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I & M 8000 Series
3170 Wasson Road • Cincinnati, OH 45209 USA
Phone 513-533-5600 • Fax 513-871-0105
lowfl[email protected] • www.lowflowvalve.com
Installation & Maintenance Instructions for
8000 Series Low Flow Control Valves
Warning: Low Flow Regulators 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!
Your LowFlow/Jordan 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 LowFlow Valve
parts, available for immediate shipment from the factory.
5. For best control, 3'-0" straight sections of pipe should
be installed on either side of the valve.
6. In preparing threaded pipe connections, care
should be exercised to prevent pipe-sealing compound from getting into pipelines. Pipe sealing compound should be used sparingly, leaving the two
end threads clean. Jordan Valve uses, and recommends, thread sealer Teflon ribbon.
7. The flow arrow on the valve body must be pointed
Ideal Installation Schematic
Main Line
in the direction of the flow. Ideally the valve should
be installed in the highest horizontal line of piping to
provide drainage for inlet and outlet piping, to prevent water hammer, and to obtain faster response.
3
4
1
Condensate Return
1
1
Steam
Trap
5
2
Bypass Line
1. Shut-off valve
2. Pipe union
3. Strainer/drainer valve
4. Pressure gauge
5. Jordan Series 708 DCV
6. Relief valve
1
1
4
6
R
8. If possible, install a relief valve downstream from the
valve. Set at 15 psi above the control point of the
valve.
9. In hot vapor lines, upstream and downstream piping near the valve should be insulated to minimize
condensation.
10. Evaluate inlet and outlet pipe friction losses and velocities to decide when smaller outlet piping might
cause excessive back pressure. When required, a
standard tapered expander connected to the outlet
of the valve is recommended.
11. When surges are severe, a pipe accumulator is rec-
Preferred Installation
ommended.
12. On steam control applications, install a steam trap
1. To control very low flow rates, Mark 8000 control
valves are often provided with trims having very
small clearances. To keep this trim functioning properly, it is essential that the fluid flowing through the
with sufficient capacity to drain the coil or condenser. Be sure to have a good fall to the trap, and no
backpressure. Best control is maintained if the coil
or condenser is kept dry.
valve be clean.
2. To protect the valve from grit, scale, thread chips
and other foreign matter, ALL pipelines and piping
components should be blown out and thoroughly
cleaned before the installation process begins.
3. Shutoff valves, pressure gauges, and by-pass piping should be installed as indicated in the Ideal In-
stallation Schematic to provide easier adjustment,
operation and testing.
4. A line strainer should be installed on the inlet side
of the valve to protect it from grit, scale, and other
foreign matter. A 0.033 perforated screen is usually
suitable for this purpose. Line strainers are available
from Jordan Valve.
If You Experience Erratic Control:
• Oversizing can cause cycling or hunting, recalculate the size required
• Undersizing can cause the control point to drop off
under peak loads, increase the trim size
• Inlet pressure to the valve may be varying significantly and the controller may not be following it, adjust controller
• Control loop may require an equal percentage trim if
higher rangeabilities are being utilized
• Controller may not be properly adjusted
• Steam traps may need reconditioning
Trouble Shooting
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• Safety relief valves may be leaking
• Valve stroke may be out of adjustment or there may
be foreign matter in the valve preventing full plug
movement
• Slowly open the inlet shutoff valve.
• Slowly open and close the outlet shutoff valve several times. This fully strokes the valve to insure satisfactory operation.
If You Experience Insufficient Flow:
• Check shutoff valves to be sure they are fully open
• Inlet pressure to the valve may be insufficient to provide the needed flow - check the inlet pressure with
a pressure gauge
• Strainers should be checked for clogging - blowdown if needed
• Steam traps may need reconditioning
• Dirt in the trim may prevent the valve from passing
its full capacity
• Diaphragm failure in reverse acting (air-to-open)
actuators would prevent the valve from properly
stroking open
• Insufficient air pressure to reverse acting (air-toopen) actuators would prevent the valve from properly stroking open.
If You Experience Overpressure (Outlet):
• Dirt in the trim may be preventing the valve from
shutting off
• Diaphragm failure in direct acting (air-to-close) actuators would prevent the valve from properly stroking closed
• Insufficient air pressure to direct acting (air-to-close)
actuators would prevent the valve from properly
stroking closed
• Incorrect actuator spring adjustment in direct acting
(air-to-close) actuators would prevent the valve from
properly stroking closed.
If You Experience Leakage:
• Excessive pressure drop across the valve could
prevent the valve from shutting off properly. Check
the catalog ratings for the maximum allowable pressure drop for your trim, action and actuator.
Start-Up Procedure
1. Be sure that the action of the control valve and of
the controller are such as to give the desired results.
See part D to change the valve action if necessary.
Controller Action
If an increase in
pressure or
temperature must
close valve
close valve
open valve
open valve
And the action
of the valve is
air to close
air to open
air to close
air to open
And the action
of the controller
must be
direct
reverse
reverse
direct
2. The control valve has been pre-set by Low Flow
Valve. However, finer adjustments may be required
to compensate for pressure drop conditions of the
application.
3. With the inlet, outlet, and by-pass 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 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 shutoff valve
first, followed by the outlet shutoff valve.
Maintenance
Warning: Be sure that there is no pressure in the valve
before loosening any ttings or joints. The following
steps are recommended:
1. Close inlet shutoff valve and by-pass valve.
2. Allow pressure to bleed off downstream.
3. When inlet pressure gauge shows that there is no
pressure in the valve, close the outlet shutoff valve.
TO REDUCE MAINTENANCE TIME, REFER TO PROPER
FIGURE AND FOLLOW STEPS INDICATED BELOW FOR
APPLICABLE MAINTENANCE OPERATION.
Proposed Maintenance Follow Steps
Renewing Valve Stem Packing Section 1
Valve Disassembly - Inspect Parts -
Replace Valve Plug or Seat Ring
Valve Reassembly Section 3
Actuator Spring Preload Adjustment Section 4
Actuator Maintenance Section 5
Changing Valve Action Reversing Action
Section 1: Packing Replacement
Renew the stem packing whenever there is leakage that
cannot be stopped by a light adjustment to the packing
flange. Additional rings can be added to the packing set
to overcome minor packing leakage and provide for additional adjustment space. This can be done without dismantling the valve.
1. Remove the actuator from the bonnet. (See VALVE
DISASSEMBLY, SECTION 2).
2. Completely remove all of the old packing (6) and
discard. Clean the valve stem (33) and packing
box thoroughly. If necessary, the valve stem may be
dressed with a very fine Crocus cloth, but generally
it is best not to as the stem has a fine machined finish. Use an approved non-residue forming solvent
for cleaning. Wipe dry with a clean cloth.
3. Insert a new packing set in the packing box. Press
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Section 2
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each ring down firmly into place with a tube.
4. After the packing is installed, assemble the packing
adapter (7), and packing nut (11). Tighten the nuts
hand-tight.
5. The final packing adjustment should be made with
the valve pressurized and the packing tightened
just enough to stop any leakage, while stroking the
valve. Excessive tightening could cause the stem to
stick and result in improper valve operation due to
high friction forces.
Section 2: Actuator to Valve Disassembly
Direct Acting Actuator: ATC (Air-to-Close)
1. Shut off pressure to actuator, and remove the supply
tubing from the actuator case.
Reverse Action Actuator: ATO (Air-to-Open)
1. Apply approximately 6 psig air pressure to the actuator to lift the plug off the seat.
2. Remove the actuator from the valve as follows: loosen the two stem nuts (36) and move them down the
stem (33). Lock these nuts together. Remove the two
nuts (31) that secure the support legs (16B) to the
actuator mounting flange (9). Using a wrench on the
nuts and on the flats of the stem adapter (46), turn
the valve stem (while holding the stem adapter in
place) until the stem disengages. The actuator will
now be free from the valve. Caution: Do not lose
the spacers (38) – they will disconnect from the
support legs when the actuator is removed from
the mounting ange.
BODY & BONNET DISASSEMBLY
1. Remove packing nut (11) and bonnet nut (8).
2. Remove stem nuts (36) from stem (33) and pull up on
stem before unthreading bonnet (2) from body (4).
3. Remove the stem (33) from the bonnet (2).
4. With a socket wrench, remove the seat (35) from the
body.
5. Soft seats are disassembled by removing the soft
seat assembly (48) from the body.
6. Clean all parts with an approved, non-residue forming solvent. Remove encrusted material with a very
fine Crocus or aluminum oxide cloth. However, do
not use these abrasives on the seating surface or
the trim surface (that portion of the plug that enters
the seat bore). The machining tolerances on these
surfaces are so closely controlled that you might
change the valve's flow characteristics.
7. Inspect all parts and replace any badly worn or
damaged parts.
Do not attempt to resurface seating surfaces of the
plug or seat. Seat and plugs are only sold in factory
matched sets. It is always advisable to replace seals and
gaskets.
Section 3: Valve Reassembly: Body
1. Lubricate the hard seat (35) or soft seat (48) threads
with a suitable lubricant such as NO-LOK and thread
the seat into the body (4). Torque to 20 ft-lbs (240 inlbs).
2. Guided Trim: coat the guided portion of the plug
(34) with Molykote G-Rapid Spray lubricant or an
equivalent light lubricant suitable for your service.
Assemble the plug to the stem.
3. Insert the stem (33) and plug (34) into the bonnet (2)
and install the packing as described in Section 1.
4. Plastic Valves Only: place the o-ring (49) around the
base of the bonnet.
5. Pull the stem up in the bonnet before threading the
bonnet (2) into the body (4).
6. Push down on the stem to allow the plug (34) to center itself in the seat (35).
7. Reassemble the two set nuts (36) onto the stem (33)
threads and lock the two nuts together.
8. If the actuator is reverse acting (ATO), apply approximately 6 psig air pressure to the actuator.
9. Install the spacers (38) onto the support legs (16B)
and insert the support legs into the actuator mounting flange (9). Thread the stem (33) into the stem
adapter (46) at least four complete turns, holding
the stem adapter with a wrench to prevent it from
turning. If the support legs are still not in full contact
with the actuator mounting flange, thread the stems
together until full contact is achieved and install nuts
(31) onto the support legs and tighten.
10. Thread both stem nuts (36) up and tighten them
against the stem adapter (46).
Section 4: Actuator Spring Pre-Load Adjustment
(Bench Setting)
1. The two stem nuts (47) should be loosened and
threaded down the stem and then locked together.
2. A regulated air supply must be provided to the actuator. Connect the air to the lower actuator case
(16A) for reverse action or to the upper actuator
case (17A) for direct action actuators.
3. Standard actuators have ranges of either 3-15 psig or
6-30 psig. The range is stamped on the valve nameplate. These instructions will assume that the range is
3-15. If yours differs, substitute the appropriate pressure where these instructions refer to 3 psig.
Direct Acting Actuator: ATC (Air-to-Close)
1. The spring preload adjustment may be made with or
without pressure in the valve body.
2. Spring preload is adjusted by threading the stem
adapter (46) into the actuator stem (22). Keep the
actuator stem from turning with a wrench and turn
the stem adapter. Threading the stem adapter into
the actuator stem increases preload while threading
out decreases preload.
3. Slowly increase the air pressure up to 3 psig while
observing the stem for movement. Correct spring
preload is when the valve stem starts to move when
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the actuator pressure reaches 3 psig.
If movement starts before 3 psig, increase the preload;
if movement starts at a pressure higher than 3 psig, decrease the preload.
Reverse Acting Actuator ATO (Air-to-Open)
1. In an ATO actuator, the valve plug is closed by the
actuator spring force which operates against the
stem thrust created by the inlet pressure pushing
up on the plug and stem. If the spring preload ad-
justment is made without pressure in the valve body,
additional preload may be needed to overcome the
effects of this thrust when the control valve is placed
in service. The amount of additional preload will be
dependent on the size of the seat orifice and the inlet
pressure. For the smallest trims and low pressures,
it will be negligible. For the largest trim it could be
significant. The catalog lists the maximum pressure
that the valve is capable of shutting off against with a
3 psig preload. If higher pressures are needed, then
a positioner should be used.
2. Spring preload is adjusted by threading the stem
adapter (46) into the actuator stem (22). Keep the
actuator stem from turning with a wrench and turn
the stem adapter. Threading the stem adapter into
the actuator stem decrease preload when the valve
stem starts to open when the actuator pressures
reaches 3 psig.
3. Slowly increase the air pressure up to 3 psig while
observing the stem for movement. Correct spring
preload is when the valve stem starts to open when
the actuator pressure reaches 3 psig.
4. If movement starts before 3 psig, increase the pre-
load; if movement starts at a pressure higher than 3
psig, decrease the preload.
5. After the preload is set , lock the travel scale indica-
tor nuts (46) against the actuator stem. The valve
travel scale indicator (24) may require adjustment
relative to the indicator (37).
Section 5: Actuator Maintenance
Disassembly and Inspection of Actuator
1. Close inlet and outlet stop valves. Operate system
on bypass, if necessary.
2. Shutoff operating medium and relieve pressure from
diaphragm by disconnecting tubing at diaphragm
case.
Direct Acting Actuator ATC (Air-to-Close)
1. Disconnect the actuator stem (22) from the stem
adapter (46) by loosening the two adapter stem
nuts (47), moving them down the stem adapter and
locking the two nuts together. With appropriate tools
holding the adapter stem nuts and the flats of the
stem adapter, thread the stem adapter out of the
actuator stem. Grip actuator stem and remove hex
bolt (20), thread seal (13), diaphragm washer (19),
diaphragm (12), diaphragm plate (18) and springs
(32).
Reverse Acting Actuator: ATO (Air to Open)
1. Remove actuator from body (refer to Section 2). Remove the actuator case bolts (20) and nuts (45) that
hold the upper case (17A) to the lower case (16A),
and remove the upper actuator case. Remove
springs (32), hex bolt (20), diaphragm plate (18),
diaphragm washer (19), and thread seals (13).
2. Check actuator stem o-ring (14), remove actuator
stems (22), unscrew the gland nut (44) from the
gland (43) and remove the o-ring.
3. Clean all parts with an approved, non-residue forming solvent. Remove encrusted material with fine
emery paper or very mild aluminum cloth. Inspect all
parts for excessive wear and/or damage. Replace
any worn or damaged parts.
Reassembly of Actuator
After all parts have been thoroughly cleaned and inspected, reassemble the actuator.
1. Greasing the o-ring, insert the actuator stem (2) through
the gland (43). Thread on, and tighten gland nut (44).
Direct Acting Actuator ATC (Air-to-Close)
2. Place springs (32) on lower actuator case (16A).
Place diaphragm plate (18) on springs, making sure
springs are nested on the punched bosses. Install
the diaphragm (12) with the holes lined up with the
bolt holes in the lower actuator case. Place the diaphragm washer (19) on diaphragm (12). Install the
thread seal (13) on the hex bolt (20) and thread hex
bolt into the actuator stem (22) and tighten.
Reverse Acting Actuator: ATO (Air-to-Open)
2. Install thread seal (13), diaphragm washer (19), diaphragm (12) and diaphragm plate (18), and tighten
down the hex bolt (2). Place the springs (32) on diaphragm plate (18) so that the springs are nested in
the punched bosses.
3. Place upper actuator case (17A) on diaphragm (12),
lining up with the bolt holes.
4. Replace four bolts (20) and nuts (45) 90° apart and
tighten fingertight. Replace the remainder of the
bolts and nuts and tighten evenly alternating across
the actuator case.
5. Thread the stem adapter (46) into the actuator stem
(22), and reinstall the actuator onto the body assembly. (Refer to Section 3: Valve Reassembly (points
6-10).
6. Adjust spring load. Refer to Section 4: Actuator
Spring Pre-Load Adjustment.
Reversing Action
CHANGING THE VALVE ACTION FROM DIRECT TO REVERSE ACTING OR FROM REVERSE TO DIRECT ACTING.
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The action of the Series 8000 control valve is changed by
reversing the action of the actuator.
1. Disassemble the actuator. Refer to Section 5.
2. Reassemble the actuator with the desired action. Refer to Section 5.
If desired, Low Flow Valve will promptly repair your regulator at a reasonable cost. To return a valve for inspection
and/or repair, please contact our customer service department for a Return Authorization Number. Phone tollfree at 1-800-543-7311. If preferred, you may fax us at
513-871-0105.
Ordering Spare Parts
Use only Low Flow replacement parts. Low Flow Valves
are ruggedly built, carefully assembled to accurate dimensions, and individually tested for performance. A
complete stock of finished parts is maintained ready for
immediate shipment. Low Flow valves are held to the
close tolerances required for precision valves. The use of
any other parts will affect valve performance.
Direct Acting (ATC)
35M Actuator
17B
20
18
4041
132019
When ordering spare parts, first make a note of the following information on the valve's nameplate:
• serial number
• model number and size
• body material and end connections
• range
• seat and seal materials
17A
12
45
17C
32
26
22
47
37
46
36
8
5
42
43
44
14
33
11
7
6
2
16A
9
Body shown 90°
out of position
Soft Seat Option
0.501
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35M Actuator
Reverse Acting (ATO)
22
21
20
15
16
24
35
34
12
2
13
22
19
33
17
18 9
5
10
28
25
7
4
3
6
1
26
27
23
8
14
18
32
11
29
31
30
Item Description Qty. Item Description Qty
1 Body 1 19 Stem, Actuator 1
2 Bonnet 1 20 Scale, Travel 1
3 Packing Set 1 21 Screw 1
4 Packing Follower 1 22 Vent 1
5 Bonnet Nut 1 23 Bottom Plate 1
6 Spacer 1 24 Spring 6
7 Packing Nut 1 25 Stem 1
8 Diaphargm 1 26 Plug 1
9 Threadseal 1 27 Seat 1
10 O-Ring 1 28 Washer 1
11 Actuator, Lower Case 1 29 Gasket 1
12 Namur Yoke 1 30 Gland 1
13 Bushing 1 31 Gland Nut 1
14 Actuator, Upper Case 1 32 Nut 8
15 Bushing 1 33 Nut 2
16 Diaphragm Plate 1 34 Threadsesal Washer 6
17 Washer, Diaphragm 1 35 Hex Bolt 6
18 Hex Bolt 9
3170 Wasson Road • Cincinnati, OH 45209 USA
Phone 513-533-5600 • Fax 513-871-0105
Bulletin IM-8000-0414
lowfl[email protected] • www.lowflowvalve.com
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