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EH21000
1/09
21000 Series
Control Valves
Complete Line of
Rugged, Top Guided,
Globe Valves with
Lo-dB / Anti-Cavitation
Capabilities
TABLE OF CONTENTS
l.
INTRODUCTION ........................................................................2
2. GENERAL ...................................................................................2
3. UNPACKING................................................................................3
4. INSTALLATION ...........................................................................3
5. AIR PIPING..................................................................................3
9. ACTUATORS .............................................................................10
7. MAINTENANCE/REPAIR ............................................................4
7.1 THREADED SEAT RING REMOVAL.....................................4
7.2 BUSHING REMOVAL ............................................................4
7.3 LAPPING SEATS ..................................................................4
7.3.1 THREADED TRIM .......................................................5
7.3.2 QUICK-CHANGE TRIM ...............................................5
7.4 Lo-dB PLUG ..........................................................................6
7.5 PLUG STEM PINNING..........................................................6
7.6 PACKING BOX ......................................................................7
7.6.1 KEVLAR/PTFE PACK. RING (STANDARD) ................7
7.6.2 EXPANDED GRAPHITE P. RING (OPTION) ...............7
7.6.3 LE PACKING (LOW EMISSION) (OPTION) ................7
7.7 SOFT SEAT PLUG ................................................................9
1. lntroduction
The following instructions should be thoroughly reviewed
and understood prior to installing, operating or performing
maintenance on this equipment. Throughout the text,
safety and/or caution notes will appear and must be strictly
adhered to, otherwise, serious injury or equipment
malfunction could result.
Tight Shutoff Class IV leakage is standard. Optional constructions (one of which is the 21600 Series soft seat plug) meet IEC
534-4 and ANSI/FCI 70.2 Class V and Vl requirements.
An optional Low Emission LE Packing is available to assure
compliance with the fugitive emission containment requirements.
Masoneilan has a highly skilled After Sales Department available for start-up, maintenance and repair of our valves and component parts.
Arrangements for this service can be made through your local
Masoneilan Representative or After Sales Department. When
performing maintenance use only Masoneilan replacement
parts. Parts are obtainable through your local Masoneilan
Representative or Spare Parts Department. When ordering
parts, always include Model and Serial Number of the unit
being repaired.
2. General
1st
2nd
Actuator Type
87 Spring Diaphragm
Air to Close
88 Spring Diaphragm
Air to Open
1st
Body
Series
21
2nd
3rd
4th
Flow
Characteristics
Plug Type
0.
1.
6.
7.
Undefined
Contoured
Soft Seat
Single Stage
Lo-dB/
Cavitation
Containment
8. Double Stage
Cavitation
Containment
9. Double Stage
Lo-dB
0. Undefined
1. Linear
2. Equal
Percentage
3. Modified
Percent
5th
6th
Seat Type
0. Undefined
4. Quick Change
5. Threaded
Optional
Configuration
A Angle Body
BS Bellows
Seal
EB Extension
Bonnet
C Cryogenic
Extension
Bonnet
5. Air Piping
The actuators are designed to accept 1/4" NPT air supply piping.
Use 1/4" OD tubing (4 x 6 mm) or equivalent for all air lines. If the
supply air line exceeds 25 feet in length (7 meters) or if the valve
is equipped with volume boosters, then 3/8" tubing (6 x 8 mm) is
preferred. AII connections must be free of leaks.
3. Unpacking
Care must be exercised when unpacking the valve to prevent
damage to the accessories and component parts. Should any
problems arise, contact the local Masoneilan Representative or
After Sales Department.
4. lnstallation
4.1 Before installing the valve in the line, clean piping and
valve of all foreign material such as welding chips, scale,
oil, grease or dirt. Gasket surfaces should be thoroughly
cleaned to insure leak-proof joints.
6. Body Disassembly
Access to the internal components of the body should be
accomplished with the actuator removed. To remove the actuator
from the body, refer to the actuator instruction No ER8788 for a
type 87/88 multispring actuator.
The purpose of this section is to provide recommended maintenance and repair procedures. These procedures assume the
availability of standard shop tools and equipment.
E. Remove plug (16) and plug stem (1) sub-assembly from the
bonnet (8).
G. Bonnet (8), plug (16), bushing (12) and seat ring (14) may
now be inspected for wear and service damage. After
determining the maintenance required, proceed to the
appropriate Section of this instruction manual.
D. Since the cage (13), seat ring (14) and seat ring gasket
(15) are held in place by the bonnet, they may now be
removed.
Note : Spiral wound gaskets (11 & 15) are standard in the
21000 Series design and it is imperative that new gaskets
be installed each time the valve is disassembled.
E. Remove packing flange stud nuts (3), packing flange (4)
and packing follower (5).
2. Install a new seat ring gasket (15) and insert seat ring
(14) in the body.
Note : Gasket (15) is temporarily placed to hold the
seat ring during lapping.
Caution : Insure that the seat ring (14), cage (13) and
bonnet (8) are properly aligned.
7. Fasten the bonnet to the body using four body stud nuts
(10) spaced equally apart. Apply slight pressure and
tighten evenly.
Caution : Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily
for guiding purposes only.
Caution : Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily
for guiding purposes only.
10. Apply slight pressure on the stem, and rotate the stem in
short oscillating strokes (around 8 to 10 times). Repeat
this step as necessary.
1. Select the correct size pin based on the plug guide diameter
and stem diameter (see Figure 9). Apply a small amount
of grease on the pin and hand assemble it into the hole in
the plug.
2. Press fit the pin into the hole using a hammer. Complete
the pinning operation by taking care to ensure that the
pin is recessed by the same amount at both sides (see
Figure 9).
PIace the plug guide on a V-block and use a suitable size drill
bit to drill the stem (use the hole in the plug as a guide).
Note : If the hole in the plug guide has been slightly damaged
while removing the old pin, choose a drill bit and a pin with a
slightly larger diameter than the normal pin.
D. Pinning
Select the correct size pin based on the plug guide diameter
and pin hole diameter. Proceed as described in part D of
the previous section, taking care not to damage the plug
guide area.
Proceed as follows :
PTFE - V-Ring
PFE - V-Ring
Scribe
Mark
Upper
Follower
7.6.3.1 Preparation
Disc
Springs
7.6.3.1.1 Stem
Inspect stem for any nicks or scratches on the surface
finish. Reject the stem for any of these reasons as they
may damage packing.
Lower
Follower
Note : Bonnets that have a lube hole are unacceptable for use with the packing arrangement
shown in Figure 7.
c. Packing should be lubricated with a generous application to the O.D. and I.D. of the packing set.
The soft seat plug used in the 21000 Series valve has a
replaceable insert. To remove and replace the insert, proceed
as follows.
A. Loosen set screw until the head of the set screw is flush
with the OD of the shank.
C. Using the appropriate tool, unscrew plug tip (counterclockwise) from the shank sub - assembly.
D. Remove insert O-ring (for valve sizes 3"- 6" only) and insert
retainer. Discard existing insert and O-ring.
C. lnstall and tighten seat ring using wrench used for removal.
Standard trim is used within these optional body configurations. Refer to the applicable sections within this instructions
manual.
9. Actuators
Note: Spiral wound gaskets (11 & 15) are standard in the
21000 Series design. It is imperative that a new gasket be
installed each time the valve is disassembled.
C. Install cage (13).
10
T-Handle
Lock Nut
Shank
Skirt &
Insert
Retainer
Flats
Flats
Set
Screw
Set
Screw
Insert
Retainer
Insert
Plug Tip
3/4" -
Plug
Tip
O-ring
Braided
Back-up Rings
Flexible
Graphite
Rings
Figure 7
LE (Low Emission) Packing Arrangement (Optional)
Figure 8
Lo-dB (Type 21900) and Anti-cavitation (Type 21800)
Double Stage Trim (Optional)
11
Cylindrical machining
diameter of the jaws =
plug guide diameter A
C Dia.
X
B
Reference Mark
Pin Hole
Dia. C
in. mm
.87 22.22
in. mm in. mm
1/2 12.70 .138 3.50
in. mm in. mm
1.25 32 .50 13
1.50 38.10
1.25 32
2.38 60.32
2.75 69.85
.50
13
19
19
Soft metal
or plastic
vise jaws
Valve
Size
in.
mm
Total
Total
Flexible
Graphite Rings
Lantern
Ring
(7)
3/4 to 4
20 to 100
6 to 8
150 to 200
Lantern
Ring
(7)
12
.75 & 1
mm
20 & 25
1.5 & 2
40 & 50
1.5
40
50
Qty.
150
200
Maximum
Pre-Load
Lbs.Ft
N.m
Lbs.Ft
N.m
Lbs.Ft
N.m
1/2"-13NC-2A
25
34
66
89
600
1/2"-13NC-2A
25
34
66
89
1"-8NC-2A
125
169
560
759
45
61
2500
1"-8NC-2A
125
169
560
759
45
61
1/2"-13NC-2A
25
34
66
89
600
1/2"-13NC-2A
25
34
66
89
7/8"-9NC-2A
100
136
300
407
30
41
2500
7/8"-9NC-2A
100
136
300
407
30
41
2500
1-1/8"-7NC-2A
160
217
640
868
60
81
5/8"-11NC-2A
45
61
132
179
10
14
600
3/4"-10NC-2A
80
108
230
312
20
27
1-1/8"-8NC-2A
225
305
830
1125
75
102
5/8"-11NC-2A
45
61
132
179
10
14
600
1"-8NC-2A
125
169
560
759
45
61
1-1/2"-8NC-2A
400
542
2100
2847
115
156
12
5/8"-11NC-2A
45
61
132
179
10
14
600
12
1"-8NC-2A
125
169
560
759
45
61
150 - 600
12
1-1/4"-8NC-2A
235
319
1200
1627
100
136
100
Minimum
Size (inch)
80
Torque Requirements
Bolting Requirements
ANSI
Class
Bolting Requirements
Minimum
Maximum
Pre-Load
Increments
Lbs.Ft
Lbs.Ft
N.m
N.m
Qty.
Size
Lbs.Ft
N.m
Lbs.Ft
N.m
1/2"-13NC-2A
20
27
30
41
5/8"-11NC-2A
25
34
55
75
10
14
1
6
4
4
3
6
12
7
2
13
5
9
10
11
Figure 12
Threaded Seat Ring - Contoured Plug - Full Capacity
Figure 13
Quick Change Trim - Contoured Plug - Full Capacity
Figure 14
Threaded Seat Ring - Lo-dB Plug
Figure 15
Quick Change Trim - Lo-dB Plug
PARTS REFERENCE
Ref.
1
2
3
4
5
6
7
8
Part Name
Ref.
Plug Stem
Packing Flange Stud
Packing Flange Stud Nut
Packing Flange
Packing Follower
Packing
Lantern Ring (optional)
Bonnet
9
10
11
12
13
14
15
16
Part Name
Body Stud
Body Stud Nut
Body Gasket
Plug Guide Bushing (Incl. w/ref. 8)
Cage *
Seat Ring
Seat Ring Gasket *
Plug
14
Ref.
17
18
19
Part Name
Plug Pin
Body
Drive Nut
15
Remove the plug pin (17), then remove the plug (16) from
the plug stem (30). (See section 10.2.1.1 for unpinning the
plug stem).
Remove the bonnet and spacer gaskets (28) and the body
gasket (11).
Lock two nuts against each other on the end of the plug
stem, and use a flat spanner on the lower nut to prevent
rotation while unscrewing the plug from the stem. The
plug is removed by turning it counter-clockwise.
Remove the two nuts from the plug stem. Complete step
10.1.1.
10.2 Repair
16
Pin Hole
Dia. C
mm in. mm in.
22.22 1/2 12.70 .138
mm in. mm in. mm
3.50 1.65 42 .70 18
3.50 2.17 55
1.25
32
5.00 2.75 70
2.00
50
5.00 2.75 70
2.00
50
Cylindrical machining
diameter of the jaws =
plug guide diameter E
29
16
30
17
28
C Dia.
E Dia.
Soft metal
or plastic
vise jaws
F Dia.
17
C. Pinning
Select the correct size pin based on plug guide
diameter and pin hole diameter. Proceed as
described in Paragraph C above, taking care not to
damage the plug guide area.
18
22
2
3
4
19
5
6
25
31
28
28
Section a
27
26
() 30
() 29
11
18
12
13
14
16
15
PARTS REFERENCE
Ref.
1
2
3
4
5
6
9
10
11
12
13
14
Part Name
Plug Stem
Packing Flange Stud.
Packing Flange Nut
Packing Flange
Packing Follower
Packing
Body Stud
Body Stud Nut
Body Gasket
Guide Bushing
Cage
Seat Ring
Ref.
15
16
17
18
19
22
25
26
27
28
29
+
Part Name
Ref.
19
+
+
30
+
+
+
+
31
Part Name
Spacer
Lower Flange
Bellow and Stem Assembly
Stem
Guide Bushing
Bellows
Upper Adapter (Bellows)
Lower Adapter (Bellows)
1/8" NPT Plug
55-11-2146-3600
55-11-2146-3610
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Fax:
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+34-93-652-6430
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Dresser Masoneilan
With its breadth of products, unequaled global presence and
advanced process control expertise, Dresser Masoneilan is
uniquely positioned to be the leading provider of flexible, best
fit control valve solutions.
Supported by an integrated network of sales offices, Dresser
Masoneilan provides the widest range of valve solutions and
services for virtually every process control application.
Dresser Masoneilan
85 Bodwell Street
Avon, MA 02322-1190
Tele: 508-586-4600 / Fax: 508-941-5497
Email: sales@masoneilan.com
www.dresser.com
EH21000 1/09