Leslie Controls DOT 3-WAY User Manual

12501 Telecom Drive, Tampa Florida 33637

Installation, Operating and

Maintenance Instructions

Supplement

10/8.5.1

Rev. 1

DOT 3-WAY CONTROL VALVE

INSTALLATION...............................................................................................................................4

VALVE POSITION...................................................................................................................................4

PROBLEM PREVENTING PROCEDURES............................................................................................4

OPERATION .......................................................................................................................................4

MAINTENANCE OF VALVE BODY SUB-ASSEMBLIES..................................5

DISMANTLING THE DOT 3-WAY CONTROL VALVE.......................................................................5

CLEANING-REPLACING PARTS ..........................................................................................................5

TABLE OF CONTENTS

ACTUATOR MAINTENANCE REPLACING DIAPHRAGMS, ETC.........5

GENERAL – FOR DIRECT AND REVERSE ACTING ACTUATORS..................................................5

DIRECT ACTING .....................................................................................................................................6

DISMANTLING SIZES 35, 55, 55A, 85
REASSEMBLY

REVERSE ACTING..................................................................................................................................6

DISMANTLING SIZES 35R, 55R, 55AR, 85R (See Figure 5)
REASSEMLBY
PRE-SETTING STEM SEAL – (55R AND 85R)
PRE-SETTING STEM SEAL – (35R)

MOUNTING ACTUATOR TO MAIN BODY..........................................................................................6

TO CHANGE VALVE ACTION FROM NORMALLY OPEN TO NORMALLY CLOSED OR VICE-

VERSA.......................................................................................................................................................8

PROCEDURE

............................................................................................................................................6

............................................................................................................................................6

............................................................................................................................................8

............................................................................................................6

...............................................................................6

.................................................................................................6

...............................................................................................................6

CONTROL VALVE REASSEMBLY AND ADJUSTMENT................................8

REASSEMBLY (SIZES 1” – 2”)...............................................................................................................8

HOW TO MAKE PRELOAD ADJUSTMENT .........................................................................................8

HOW TO ADJUST CONTROL VALVE FOR RATED TRAVEL AND POSITIVE COMPRESSION

FORCE.......................................................................................................................................................8

CONTROL VALVES WITH DIRECT ACTING ACTUATORS.............................................................9

CONTROL VALVE WITH REVERSE ACTING ACTUATORS (AIR PRESSURE MOVES VALVE

PLUG STEM UPWARD.) .........................................................................................................................9

SHORT VALVE TRAVEL........................................................................................................................9

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ILLUSTRATION INDEX

FIGURE 1 – CONVERGING OR MIXING SERVICE.........................................................................................................................................4

FIGURE 2 – DIVERGINGSERVICE....................................................................................................................................................................4

FIGURE 3 – DOUBLE PORTED CONTROL VAVLE........................................................................................................................................5

FIGURE 4 – 55 & 55A ACTUATORS..................................................................................................................................................................7

FIGURE 5 – 55R (AR) & 85R (AR) ACTUATORS.............................................................................................................................................7

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INTRODUCTION

This Installation, Operation, and Maintenance Manual is
intended to be as complete and up to date as possible. It
covers installation, operation, and maintenance procedures
for Leslie Controls, Inc. DOT 3-Way Control Valve. Leslie
reserves right to update this manual and other product
information concerning installation, operation, and/or
maintenance, at any time and without obligation to notify
product owners of such changes.

Leslie is not responsible for injury to personnel or product
damage due to improper installation, operation, and/or
maintenance Leslie Controls, Inc Back Pressure
Regulators. All installation, operation, and maintenance
procedures should only be performed by trained/certified
personnel. All personnel performing these procedures
should completely and carefully read and understand all
supplied materials before attempting procedures. All
personnel should pay strict attention to all Notes, Cautions,
and Warnings that appear within procedures detailed in
this manual.

Leslie welcomes user input as to suggestions for product or
manual improvement.

Contact Information

For information concerning warranties, or for questions
pertaining to installation,
Operation or maintenance of LESLIE products, contact:

LESLIE CONTROLS INC.
12501 Telecom Drive
Tampa, FL 33637

USA Phone: [phone]
USA Fax: [phone]

www.LESLIECONTROLS.com
To order replacement parts, contact LESLIE CONTROLS
at address listed above, or call toll free:

USA/Canada/Caribbean Phone: [phone]

Note: Please include model and serial number of unit for
which parts are being ordered. If ordering by phone, please
have this information readily available.

GENERAL NOTES AND WARNINGS

Notes:

• If questions are not answered by this manual, or if

specific installation, operation, and/or maintenance
procedures are not clearly understood, contact Leslie
Controls, Inc. for clarification before proceeding.

• If unit is damaged during installation, operation, or

maintenance, complete following steps:

1. Turn off and lock out pneumatic supply to unit in
an approved manner.

2. Turn off all incoming valves.

3. Contact in-house maintenance personnel or Leslie
Controls, Inc. for instructions.

Note: Throughout this manual, warnings will be
denoted by BOXES

Piping system must be adequately designed and

supported to prevent extraordinary loads to pressure

It is strongly recommended that this document be reviewed
before attempting any installation, operation, or
maintenance procedures.

CAUTION!

equipment.

3

INSTALLATION

VALVE POSITION

Install control valve in an accessible location. Connect
supply and outlet pipe lines to valve as described below.
Control valve may be placed in any position but upright is
preferable for ease of maintenance. Connect operating
medium tubing from control pilot, instrument or loading
device to diaphragm chamber connection of control valve
or to valve positioner if one is in use.

PROBLEM PREVENTING PROCEDURES

a. Provide removal space above, below and around

control valve for easy removal of parts during
maintenance.

b. Blow or flush out pipe lines thoroughly before

installing control valve.

c. Protect control valve and following equipment with

a Self-Cleaning Strainer.

d. Install stop valves and gauges in inlet and outlet

lines to provide means for checking equipment.

e. Adhere to good piping practice.

OPERATION

See Leslie application guide for other operating
instructions.

a. Close inlet and outlet stop valves.
b. Check that control valve responds properly through

rated travel in relation to changes in operating
pressure on the diaphragm. Rated travel is shown by
position of travel indicator disc on valve stem
relative to travel indicator scale on yoke.

c. Manually operate control valves fitted with manual

operating devices through rated travel to check
freedom of movement.

d. Place control valve in operation in accordance with

instructions furnished with control pilot or other
operating device.

4

MAINTENANCE OF

VALVE BODY SUB-

ASSEMBLIES

1. DISMANTLING THE DOT 3-WAY

CONTROL VALVE

a. Loosen stem nut. Unscrew the valve plug stem

from the actuator stem. (In large valves, support
the valve plug stem to prevent the valve plug
from suddenly falling downward when the stem
clears. Loosen and remove the yoke capscrews.
Lift the actuator from the bonnet.)

b. Lift the valve stem carefully and pull upwards

until the bonnet and cage come out of the main
body. Remove both “O” rings and lift the load
ring out of the main body. Remove main valve
from cage.

c. Loosen the two set screws and remove the bonnet

from the cage.

d. Remove the packing screws from the packing

flange. Remove the packing follower, packing,
packing washer and packing spring.

2. CLEANING-REPLACING PARTS

Clean all parts thoroughly, including the packing box. Use
an approved, non-residue forming solvent. To remove
encrusted materials use crocus or a very mild aluminum
oxide cloth. Examine all parts. Replace any badly worn or
damaged part.

ACTUATOR

MAINTENANCE

REPLACING

DIAPHRAGMS, ETC.

GENERAL – FOR DIRECT AND REVERSE
ACTING ACTUATORS

Remove Compression on actuator spring by screwing
spring adjustor counterclockwise until actuator spring is
free.

NOTE: Count the number of turns to relax spring
compression. Return to the same setting when assembling.

Figure 3 – Double Ported Control Valve (Single Disc Design)

5

1. DIRECT ACTING

DISMANTLING SIZES 35, 55, 55A, 85

Remove bolts/nuts, upper diaphragm case and old
diaphragm.
To examine, clean or replace other internal components lift
out diaphragm plate assembled with actuator stem,
actuator spring, washer and unscrew spring adjustor from
adjustor sleeve.

REASSEMBLY

Replace internal parts. Install new diaphragm. In sizes 35,
55, 55A and 85 line up holes with those in lower
diaphragm case. Replace upper diaphragm case on
diaphragm. Assemble four bolts and nuts through parts
(90º apart). Fingertighten. Assemble balance of bolts/nuts
to actuator. Tighten evenly and alternately across
diaphragm case. (Before tightening bolts in 35 actuators or
where flat stock diaphragm material is used in other sizes
as an emergency measure) consult note relating to
performing actuator diaphragm.

2. REVERSE ACTING

DISMANTLING SIZES 35R, 55R, 55AR, 85R (See
Figure 5)

Remove bolts/nuts and upper diaphragm case. Insert rod
through holes in yoke and actuator stem to prevent twisting
of stem seal when removing self-locking nut. (In size 35R
use wrench on flats on actuator stem) Remove self-locking
nut, stem seal. Remove stem seal as follows: In 35R
remove stud nuts and disassemble lower diaphragm base
from yoke. Lift out stem seal. In 55R and 85R DO NOT
remove lower diaphragm base unless gasket is to be
replaced. Stem seal is held in place by seal ring and
screws. Take out these parts and lift out stem seal.

NOTE: To check actuator spring and other components. In
35R, 55R and 85R parts are taken out from the underside.

REASSEMLBY

Reassemble spring adjustor, washer, actuator spring, and
top spring seat to actuator stem (if they have been
removed.) Replace assembled parts in yoke. Place stem
seal collar on actuator stem. Position stem seal on stem
collar. In sizes 55R and 85R place bead of stem seal in
recess of stem seal collar.
In 35R reassemble lower diaphragm base to yoke. Insert
capscrews through holes in lower diaphragm case and

diaphragm and into threads in yoke. Tighten after resetting
stem seal as described below.
In 55R and 85R actuators replace sealing ring and screws.
Tighten.

PRE-SETTING STEM SEAL – (55R AND 85R)

Place collar on stem seal, making sure that bead on stem
seal enters recess in collar. Reassemble diaphragm over
actuator stem. Fit center hole in diaphragm around raised
face of collar. Replace diaphragm plate and self locking
nut. Hold actuator stem steady with rod through yoke and
stem (35R) then tighten self-locking nut. Replace upper
diaphragm case and bolts/nuts. Tighten as described
previously.

PRE-SETTING STEM SEAL – (35R)

Place collar on stem seal, assemble self-locking nut to
actuator stem and tighten down against parts. Then press
actuator stem downward to make stem seal move to taut
position. Tighten capscrews and remove self-locking nut.

3. MOUNTING ACTUATOR TO MAIN
BODY

Set preload on actuator spring, reassemble actuator to
valve body assembly, if it had been removed, adjust valve
for rated travel and reconnect operating medium tubing.

SOME IMPORTANT NOTES

FLAT SHEET RUBBER MATERIAL

Flat sheet rubber materials may be used in 55(R) and
85(R) actuators as emergency replacement material,
but for guaranteed results it should be replaced at the
earliest opportunity with the Leslie Rolling Action
Diaphragm designed specifically for these actuators.
When flat material is used in emergency perform as
described below.

PERFORMING 35(R) ACTUATOR DIAPHRAGMS

Flat stock material is used for diaphragms in 35(R)
actuators. When assembling first fingertighten all
diaphragm case bolts. Then compress actuator spring
sufficiently to move diaphragm through full travel to
upper or lower diaphragm case depending on whether
actuator is direct or reverse acting. This performs
diaphragm and permits full movement through rated
travel without resistance from a taut diaphragm.

6

Figure 4 - 55 & 55A ACTUATORS

Figure 5 - 55R (AR) & 85R (AR) ACTUATORS

7

4. TO CHANGE VALVE ACTION FROM
NORMALLY OPEN TO NORMALLY
CLOSED OR VICE-VERSA

To reverse the action of a single ported diaphragm control
valve it is only necessary to replace the actuator in use with
one having the opposite action. A single “D” in the control
valve class indicates actuator is “DIRECT ACTING” – Air
moves diaphragm downward. A double D (“DD”) indicates
actuator is “REVERSE ACTING” – Air moves diaphragm
upward.

PROCEDURE

To change actuator, loosen valve plug stem locknut under
travel indicator and turn valve plug stem all the way out of
the actuator stem. Remove capscrews securing actuator to
bonnet. Replace actuator with one having desired action.
Re-insert and tighten actuator spring preload and set valve
for rated travel.

CONTROL VALVE

REASSEMBLY AND

ADJUSTMENT

1. REASSEMBLY (SIZES 1” – 2”)

a. Install the bonnet into the cage and tighten the

two set screws.

b. Insert the main valve up through cage and bonnet.
c. Insert the packing spring and packing washer unto

the bonnet.

d. Install new set of packing in the order in which

they are packed.

e. Install the packing follower, then install the

packing flange.

f. Insert cap screws through the packing flange and

hand tighten.

g. Lubricate “O” Rings and install on bonnet and

cage.

h. Insert the load ring into the bottom of the main

body. Be sure to replace in a concave manner.
(See diagram)

i. Insert main valve, cage and bonnet of the main

body. (Be careful not to damage the “O” rings.)

j. Position actuator on bonnet. Insert the capscrews

through the yoke and intro threads in the bonnet.
Tighten capscrews firmly.

k. Lift the valve plug stem and engage its threads

with those of the actuator stem. Screw into
actuator stem one to two diameters. Then adjust
the control valve for starting pressure preload,
rated travel and positive compression force.

2. HOW TO MAKE PRELOAD
ADJUSTMENT

a. Connect controlled air line to diaphragm case

connection at “A”.

b. Supply 3 psig air pressure to actuator diaphragm.
c. Compress actuator spring until travel indicator

begins to move when air pressure is 3 to 4 psig.

NOTE: The valve travel should be checked under actual
operating conditions for rated travel. If the stem travel is
less than full, some additional spring compression will be
required.

d. To compress spring, screw-adjusting nut upward

on both reverse and direct acting actuators.

3. HOW TO ADJUST CONTROL VALVE
FOR RATED TRAVEL AND POSITIVE
COMPRESSION FORCE

In all cases full valve travel is mechanically predetermined
by the distance between seats valves must be adjusted to
make full contact with seat in either direction.
In direct acting actuators spring force brings vale plug in
contact with upper seat, air force with lower.
In reverse acting actuators air force brings valve plug in
contact with upper seat, spring force with lower.
In reverse acting actuators air force brings valve plug in
contact with upper seat, spring force with lower.

8

4. CONTROL VALVES WITH DIRECT

ACTING ACTUATORS
(AIR PRESSURE MOVES VALVE PLUG
STEM DOWNWARD.)

a. Screw valve plug stem upward into actuator stem

until valve plug contacts upper seat.

b. Connect air line to actuator. Supply sufficient air

pressure to move valve plug slightly away from
seat.

c.

Then turn valve plug stem one full turn further
into actuator stem to make positive compression
contact of valve plug with upper seat at rated
travel.

d. Tighten stem nut and travel indicator against

actuator stem. Tighten package flange bolts.

5. CONTROL VALVE WITH REVERSE

ACTING ACTUATORS (AIR PRESSURE
MOVES VALVE PLUG STEM UPWARD.)

a. Screw valve plug stem upward into actuator stem

approximately one diameter (thickness of stem.)

b. Connect air line to actuator. Supply 20 psig air

pressure to actuator diaphragm to move actuator
through full travel.

c. Turn valve plug stem upward into actuator stem

until valve plug contacts upper seat.

d. Reduce air pressure on diaphragm to permit valve

plug to move slightly off seat.

e. Then turn valve plug stem one full turn further

into actuator stem to make positive compression
contact with upper seat at rated travel.

f. Tighten stem nut and travel indicator against

actuator stem. Tighten packing flange bolts.

6. SHORT VALVE TRAVEL

If valve travel is too short when required maximum air
pressure is supplied to actuator diaphragm, incorrect
adjustment is indicated. To correct, loosen stem nut and
turn valve plug stem out of actuator stem amount
necessary to obtain full travel. Travel indicator on yoke
shows full travel. Recheck positive compression force then
tighten stem nut.

NOTE: In 21/2” and larger bronze valve ONLY, the
bonnet is of a two piece construction. Be sure to replace
the caution plate (1”-2” valves) before mounting the
actuator.

9

It is solely responsibility of system designer and user to select products and materials suitable for their specific

application requirements and to ensure proper installation, operation and maintenance of these products. Assistance

shall be afforded with selection of materials based on technical information supplied to Leslie Controls Inc.; however,

system designer and user retain final responsibility. Designer should consider applicable Codes, material

compatibility, product ratings and application details in selection and application. Improper selection, application or

use of products described herein can cause personal injury or property damage. If designer or user intends to use

product for an application or use other than originally specified, he must reconfirm tat selection is suitable for new

operating conditions. Life expectancy for this product defaults to warranty period of sales contract.

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