4057650/5
IM-P405-46
EMM Issue 5
ABV21i and ABV40i
Air Actuated Boiler Blowdown Valves
Installation and Maintenance Instructions
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
8. Fault finding
IM-P405-46 EMM Issue 5 1
© Copyright 2017
Printed in GB
1. Safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11)
in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of
tools and safety equipment must also be complied with.
WARNINGS
Before commencing any dismantling work on a boiler, depressurise, drain,
and vent the boiler to atmosphere.
Pipelines must be adequately isolated, depressurised, and drained. Isolation
valves must be turned on and off gradually to avoid system shocks.
Ball valves can trap pressurised media in the body, so make sure there is no
pressure to the valve body, or any pressure remaining in the body, before
loosening or removing the flange bolts. The actuator must belated both
pneumatically and electrically before any maintenance is carried out.
Do not attempt to service the actuator without first consulting the Installation
and Maintenance Instructions, as the end caps contain springs under pressure.
Failure to follow the instructions could result in injury. The actuator must be
vented before dismantling.
If the valve should seize in the partly open position, the springs in the actuator
will still be par tly compressed, and will consequently be storing a large
amount of energy, which could cause injury if released suddenly. If there is
any possibility that this is the case follow the instructions given in the
'Maintenance' section of this booklet - 'Dismantling a seized valve assembly'.
Maximum supply pressure 8 bar g (116 psi g)
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Infor mation She et, check th at the produc t is suitabl e for the inten ded use / appli cation.
The products listed below comply with the requirements of the European Pressure
Equipment Directive 2014/68/EU and carry the mark when so required.
The products fall within the following Pressure Equipment Directive categories:
Product
ABV21i and ABV40i
Group 2
Gases
DN25 SEP SEP
DN32 SEP SEP
ABV21i 1 SEP
DN40 - DN50
ABV4 0i 1 SEP
DN65 1 SEP
IM-P405-46 EMM Issue 52
Group 2
Liquids
i) The products have been specifically designed for use on steam, compressed air,
water and other industrial fluids that are in Group 2 of the above mentioned
Pressure Equipment Directive. The products' use on other fluids may be possible
but, if this is contemplated, Spirax Sarco should be contacted to confirm the
suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers f rom all connections and protective f ilm from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the ef fect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
IM-P405-46 EMM Issue 5 3
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessar y, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and / or heavy products may present a risk of injur y. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of these products
may reach temperatures of 260 °C (500 °F).
These products are not self-draining. Take due care when dismantling or removing
them from an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage in environments where they may be exposed to temperatures below freezing
point.
IM-P405-46 EMM Issue 54
1.15 Safety information - Product specific
Hydraulic locking
Ball valves are prone to lock-up when used on certain heating / cooling applications
where both steam and liquid will pass through the valve. This is caused by liquid
trapped in the ball during closure being heated to create a high hydraulic pressure
inside the ball cavity. To prevent this, during manufacture, a minute hole is drilled
in the ball, so, that in the closed position, any excess pressure will be relieved. Spirax
Sarco ball valves for these applications are clearly marked to allow the valve to be
correctly installed, such that, when closed, the hole is facing the steam source.
1.16 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product
is recyclable and no ecological hazard is anticipated with its disposal providing due
care is taken.
1.17 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions to be taken due to contamination residues or mechanical
damage which may present a health, safet y or environmental risk. This information
must be provided in writing including Health and Safety data sheets relating to any
substances identified as hazardous or potentially hazardous.
IM-P405-46 EMM Issue 5 5
2. General product information
2.1 General description
The Spirax Sarco ABV21i and ABV40i are one piece end entry, reduced bore ball valves
having ISO mounting as standard. They are fitted with a 90° rotary spring return pneumatic
actuator, and a limit switch box. They are used in conjunction with a Spirax Sarco blowdown
timer to provide timed control of bottom blowdown, ensuring that the recommended boiler
blowdown cycles occur with minimum heat loss, avoiding duplication or omission.
The valve is suitable for a maximum pressure of 17.25 bar g @ 208 °C (250 psi g at 406 °F).
A NAMUR (VDI / VDE 3845) solenoid valve is also required, and may be selected from the
Spirax Sarco MV range. Alternatively, an air supply (maximum pressure DN25 8 bar (116 psi),
DN32 to DN65 6 bar (87 psi)) may be connected directly to the actuator por t 'A' (¼" BSP), for
applications where it is necessary to install the solenoid valve remote from the actuator.
A standard ¼" BSP 3-way solenoid valve may also be used.
ISO mounting
The integral ISO body mounting allows the valve to be automated without losing seal intregrity,
as the body does not require disassembly.
2.2 Product availability
Valve type Valve size Actuator Switch box
DN25 BVA315S /14 LSB 31
DN32 BVA320S /14 LSB31
ABV21i and ABV40i
DN40 BVA32 5S /14 LSB 31
DN50 BVA325S /14 LSB 31
DN65 BVA330S /14 LSB31
2.3 Actuator
The actuator uses a rack and pinion system with a quarter-turn operation. A position indicator
is fitted to the top of the pinion shaf t, below the switch box. BVA actuators are factory
lubricated, and do not require a lubricated air supply. The air must, however, be dry and clean.
Any other non-corrosive gas can be used as the operating medium.
2.4 Switch box
LSB limit switch boxes are normally used for indicating valve open or valve closed position.
They also allow switching points to be adjustable over the full range of actuators. There is an
open / closed valve position indicator mounted at the end of the switch box axis, at the top
of the cover. LSB's include a stainless steel linkage kit for direct mounting to BVA300 series
actuators.
IM-P405-46 EMM Issue 56
Fig. 1 ABV21i
Inlet port 'A'
LSB31 limit switch box
BVA300 series pneumatic actuator
Air inlet port
Solenoid valve
Fig. 2
3/2
5/2
MV11 / MV12 / MV11 / MV12
General view
Solenoid override screw
Use '3/2' adapter plate for this application
IM-P405-46 EMM Issue 5 7
2.5 ABV21i - Pressure / temperature limits
Pressure psi g
Temperature °F
Steam
saturation
curve
Temperature °C
Pressure bar g
The product must not be used in this region.
Valve
Body design conditions PN40
PMA Maximum allowable pressure 40 bar g @ 120 °C (580 bar g @ 248 °F)
TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum allowable temperature -29 °C (-20 °F)
Maximum operating pressure for
PMO
saturated steam service
TMO Maximum operating temperature 260 °C @ 0 bar g (50 0 °F @ 0 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
Maximum differential pressure is limited to the PMO
PMX
Designed for a maximum cold hydraulic test pressure of: 60 bar g (870 psi g)
17.25 bar g @ 208 °C (250 psi g at 406 °F)
Actuator
Maximum ambient temperature 80 °C (176 °F)
Minimum ambient temperature 0 °C (32 °F)
Maximum air supply pressure 8 bar g (116 psi g)
Minimum air supply pressure is dependant on operating conditions
MV series solenoid
Maximum ambient temperature 50 °C (122 °F)
Minimum ambient temperature 0 °C (32 °F)
IM-P405-46 EMM Issue 58
2.6 ABV40i - Pressure / temperature limits
Pressure psi g
Temperature °F
Steam
saturation
curve
Temperature °C
Pressure bar g
The product must not be used in this region.
Valve
Body design conditions ASME 300
PMA Maximum allowable pressure 51 bar g @ 38 °C (739 bar g @ 100 °F)
TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum allowable temperature -29 °C (-20 °F)
Maximum operating pressure for
PMO
saturated steam service
TMO Maximum operating temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
Maximum differential pressure is limited to the PMO
PMX
Designed for a maximum cold hydraulic test pressure of: 76.5 bar g (1 109 psi g)
17.25 bar g @ 208 °C (250 psi g at 406 °F)
Actuator
Maximum ambient temperature 80 °C (176 °F)
Minimum ambient temperature 0 °C (32 °F)
Maximum air supply pressure 8 bar g (116 psi g)
Minimum air supply pressure is dependant on operating conditions
MV series solenoid
Maximum ambient temperature 50 °C (122 °F)
Minimum ambient temperature 0 °C (32 °F)
IM-P405-46 EMM Issue 5 9
3. Installation
Note: Before actioning any installation read the 'Safety information' in Section 1.
Although the valve has great structural integrity, severe misalignment and / or the pulling
effect of incorrect pipe length will have a detrimental effect on the valve and must be avoided.
Particular attention should be paid to correct pipe alignment such that the inlet pipework and
valve are all on the same axis.
Wherever practicable, valves should be installed where there is adequate space available so
that they can be conveniently operated and maintained.
Before installing a valve, check to ensure that size, pressure rating, materials of construction,
end connections, etc. are suitable for the service conditions of the particular application.
Care must be taken to ensure that all dirt which may have accumulated in the valve during
storage is removed before installation, maintain cleanliness during installation since the
introduction of dirt can result in damage to the valve seats and operating mechanism. To
minimise the danger of abrasive particles damaging the seats, pipeline strainers should be
fitted upstream of the valves.
Install the valve with the actuator uppermost. The preferred position is with the stem vertical.
The air supply to the solenoid valve/actuator must be in 10 mm ( ") minimum diameter pipe.
The air inlet connection is ¼" BSP (G).
Table 1 Maximum air pressure
Valve size Actuator Maximum air pressure
DN25 BVA315 S /14 8 bar g (116 psi g)
DN32 BVA32 0S /14 8 bar g (116 psi g)
DN40 and DN50 BVA325S /14 8 bar g (116 psi g)
DN65 BVA3 30S /14 8 bar g (116 psi g)
3.1 To fit an MV type solenoid assembly to the valve actuator:
Turn the spring loaded solenoid override screw anticlockwise to release it for normal
-
working.
Fit the screwed location pin from the MV kit in the top centre position above the actuator
-
ports (see Figure 3). Ensure the pin is screwed far enough into the actuator to allow a
good seal to be made i.e. that it is not holding the solenoid away from the actuator.
Use the '3/2' adapter plate supplied with the solenoid assembly. Discard the '5/2' plate.
-
Note: Earlier versions used a double-sided plate. For this type, align the arrow on the
plate with the '3/2' on the valve assembly.
Fit the solenoid assembly to the actuator using the 2 screws provided in the kit. Do not
-
overtighten the screws as this could distort the plastic body and prevent proper working.
Connect the air supply to port 1 (¼" BSP). Note that port 3 is blanked for this application.
-
The unmarked port near the override screw is not connected in this application.
The solenoid override is operated by using a screwdriver to push the spring loaded plastic
screw inwards and turning it clockwise to lock it in the 'override' position. This bypasses
the solenoid and allows the ABV to be operated without an electricity supply. The screw is
released by turning it anticlockwise.
IM-P405-46 EMM Issue 510
Fit locating grub screw (in MV solenoid kit) here.
Inlet
A
port
Fig. 3 BVA actuator showing inlet and exhaust ports
Exhaust
port B
3.2 Switch box wiring and terminal connections are shown in Figure 4
The switch box is supplied with Pg 11 cable gland.
The switches are suitable for 10 A, 250 Vac operation.
LSB31 connections
LSB3 connections
Fig. 4
For the wiring of alternative versions of the LSB switch refer to IM-P372-27
BT1000 connections
Valve
closed
NO CNC NO
BT1050 BB switch connections
Valve
open
C NC
Screen
IM-P405-46 EMM Issue 5 11
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests
on any alarms or protective devices.
5. Operation
The air supply is switched on by the solenoid valve, causing two pistons in the actuator to
move apart against spring pressure.
Racks attached to the pistons turn the actuator pinion and shaft, opening the valve fully.
On release of the air pressure, the springs return the valve to the closed position.
Cable connector
Solenoid can be repositioned if required
Solenoid override screw
Blanked off (use the plug supplied)
Not used
Use the '3/2' adapter plate for this application
Air inlet port (¼" BSP)
'O' ring
Fig. 5
IM-P405-46 EMM Issue 512
6. Maintenance
Actuator
Note: Before actioning any maintenance programme read the 'Safety information' in
Sec ti on 1.
6.1 G e ner a l
Periodically check that all fasteners remain tight.
No routine maintenance is required, as the actuator is supplied with sufficient lubrication
for a normal working life. Depending on the severity of actuator operating conditions, periodic
replacement of the 'O' rings may be required. Spares are available - see Section 7.
6.2 Preventitive maintenance
6.2.1 We recommend a periodic inspection to check the actuator function.
6.2.2 Actuators must be operated at least once ever y six months.
6.2.3 Replace the 'O' rings, guides and washers if necessar y.
6.3 Reasons for parts repair and replacement
Repair or replace the actuator components as soon as leakage is detected through the
upper 'O' ring (16) or lower 'O' ring (7) of the pinion, through the piston 'O' ring (8) or through
the 'O' rings (11) of the end caps.
Exploded view of the
spring set
8 11
16
11 8
Fig. 6 BVA300 series shown
IM-P405-46 EMM Issue 5 13
7
6.4 Disassembly and reassembly of the actuator
6.4.1 Precautions before disassembly:
Isolate and test the air and electrical supplies before working on the actuator.
-
Disconnect the actuator and its accessories from the air tubing and electrical wiring.
-
Disassemble the solenoid from the actuator.
-
Disassemble the actuator from the valve and / or from its couplings.
-
Exploded view of
the spring set
11 8
420 2
Fig. 7 BVA300 series shown
23
24
12
22
21
13
5
18
27
14
15
8 11
16
10
26
3
7
1
2042
IM-P405-46 EMM Issue 514
6.4.2 Disassembly
Once the precautions prior to the disassembly have been taken, follow the next steps:
Disassemble the end caps (4) of the actuator by untightening the external bolts (20).
-
Please note - With spring return actuators there is no inherent danger during this
operation, as the fastening bolts for the caps are designed with adequate length.
Unfasten the nuts (24) in order to remove the levelling screws (23).
-
Turn the pinion (3) anticlockwise to disengage the pistons (2) in normally closed actuators
-
and clockwise in normally open ones. Remove the pistons from the cylinder.
Disassemble the position indicator (21, 22 and 27), the slip washer (13), the soft pinion
-
washer (15) and the metallic pinion washer (14) from the upper side.
Disassemble the pinion (3) from the lower part of the body (1) of the actuator. To do this
-
operation, disassemble the upper pinion bearing (10) and the stop (12) through the inside
of the body.
Clean all the parts of the actuator.
-
Examine all parts in order to inspect for wear. Important: Carefully examine the inside
-
of the cylinder.
If everything is in good condition, fit the new 'O' rings, bushings, slide guides and washers
-
included in the Spirax Sarco BVA300 series maintenance kit before reassembling the
actuator - see Section 6.4.3.
Lubricate the parts of the actuator with Molykote B 2-2 plus grease. Apply a thin layer
-
of grease on the 'O' rings (7, 8 and 16).
6.4.3 Reassembly
After disassembly, and the inspection and lubrication of the relevant par ts, proceed to
reassemble them following the sequence below:
Correctly assemble all the parts included in the Spirax Sarco BVA300 series
-
maintenance kit. Note: lubricate where stated in Section 6.4.2.
Place the pinion (3) in the body (1) from underneath. Once the pinion appears through
-
the inside of the body, assemble the pinion stop (12) in its correct position and also the
upper pinion bearing (10).
Place the soft pinion washer (15), the metallic pinion washer (14), the slip washer (13)
-
and the position indicator (21, 22 and 27) in the upper part of the pinion.
Assemble both pistons, checking that they engage at the same time when turning the
-
pinion (3) clockwise for normally closed actuators and anticlockwise for normally open
actuators.
Assemble the actuator end caps (4) tighten the bolts (20) in sequence. Check that the
-
open and closed positions coincide with the position indicated in the upper part of the
pinion (see Figure 6).
Important: Once assembled, operate the actuator a few times and recommission - see
Section 4.
IM-P405-46 EMM Issue 5 15
Valve
Note: Before actioning any maintenance programme observe the 'Safety information'
in Section 1.
6.5 Maintenance
As with all mechanical devices, regular maintenance is the most efficient means of ensuring
continued operational efficiency. Regular scheduled inspection of all valves is essential
especially on valves which are operated only occasionally.
6.6 General maintenance
Remove the complete flanged valve from
the pipeline. The complete body assembly
can then be removed and new parts fitted.
Please note: A special tool, that is only
available from Spirax Sarco, is required
in order to remove the insert (2) - See
Section 7, Available spares. When the
seats have been replaced and the valve has
been reassembled it is recommended that
the following tests are conducted before
commissioning back into service:
Cold hydraulic test to the ABV21i body at
-
60 bar g (870 psi g), and the ABV40i body
at 76.5 bar g (1 109 psi g).
Seat leakage test using compressed air
-
at 7 bar g.
6.7 How to replace the seats (5)
Remove the body as described in
-
Section 6.2.
With the body removed, remove the
-
seats (5) and 'O' ring (6).
Fit new seats (5) pushing them into the
-
body chamber.
Insert a new 'O' ring (6) replace the
-
ball valve insert (2) and tighten to the
recommended torque - See Table 1.
6.8 How to replace the stem
seals (9 and 10)
Remove the body as described in
-
Section 6.2.
Remove the nut (15).
-
Replace the stem seals (9 and 10).
-
Insert a new 'O' ring (6) replace the
-
ball valve insert (2) and tighten to the
recommended torque - See Table 1.
6.9 Reassembly
Reassemble in reverse order to instructions
given above. The stem nut (15) and the ball
valve insert (2) should be tightened to the
recommended torques shown in Table 1.
6.10 Tes t ing
Ensure that the stem can rotate freely,
-
without undue friction.
Carry out seat leakage and body
-
hydraulic testing as appropriate:
- Seat leakage test at
6 bar g (87 psi g) (air under water)
- Cold hydraulic test at
78 bar g (1 131 psi g) (Class 300)
6.11 Assembly
Refit actuator/bracket assembly ensuring
-
that the valve is fully closed before
attempting to locate the drive adapter.
Connect an air supply and check that
-
the valve opens and closes correctly
and fully.
IM-P405-46 EMM Issue 516
6.12 Switch box To adjust switch box mircoswitch settings
a) Switch off power supply to switch box.
b) Remove switch box cover.
c) Remove indicator disc.
d) Turn the cam to the required position.
e) Replace indicator disc - ensure it is aligned correctly.
f) Replace cover and switch on air and power correctly.
Fig. 8 DN25 to DN50 shown
15
Please note: You will need to order the Insert
tool listed in the table above to aid removal.
12
7 7
Ball valve insert (2)
(not an available spare).
8
11
655
Table 1 Recommended tightening torques
Item no. Part Siz e N m lbf ft
DN25 and DN32 108 - 135 80 - 100
2 Insert
15 Nut
DN40 135 - 160 100 - 120
DN50 215 - 245 160 - 180
DN65 245 - 270 180 - 200
DN25 17.5 - 20.3 13 - 15
DN32, DN40, DN50 and DN65 3 4 - 40 25 - 30
IM-P405-46 EMM Issue 5 17
7. Spare parts
Actuator
A valve spares kit is available, which includes all seals and gaskets and a valve ball. Spare
valve stems are also available. An actuator spares kit is available. State actuator type on
order. No spares are available for the switch box.
Caution: The vent hole in the ball must be on the upstream side of the valve.
Note: Before actioning any maintenance programme observe the
'Safety information' in Section 1.
Any parts replacement must be implemented with original
Spirax Sarco spare parts, or any warranty implied or expressed
is null and void.
The manufacturer will not be responsible for any actuator
dysfunction, if original Spirax Sarco parts have not been used.
13
14
15
Exploded view of the spring set
11 17 8
Fig. 9 BVA300S /14 spare parts
12
6
5 16
10
18
7
IM-P405-46 EMM Issue 518
7.1 Spare parts for the BVA300S /14
The available spare parts for the BVA300S /14 are listed opposite.
No other parts are available as spares.
6 8 17 115
Spare parts
The spare parts available are detailed below. No other parts are supplied as spares.
Available spares
'O' rings set (NBR) 7, 8, 11, 12, 16
BVA300 series maintenance kit
Pinion washers 13, 14 , 15
Others 5, 6, 10, 17, 18
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the nomenclature of the pneumatic actuator that they are intended for.
Note: all the spares mentioned above are sold together in one spare part kit.
Example: 1 - BVA300 series maintenance kit with 'O' rings in NBR for a Spirax Sarco
BVA320 S /14 pneumatic actuator.
IM-P405-46 EMM Issue 5 19
Valve
7.2 DN25 to DN50 Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Seats, insert 'O' ring and stem seals 5, 6, 9, 10
Insert tool - Required to aid the removal of the ball valve insert (2) Not shown
Please note: Spare par ts are common for both the ABV21i and ABV40i.
Caution: The ball must be installed with the vent hole on the upstream side of the valve.
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of ball valve.
Example: 1 set of seats, insert 'O' ring and stem seals for a Spirax Sarco DN50 ABV21i
boiler blowdown valve.
Ball valve insert (2)
Please note: You will need to order the Insert
10
tool listed in the table above to aid removal.
(not an available spare).
Fig. 10
9
6955
IM-P405-46 EMM Issue 520
7.3 DN65 Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Seats, insert 'O' ring, seat 'O' ring, stem 'O' ring, lower stem seals and
upper stem packing
Insert tool - Required to aid the removal of the ball valve insert (2) Not shown
Please note: Spare par ts are common for both the ABV21i and ABV40i.
Caution: The ball must be installed with the vent hole on the upstream side of the valve.
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of ball valve.
Example: 1 set of seats, insert 'O' ring, seat 'O' ring, stem 'O' ring, lower stem seals and
upper stem packing for a Spirax Sarco DN50 ABV40i boiler lowdown valve.
Please note: You will need to order the Insert
tool listed in the table above to aid removal.
12
5, 6, 7, 8, 11, 12
Ball valve insert (2)
(not an available spare).
8
11
Fig. 11
IM-P405-46 EMM Issue 5 21
7 7
655
8. Fault finding
Before dismantling the actuator, consult the instructions given below:
8.1 Actuator with solenoid valve
If the actuator does not function check that:
A
1. The valve is free to rotate.
2. The actuator is of the correct size.
3. The speed control screws, if fitted, are loose (if screws are tightened all the way the
actuator will not operate).
4. The correct voltage is supplied to the solenoid (the valve coil is tagged with the correct
volt ag e).
5. Sufficient compressed air is available at the solenoid valve.
If the proper voltage and air pressure have been verified and the
B
valve is free to move proceed as follows:
1. Apply the correct voltage to the solenoid valve. Check for a clicking sound.
2. If no sound is detected:
i) Carefully unscrew the solenoid and solenoid stem from the block.
ii) Re-apply voltage and observe the solenoid plunger. If it does not retract replace
the solenoid valve.
3. If the solenoid functions, remove both it and the mounting block for a bench test. Connect
with a minimum 3 bar g air supply and correct voltage. Switch it on and off and check
the air flow. Air should flow out of only one outlet port when the solenoid is energised.
(Slight backpressure may be required to shift the valve spool. This may be generated
by obstructing the outlet port).
If the actuator functions but exhibits leak or power loss accompanied
C
by leakage proceed as follows:
1. Check the voltage. It must be within 10% of the specified voltage.
2. Check the compressed air supply. Ensure that no intense pressure drops occur as the
unit is cycled. Loss of pressure can cause incomplete shifting of the spool valve in the
block or at one of the piston seals of the actuator. A leaking piston seal will usually leak
on either cycle. On spring return actuators, piston seal leakage will show at port B on
the air manifold flange. A leaking spool valve will require replacing. Leaking piston seals
can be cured by replacing the 'O' rings with new ones.
IM-P405-46 EMM Issue 522
8.2 Actuator without a solenoid valve.
For actuators without a solenoid valve, (or those where the solenoid
valve and mounting block are working correctly), remove the actuator
from the valve, disassemble and check the following:
1. Make sure all porting is clear of obstructions.
2. Make certain the actuator is lubricated and that there is no solidified grease between
the pinion and piston racks. If solidified grease is present, clean, dry, regrease and
reassemble.
3. Verify that the actuator pinion shaft and / or pistons are not seized. If seized, reassemble
as per the reassembly instructions in Section 6.4.3.
4. If the unit exhibits excessive backlash, check the teeth on the piston racks for wear.
5. With spring return actuators, check for misplaced or broken springs. If springs are
broken, check the body for scoring.
6. If the actuator and valve are free, reassemble the actuator and retest. If the unit still
fails to operate, consult Spirax Sarco.
IM-P405-46 EMM Issue 5 23
IM-P405-46 EMM Issue 524
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