”). Remove
packing. Clean valve plug stem (9) and packing box
thoroughly. Polish valve plug stem (9) with crocus
cloth. Use approved non-residue-forming solvent for
cleaning. Wipe dry with clean cloth.

2. Insert a new set of packing (13) in packing box. Press

each ring down in place with a tube as it is installed.

3. After packing is installed, assemble packing follower
(11), packing nut (15) to bonnet (4).

Valve Disassembly

1. Close inlet and outlet stop valves. Operate system by­pass if necessary.

2. Following instructions according to valve action:

3a. Direct Acting Actuator (ATC): shut off operating me-

dium and relieve pressure from diaphragm by discon­necting tubing at diaphragm case. To remove the ac­tuator from the valve body assembly: loosen the two
stem nuts (28) and move down the stem (9). Lock the
nuts together and, using a wrench on these nuts and
the flats on the stem connector (34), turn the valve
stem out of the stem connector threads until it dis­engages. Loosen and remove the four yoke bolts (6)
and lift the actuator assembly from the bonnet (4).

3b. Reverse Acting Actuator (ATO): apply air pressure to

actuator to lift plug off of seat. To remove the actuator
from the valve body assembly: loosen and remove
the four yoke bolts (6) and lockwashers (8). Loosen
the two stem nuts (28) and move down the stem (9).
Lock the nuts together and, using a wrench on these
nuts and the flats on the stem connector (34), turn
the valve stem out of the actuator stem threads until it
disengages. Lift the actuator assembly from the bon­net (4).

4. Loosen packing nut (15).

5. Remove bonnet (4), o-ring (29), compressor (5) and
cage (2) from the body (1).

6. Remove support washer (42) [on soft seated valves
in 1/2” – 3/4” sizes only], seal (41) [soft seated valves
only], seat (3), and seat o-ring (30) from the body.

7. Remove the two stem nuts (28) from the stem (9).

8. Remove plug/stem (9) from the bonnet (4).

9. Remove packing nut (15), packing follower (11) and
packing (13).

10. Cleaning: clean all parts with an approved, non-res­idue-forming solvent. Remove encrusted materials
with crocus or very mild aluminum oxide cloth. Clean
packing box thoroughly.

11. Inspect all parts including plug, seal and seat. Re­place any badly worn or damaged parts.

12. Replacing Seats (Hard Seated Valves Only): if seat is
badly worn or damaged, it should be replaced. Very
minor cuts on the seating surface, however, may be
lapped out. NEVER lap to the extent that the valve
plug becomes grooved.

13. Lapping in Valve Plug & Seat Ring: replace valve plug
(9) in bonnet (4). Apply superfine lapping compound
to valve plug seating surface at several points. Re­place seat o-ring (30) and seat (3) in body (1). Re­assemble bonnet (4) to body (1). Use stem to align
seat to plug in the body. Lap valve plug and seat ring
in until a fine continuous ring of contact has been
made on both surfaces. DO NOT lap until a ridge is
formed in valve plug seating face. A few turns are suf-

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ficient. When lapping, turn valve plug in short arcs
and occasionally lift valve plug off seat ring and turn
in 1/4 turn to maintain even distribution of lapping
compound. When lapping is completed, disassemble
bonnet from body and remove all traces of lapping
compound.

Valve Reassembly

1. Place seat o-ring (30) on seat (3) [use small amount
of grease to hold these parts together] and place in
valve body (1). Place seal (41)(soft seated valves) and
support washer (42)(1/2” & 3/8” only) into groove in
seat (3). Place cage (2) and compressor (5) into body.

2. Assemble stem/plug (9) to bonnet (4).

3. Reassemble the o-ring (29) and bonnet (4) to the
valve body (1) making sure that seat o-ring (30), com­pressor (5), cage (2), seat (3), seal (41), and support
washer (42) are properly in place.

4. Install a new set of packing (13) as described in “Pack­ing Replacement”.

5. Reassemble two stem nuts (28) and indicator washer
(12) to valve stem (9).

6. Insert threaded end of bonnet (4) through hole in
yoke (33) and secure actuator to the body with four
bolts (6) and lockwashers (8). Tighten to 10 ft/lbs.

7. Lift the valve stem (9) and thread it into the stem
connector (34) at least one diameter. Adjust actuator
spring preload as described in the following section.

Actuator Spring Preload Adjustment

(Starting Pressure)

Caution: Do not apply more than 45 psig to actuator.

 Direct Acting Actuator (ATC): Actuator spring pre-

load adjustment can be made either with or without
pressure in valve body. Once correct compression is
made, no further adjustment is necessary.

 Reverse Acting Actuator (ATO): Note: ATO 3-15

psig rated valves are bench set at the factory at 5-17
psig. Please insure that any I/P utilized with this con­trol valve is capable of 17 psig output to ensure full
valve travel. If desired, the range may be changed to
suit your needs by following the instructions below.
The valve plug is closed against upward fluid thrust
by actuator spring force. Total compression placed on
actuator spring must be sufficient to provide the re­load plug force required to close the valve. If preload
adjustment is made with no pressure in valve body,
then, when the control valve is placed in operation,
body, then, when the control valve is placed in opera­tion, additional compression must be placed on the
spring to provide valve closure force. With proper ad­justment, valve will close tightly and will not begin to
open until the preload pressure is exceeded.

Adjusting Spring Preload:

1. Loosen two stem nuts (28), move down the stem (9)
and lock two stem nuts together.

2. Connect control air supply line with a pressure gauge
to the diaphragm case (16 for ATO or 26 for ATC).

3. Direct Acting Actuator (ATC 3-15 Range):
Note: If range is other than 3-15, adjust preload to low
end of range.

Adjust spring preload until valve starts to close
when 3 psig air pressure is supplied to the actuator
diaphragm. If there is valve movement at less than
3 psig: thread the valve stem (9) into the stem con­nector (34), wrenching on locked stem nuts (28) on
stem connector (34) to increase the spring preload.
If there is no movement at 3 psig: thread the valve
stem (9) out of the stem connector (34) to decrease
the spring preload.

4. Reverse Acting Actuator (ATO 3-15 Range): Jordan
control valves rated 3-15 (ATO) are bench set at the
factory at 5-17 psig. Please insure that any I/P utilized
with this control valve is capable of 17 psig output to
ensure full valve travel. If desired, the range may be
changed to suit your needs by following the instruc­tions. In general, adjust 3-15 range to 5 psig; all other
ranges are adjusted to the low end of the range.

Adjust spring preload until valve just starts to open
when 5 psig air pressure is supplied to the actuator
diaphragm. If there is valve movement at less than 5
psig: thread the valve stem (9) out of the stem con­nector (34), wrenching on locked stem nuts (28) and
flats on stem connector (34) to increase the spring
preload. If there is no valve movement at 5 psig:
thread the valve stem (9) into the stem connector
(34), wrenching on locked stem nuts (28) and flats on
stem connector (34) to decrease the spring preload.

Note: alternately adjust preload and check pressure
to start valve movement by raising pressure to 5 psig
(or pressure required to start movement) until proper
adjustment is attained.

5. After proper spring preload has been attained, loosen
two stem nuts (28), thread them along with the indi­cator washer (12) up the stem (9) and lock against the
end of the stem connector (34). If necessary, adjust
the position of the travel indicator (35) by loosening
screw(s) (37) and moving the travel indicator until it is
properly aligned with the indicator washer (12).

Note A: a control valve which has been adjusted to
provide 3 psig starting pressure plus valve closure
force (with pressure in body) will have a considerably
higher start-pressure than 3 psig, when tested at 0
body pressure.

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