Binder 6

Manual
EHC
Double acting electro hydraulic actuators
M516.01en
© CCI
EHC Service Instruction
Table of contents
1 General....................................................................................................................................... 5
1.1 Introduction........................................................................................................................ 5
1.2 Cleaning and installation instructions................................................................................ 5
1.2.1 Installation.................................................................................................................. 5
2 Maintenance............................................................................................................................... 6
2.1 Disassmebly and reassembly ............................................................................................. 6
2.1.1 Spring house disassembly .......................................................................................... 7
2.1.2 Disassembly of actuator............................................................................................. 8
2.1.3 Reassembly of actuator ............................................................................................ 11
2.1.4 Spring house reassembly.......................................................................................... 12
3 Components and spare parts .................................................................................................... 15
3.1 Parts list and sectional drawing........................................................................................ 15
4 Ordering procedure .................................................................................................................. 19
M516.01en 1
Service Instruction EHC
2 M516.01en
List of illustrations
Figure 1 – EHC-VC ......................................................................................................................... 16

Figure 2 – EHC-VSC (spring close) ................................................................................................ 17
Figure 3 – EHC-VSO (spring open) ................................................................................................ 18
Figure 4 – Type sign for valve with marked ordering data.............................................................. 19
M516.01en 3
4 M516.01en
1 General
1.1 Introduction
The electro hydraulic actuators (EHC) by CCI are double-acting piston actuators*. Actuation
control is performed by solenoid operation spool valves. The EHC actuator can be equipped with
built-in transducer with analog output (EHCE) or with digital output (EHCP).
The EHC actuators are available in three versions:
EHC* -VC: double-acting, no spring.

EHC* -VSC: double-acting, spring close.
EHC* -VSO: double-acting, spring open.
1.2 Cleaning and installation instructions
Special care should be taken to make sure the cylinder, particularly its internal parts, is kept clean
during installation and servicing.
1.2.1 Installation
Special attention has to be paid to the associated hydraulic pipe work. Mechanical or thermal stress
from the fixing points or from the pipes must be avoided as they cause distortion or misalignment
of the cylinder or its components.
Flexible pipes (hoses) shall be installed in such a manner as to avoid buckling, pinching, abrasion
or twisting. Check that sufficient slack is available to compensation for movement.
If the hydraulic supply pressure comes form another source than a CCI Hydraulic Supply Unit, it is
recommended to install a high pressure filter (PN 250) in the pressure line, “P”, close to the
hydraulic valve panel.
M516.01en 5
2 Maintenance
Hydraulic systems should be left in state of closed circuit as long as there are no signs that indicate
the necessity to open them. All parts are long life components, therefore preventive maintenance is
restricted to the outside of the actuators.
In case inner seals should leak or due to other significant indication of fault it may be necessary to
perform maintenance work on the actuator. To do this, remove the actuator from the valve and
perform all work in a clean workshop. A crane or hoist is normally not required for the smaller size
actuators.
NOTE! In case of only removal of actuator, not maintenance of actuator, the spring
housing is not required to be removed from actuator.
2.1 Disassmebly and reassembly
Make sure that the system is not in operation, controls off and system is
completely depressurized.
Make sure that the oil supply station is switched off and all hydraulic
pressure is relieved!
WARNING Hydraulic accumulators must be depressurized!
Actuators with spring close or spring open function contains prestressed

spring.
• Make sure the system is depressurized.

• Wash the complete actuator with a suitable solvent and dry. Special cleanliness is indicated
for the areas around the hose connections.
• Disconnect cable connectors from solenoids of spool valves (if mounted on actuator).
• Remove the position transducer by unscrewing it. Carefully pull the transducer out and
place it in safe, clean environment.
NOTE! For description of actuator disassembly and reassembly from valve, please see
latest product specific control valve manual. Please contact CCI for latest
manual.
6 M516.01en
2.1.1 Spring house disassembly
2.1.1.1 EHC – VSC (spring close)
NOTE! The housing contains a pre-stressed spring and should not be taken apart. The
bolts (Figure 2, position 12) shall never be loosened/removed.
1. Make sure the actuator piston rod is fully extracted.

2. Loosen the screws (Figure 2, position 13).
3. Remove the complete spring with housing from the actuator (Figure 2, position 5 and 11).
2.1.1.2 EHC – VSO (spring open)
1. Make sure the actuator piston rod is fully retracted.

2. Loosen the screws (Figure 3, position 9).
3. Remove the spring housing (Figure 3, position 7).
4. Mount a spring adjustment flange with threaded rods with sufficient length and nuts. The
flange is mounted against the pressure plate (Figure 3, position 5) and the threaded rods are
mounted with nuts through the holes for screws (Figure 3, position 9). Be careful to use
same number of rods as there are holes in bottom plate (Figure 3, position 8).
5. Tighten the nuts on the threaded rods until the clamp ring (Figure 3, position 4) can be
removed.
6. Uniformly loosen the nuts on the threaded rods until spring pre-stress is unloaded.
7. Remove the complete spring package (Figure 3, position 5,6,8).
M516.01en 7
2.1.2 Disassembly of actuator
2.1.2.1 EHC – VC
1. Unscrew the lower guiding ring (Figure 1, position 13) using the special tools from CCI.
2. Pull lower guiding ring carefully over the piston rod threads. Be careful not to damage the
sealings.
3. Pull the complete piston rod (Figure 1, position 7 and 10) carefully out of the cylinder.
4. Clean and inspect all parts.
NOTE! Damaged or corroded parts must be replaced.
8 M516.01en
sealings.
4. Unscrew and remove the upper guiding ring (Figure 2, position 15) using the special tools
from CCI.
M516.01en 9
2.1.2.3 EHC – VSO (spring open)
sealings.
4. Unscrew and remove the upper guiding ring (Figure 3, position 10) using the special tools
from CCI.
10 M516.01en
2.1.3 Reassembly of actuator
NOTE! Assembling dirty components will lead to hydraulic system failure or

hysteresis! Therefore do all work with the utmost care and cleanliness.
• Wash all components carefully in a suitable solvent.

• For drying purpose, use filtered compressed air and clean synthetic towels only.
• Prepare and lay out all components to be assembled.
• Inspect all parts to be assembled carefully. Discard defective parts and replace by new
ones.
NOTE! Never install old seals, packings and used lock washers.
1. Install all sealings. Make sure to install the softest piston rod seal (polyurethane) closest to
lip seal.
2. Install upper guiding ring (Figure 2, position 15 and Figure 3 position 10) using CCI
service tool (applicable for EHC-VSC and EHC-VSO).
3. Slide the complete piston rod carefully into the cylinder.
4. Install lower guiding ring (Figure 1, position 13 and Figure 2, position 23 and Figure 3,
position 18). Be careful not to damage the sealings.
NOTE! Be careful not to damage the sealings when sliding them passed the threads.
Tighten with suitable torque (see Table 1: Torque specification, [Nm]).
5. Reinstall position transducer (if any).

6. Check the high pressure oil filter.
7. Reinstall actuator to yoke (see latest product specific control valve manual).
M516.01en 11
2.1.4 Spring house reassembly
1. Install actuator, insert screws with new lock washers.

2. Tighten all yoke screws with a torque wrench at 50% of the specified torque (see Table 1:
Torque specification, [Nm]).
3. Tighten all yoke screws with a wrench according to specified torque (see Table 1: Torque
specification, [Nm]).
4. Install the complete spring with protective housing on actuator.
5. Tighten all screws (Figure 2, position 13) with torque wrench according to the specified
torque (see Table 1: Torque specification, [Nm]).
6. Reinstall the position transducer (if any).
NOTE! Never install old piston rod seals and used lock washers.
7. Check if the high pressure oil filter is clean (only if hydraulic supply pressure comes from
another source than CCI).
12 M516.01en
2.1.4.2 VSO (spring open)
1. Install actuator, insert screws with new lock washers.

2. Tighten all yoke screws with a torque wrench at 50% of the specified torque (see Table 1:
Torque specification, [Nm]).
3. Tighten all yoke screws with a wrench according to specified torque (see Table 1: Torque
specification, [Nm]).
4. Install the complete spring on actuator, by inserting the threaded rods into the upper flange
of the actuator. Lock with nuts on the threaded rods.
5. Uniformly tighten the nuts on the threaded rods until full spring pre-stress is achieved.
6. Install clamp ring (Figure 3, position 4) so the spring is correctly pre-stressed.
7. Loosen the nuts and remove the spring adjustment flange and the threaded rods.
8. Install the spring housing on the actuator.
9. Tighten all screws (Figure 3, position 9) with torque wrench according to the specified
torque (see Table 1: Torque specification, [Nm]).
10. Reinstall the position transducer (if any).
11. Check if the high pressure oil filter is clean (only if hydraulic supply pressure comes from
another source than CCI).
NOTE! Never install old piston rod seals and used lock washers.
M516.01en 13
Table 1: Torque specification, [Nm]

≤400°C
≤200°C
Bolt joint
Bolt joint
Bonnet – Cover plate
Yoke – Actuator
Yoke – Valve
8.8
21CrMoV57
Screw diam. Lubricated Dry Lubricated Dry
M8 18 20 15 17
M10 35 39 26 29
M12 61 68 45 50
M14 97 108 71 79
M16 148 165 109 121
M20 289 322 213 238
M24 500 558 368 411
M27 723 807 532 594
M30 987 1100 726 810
Avoid mounting the screws without a high temperature lubricant.
14 M516.01en
3 Components and spare parts

3.1 Parts list and sectional drawing
See next spread.
NOTE! Use CCI original parts or parts of approved material only.
M516.01en 15
11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10
17 18
Figure 1 – EHC-VC
1 Cable 10 Actuator stem

2 Position transducer 11 O-ring
3 O-ring 12 Support ring
4 Screw 13 Lower guiding ring
5 Tape bearing 14 Piston rod seal (Teflon)
6 Piston seal 15 Piston rod seal (Polyurethane)
7 Piston 16 Lip seal
8 Stop screw 17 Magnet
9 Cylinder house 18 O-ring
16 M516.01en
1 2 3 4 5 6 7 8 9 10 11 12 13 18 14 20 22 28 24 25
26 27 16 15 17 19 21 23
Figure 2 – EHC-VSC (spring close)
1 Position transducer 15 Upper guiding ring

2 Screw 16 Piston rod seal
3 Magnet 17 O-ring
4 Magnet cylinder 18 Tape bearing
5 Spring house 19 Piston seal
6 Rivet 20 Hydraulic piston
7 Product sign 21 Piston rod
8 Spring 22 O-ring
9 Pressure plate 23 Lower guiding ring
10 Stroke limitation 24 Piston rod seal
11 Base plate 25 Lip seal
12 Screw 26 Lip seal
13 Screw 27 Piston rod seal (Polyurethane)
14 Hydraulic cylinder 28 Piston rod seal (Teflon)
M516.01en 17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 25 19 20
21 24 22 23
Figure 3 – EHC-VSO (spring open)
1 Position transducer 14 Hydraulic cylinder

2 Magnet 15 Piston rod
3 Screw 16 Stroke limitation
4 Clamp ring 17 O-ring
5 Pressure plate 18 Lower guiding ring
6 Spring 19 Piston rod seal
7 Spring house 20 Lip seal
8 Bottom plate 21 Lip seal
9 Screw 22 Piston rod seal
10 Upper guiding ring 23 O-ring
11 Tape bearing 24 Piston rod seal (Polyurethane)
12 Piston seal 25 Piston rod seal (Teflon, PTFE)
13 Piston
18 M516.01en
4 Ordering procedure
Important!
When ordering parts, please state data marked with arrows below.
Type of valve:
Manufact. no:
Tag no:
Year:
Inlet:
Outlet:
Water:
CCI Valve Technology AB Box 603, 661 29 Säffle - SWEDEN
Connection Material Design p/t Test p

Type of valve Manufact. no.
Inlet --- --- --- --- ---
--- ---
Tag no. Year Outlet --- --- --- ---
--- --- Water --- --- --- ---
Figure 4 – Type sign for valve with marked ordering data
M516.01en 19
Service instructions
VLB
Steam conditioning valve
M573.02/4en
©CCI
Table of contents
1 Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.1 Removal of actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.2 Inspection and maintenance of valve interior . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.2.1 Dismantling for inspection of valve interior. . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.2.2 Crack detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.2.3 Erosion damages inside the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.3 Reconditioning of valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.4 Valve seat replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.5 Disassembly of valve bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.6 Inspection before reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.7 Disassembly/reassembly of BT-plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.8 Reassembly of valve bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.9 Stuffing box maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.10 Reinstallation of actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.10.1 Clean water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4.10.2 Contaminated water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4.11 Inspection of spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.11.1 Disassembly of OP spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.11.2 Reassembly of OP spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.11.3 Disassembly of SE spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.11.4 Reassembly of SE spray nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Components and parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Ordering procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
M573.02/4en Service instructions VLB I

©CCI
II Service instructions VLB M573.02/4en
©CCI
List of illustrations
Fig 1 Pressure seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fig 2 Valve stem, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fig 3 BT-plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fig 4 Stuffing box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fig 5 Yoke, welded design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fig 6 Good atomization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig 7 Clean water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig 8 Unsatisfactory atomization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig 9 Debris in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig 10 Cross-section of spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fig 11 Removing of nozzleholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fig 12 Cross-section of spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fig 13 Cross-section of nozzle head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fig 14 Cross-section of spray nozzle type SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fig 15 Removing of nozzleholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fig 16 Cross-section of spray nozzle type SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fig 17 VLB-B. Balanced plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig 18 VLB-T. Tight plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig 19 VLB-BT. Balanced and tight plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig 20 VLB-BC. Balanced plug with cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig 21 Type sign for valve with marked ordering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
M573.02/4en Service instructions VLB III

©CCI
IV Service instructions VLB M573.02/4en
©CCI
1 - Service and maintenance
1 Service and maintenance
1.1 General
Since BTG steam conditioning valves combine pressure control and
steam desuperheating in one unit, it is very important to follow the
following instructions carefully.
The throttling insert (seat body) is designed for replacement on site.
Ö Due to thermal stresses it is very important that any replaced part

is made of material approved by BTG.
1.2 Inspection
!!! The valve body inside and the internal parts of the valve must be
For a satisfactory service inspected periodically according to a
life length of this type of Plant Inspection and Preventive Maintenance Plan.
valve installations, always
make sure that all control A first inspection is indicated at the end of the commissioning period.
loops are in perfect Inspection of all internal parts of the valve should be carried out every
condition and function 15 - 20000 operating hours (typical interval).
properly.
For service and maintenance of Grafoil stem seal – see SI500.11.
Oscillating cooling water Cleaning methods for steam pipe systems – see SI500.10.
control and/or oscillating
pressure control may Check frequently
result in thermal fatigue
and can cause damage to • the pressure control system
the valve and its internal • the temperature control system
parts.
• that the cooling water cuts off when the steam valve closes
The valve body – upstream
and downstream – must all Check periodically
the time be kept drained • that the preheating/draining functions and that the insulation is
and preheated. Free water
in the system is not undamaged
allowed, neither in the • the condition of actuator, positioner and other actuator components
piping system nor in the
valve, as it may lead to • that area around the valve is kept clean and free from foreign particles
severe water hammer with
subsequent danger of
damage to persons and
material.
M573.02/4en Service instructions VLB 1

©CCI
1.3 Trouble Shooting
Symptom Probable Cause and Action
Pressure control does not function. See instruction manual for pressure trans-
mitter and pressure controller in question.
The valve does not make a full stroke. 1. Check that valve and actuator are
correctly mounted and adjusted.
2. Foreign particles in the valve. If yes, the

valve must be opened in accordance
with instructions in the following sections.
Temperature control does not function. 1. Temperature transmitter or temperature

controller does not function. See instruc-
tion manual for respective instrument.
2. Check that the water valve and its

actuator are correctly mounted and
adjusted.
3. Check the condition of the spray

nozzles, which are sensitive to water im-
purities. If the nozzles are out of function
due to particles in the water, they must
be disassembled and cleaned.
4. If the water is contaminated we

recommend installation of a filter –
100 µm.
The valve is not tightly closing. Inspect plug and seat.
1.4 Maintenance
1.4.1 Removal of actuator
1. Disconnect all electrical connections (if any).
2. Disconnect all hydraulic/pneumatic connections.
Ö Plug all openings immediately.
3. Mark exact position of valve and actuator stem in the stem coupling to
facilitate reassembly.
4. Remove coupling between actuator piston rod and valve stem.
5. Remove actuator and yoke.
Use a hoist which is adjustable in length for
Horizontal installation: Connect the hoist hook to three sling rope
straps, two on the yoke (one strap on each “leg”) and one on the top
of the cylinder. Connections should be adjustable in length.
Vertical installation: Connect the hoist hook to the sling ropes

strapped around each leg on the yoke.
2 Service instructions VLB M573.02/4en

©CCI
Caution: The centre of the gravity can be above the strapping

points. In the case, the yoke/actuator assembly must be secured in
such a way that the sling ropes cannot be twisted.
Caution: Make sure that piping, accessories, e.g. positioners, feed-
back transmitters, air filters. etc. will not be damaged during the lift-
ing phase.
!!!
1.4.2 Inspection and maintenance of valve interior
This valve is connected to a
steam system of high pres- Inspect valve interior as follows:
sure and high temperature. a. condition of valve body
Before opening any pres-
sure vessel, you must per- b. condition of valve seat
sonally make absolutely
sure that: c. condition of guiding surfaces
– the steam boiler is shut
down, the fluid system is d. condition of stem surface
completely depressurized e. condition of bonnet
and drained or that a suffi-
cient shut-off system in
1.4.2.1 Dismantling for inspection of valve interior
compliance with pressure
vessel standards is in- See fig 1 and drawing in section 2.1.
stalled, and closed, and that
water – even cold 1. Remove gland nut and gland bush from bonnet.
water – cannot enter the
piping system and that the 2. Insert a cylindrical pin in the hole underneath the stem thread –
valve material has been see fig. 2 and table 1 for dimensions. This to prevent the valve stem
cooled to a temperature from sliding through the stuffing box when the bonnet is removed.
below 60°C/140°F.
– draining or air vent valves 3. Remove lock nut/screws and cover plate and push bonnet, a bit, into
mounted in a joint pipe line the valve body.
are open and the fluid has
stopped flowing out. 4. Remove segment ring by driving through the dismantling holes in the
Failing to observe these valve body with a mandrel.
precautions means a very
5. Pull the complete valve bonnet together with the plug/stem out of the
high risk of lethal injury or
burns by hot steam valve body by means of a hoist until visual inspection of the valve in-
discharge or evaporating terior is possible.
hot water.

©CCI
Cover plate
Fig 1 Pressure seal
Segment ring
Dismantling hole
Spacer ring
Pressure seal gasket
Valve body
Bonnet

©CCI
Fig 2 Valve stem, dimensions
Table 1: Valve stem, dimensions Diameter (D) Diameter (d)

mm/inch mm/inch
18/0.7 4.2/0.15
22/0.9 5.2/0.2
28/1.1 6.2/0.24
32/1.3 6.2/0.24
36/1.4 8.2/0.3
40/1.5 8.2/0.3
45/1.8 10.2/0.4
50/2 10.2/0.4
56/2.2 12.2/0.5
63/2.5 14.2/0.55
72/2.8 14.2/0.55
80/3.2 16.2/0.65
90/3.5 16.2/0.65
100/3.9 18.2/0.7
112/4.4 18.2/0.7
125/4.9 20.2/0.8
140/5.5 20.2/0.8

©CCI
1.4.2.2 Crack detection

• Perform fluid penetrant test (PT) of the entire interior (as far as
accessible).
• In case small thin cracks (thermoshock cracks) are observed, remove
them by grinding. Recheck with fluid penetrant test.
• If seal weld cracks are observed, remove by grinding, preheat and
reweld with a soft nickel-based (≈ 70% Ni) electrode, e.g.
AWS ≈ ENiCrFe-2.
Preheating temp. 200 - 250°C/390 - 480°F.
• Where small impressions in the seat sealing surface (resulting from
clamped-in foreign particles) are observed, remove by lapping with
cast iron disc.
1.4.2.3 Erosion damages inside the valve

Erosion damages shall not occur inside the valve during normal service.
However, if by mistake, the inlet steam to the valve contains free water
the resulting erosion can cause damages on the valve internal parts and
the body.
Therefore, carefully check the inside of the valve if any damages can be
found caused by free water in the steam.
1.4.3 Reconditioning of valve seat

Particles in the medium can stick between plug and seat. These will give
marks that eventually can lead to a leaking valve. In most cases the valve
seat can be reconditioned several times by grinding or machining if
lapping isn't sufficient any more.
For reconditioning work it is necessary to have a high speed electric or
pneumatic tool and a robust fixture.
If the valve seat cannot be reconditioned by grinding or
machining/grinding, it has to be replaced.
1.4.4 Valve seat replacement

To cut out the seat, a seat cutting tool or machine is required.
Ö BTG can deliver seat cutting tools, specially fitted to the different
valve types.
1. Cut the seal weld with available tool or machine through its full depth.
2. Pull out the seat.
3. Reshape the weld grooves in the body by machining or grinding.

©CCI
4. Fit the new seat and prestress it in its right position.
Ö Protect the sealing surface of the seat with a copper or brass plate.
Secure the plate to the seat by means of a screw in the silencer ga-
ble or by means of a flat bar and clamp it to the downstream side of
the body.
Ö BTG can deliver prestressing tools, of own manufacture, specially

fitted to protect the seat sealing surface.
Ö Keep prestress firm during welding operation.
5. Carry out the seal weld in several passes with electrodes of diameter
2 - 2.5 mm/0.07 - 0.1". Use a soft nickel-based (≈ 70% Ni) electrode,
e.g. AWS ≈ ENiCrFe-2.
Ö Preheat welding area to 200 - 250°C/390 - 480°F.

(100 - 200°C/210 - 390°F if the material is carbon steel)
Ö This weld does not require any subsequent heat treatment.
6. Release the prestress as soon as the weld has cooled down.

7. Check the weld for end craters, cracks or slag inclusions on the
surface. Use penetrant.
8. Check contact between plug and seat by help of marking ink. The
contact area must be intact around the seat periphery.
Ö Lapping is required to obtain good tightness between plug and

seat.
9. Reassemble bonnet and actuator.
1.4.5 Disassembly of valve bonnet

1. Place extracted bonnet with stem/plug in horizontal position.
2. Remove stem/plug from bonnet. Check bonnet inside for
possible damages. If the plug is furnished with piston rings – also
check their condition.
Ö Plug and stem are shrink-fitted in B and T versions and cannot be

taken apart.
3. In case of leakage, remove stem packings. Replacement is normally

not necessary.
4. Remove stem guide, if required.
5. Remove spacer ring and pressure seal gasket from bonnet (only if
required).

©CCI
1.4.6 Inspection before reassembly

The following check routines are appropriate after e.g. clean blowing of
the valves.
• Check all mating surfaces for damages.
Recondition by lapping with carborundum, if necessary, i.e. blend-in
scratches or indentations due to clamped-in foreign particles.
• Check sealing surfaces with blue ink.
The contact area must be intact around the seat periphery.
• Carry out a thorough visual inspection of all parts that are to be
assembled.
1.4.7 Disassembly/reassembly of BT-plug

1. Remove the snap ring.
2. Unscrew the stem guide.
3. Pull out the stem.
Reassemble in reverse order.
Fig 3 BT-plug
Stem
Snap ring
Stem guide
Pilot plug
Rotation block
Pilot seat
Plug
Seat

©CCI
1.4.8 Reassembly of valve bonnet

See fig 1 and drawing in section 2.1.
1. Clean all parts and inspect them carefully! No defective components
must be reused. If necessary, recondition, repair or replace!
2. Polish all bonnet, stem and gland guiding areas. If necessary, also
polish stem guide surfaces.
3. Install stem guide in bonnet, if dismantled.
4. Install stem/plug in bonnet.
5. Insert new stem packing rings if the old rings are worn and require
replacement.
See section 1.4.9 or SI500.11 for service and maintenance of Grafoil
Stem Seal.
Ö Do not overfill gland with packing rings. Leave at least height of

one ring free to accept gland bush.
6. Insert gland bush, gland nut and screws. Tighten the stuffing box
slightly with the screws.
Ö Do not overtighten the stuffing box.
7. Secure stem from dropping through packing box by inserting a pin

through the hole in the stem — see fig 2 and table 1.
8. Apply a thin coating of a high temperature lubricant on the guide
surfaces for the bonnet in the valve body.
9. Lift the complete bonnet assembly with stem/plug by means of a hoist
and slide it carefully into the valve body.
10.Replace the pressure seal gasket and insert spacer ring, if dismantled.
11.Insert segment ring. Make sure the segment ring joints are not
positioned opposite to the dismantling holes!
12.Mount cover plate.
13.Install lock nut/screws. Preload pressure seal gasket by tightening
lock nut/screws. Screws must be tightened uniformly.
14.Mount the actuator yoke by means of screws. Use lubricant for high
temperature on the threads and new lock washers.
Ö Make sure that the yoke is correctly mounted.

©CCI
Table 2: Torque specification,

[Nm]
< 200°C < 400°C
Bolt joint Bolt joint

Yoke – Actuator Bonnet – Cover plate
8.8 Yoke – Valve
21CrMoV57
Screw diam. Lubricated Dry Lubricated Dry
M8 18 20 15 17
M10 35 39 26 29
M12 61 68 45 50
M14 97 108 71 79
M16 148 165 109 121
M20 289 322 213 238
M24 500 558 368 411
M27 723 807 532 594
M30 987 1100 726 810
Avoid mounting the screws without a high temperature lubricant.

©CCI
1.4.9 Stuffing box maintenance
!!! If the gland has no more tightening margin but does not yet leak, add an
adequate number (1 or 2) of packing rings.
Before opening any
pressure vessel, make Ö Do not overfill gland with packing rings. Leave at least height of
absolutely sure that the one ring free to accept gland bush.
fluid system is completely
depressurized! Opening Gland nut must at least engage as much that gland bush properly enters
an only slightly pressur- the bore of the stuffing box.
ized valve or being linked
to hot fluid may lead to If the stuffing box cannot be completed by adding of packings, proceed
severe injury or even as follows:
death!
1. Use standard extractor (corkscrew type) to pull out all used packings.
2. Thoroughly clean the stuffing box bore, the gland bush and the gland
nut.
Ö Take this opportunity to inspect condition of valve stem surface,

polish if necessary.
3. Insert new packing rings, 4-6 pcs depending on their height, one by
one.
Ö For service and maintenance of Grafoil stem seal – see SI500.11.
4. Reinsert gland bush and gland nut, tighten gland nut slightly.
Ö Do not overtighten the stuffing box.
5. After reinstallation of actuator, have valve carry out several full

strokes to check free movement of the stem.
6. Pressurize system and retighten gland nut if necessary.
Fig 4 Stuffing box

Make sure that the Gland nut
gland bush is well Gland bush
accepted in the
stuffing box Packing rings
Stem guide

©CCI
1.4.10 Reinstallation of actuator

1. Install yoke with dry-lubricated screws and tighten firmly, see table 2
for suitable torque.
2. Install actuator with dry-lubricated screws, new lock washers and
tighten firmly, see table 2 for suitable torque.
Ö Make sure that the actuator rod and the valve stem align — in both
end positions.
3. Install the coupling between the valve stem and the actuator piston
rod.
Ö To ensure that the valve is tight in closed position, relieve actuator

control piston 2 - 3 mm/0.08 - 0.12" from its bottom position before
mounting the coupling.
Ö Make sure that the threads on actuator and valve side match the
coupling threads correctly! If necessary, adjust by slightly turning
the valve stem by inserting a cylindrical pin through the drilled hole
of the stem near the threads, see fig 2 and table 1.
4. Tighten the coupling screws firmly.

5. Reinstall the feedback system and adjust (if any).
6. Check the limit switches and adjust (if any).
7. Make sure that the coupling moves freely in the yoke.
8. Connect the hydraulic/pneumatic piping.
9. Connect the electric cables (if any).
Ö Check the complete installation once more.
10.Put the actuator in service and make a test run.

11.Reinstall the thermal/acoustic insulation.
Ö The whole valve must be heat-insulated before start-up.
The valve is now ready for plant operation.

©CCI
Fig 5 Yoke, welded design

Actuator
Yoke
Screw
Stem coupling
Valve

©CCI
1.4.10.1Clean water
Fig 6 Good atomization

1 High waterpressure
2 Filter in waterline
Fig 7 Clean water

1 Nozzle closes
Even surface
1.4.10.2Contaminated water
Fig 8 Unsatisfactory
atomization
1 Low waterpressure
2 Debris in water
Fig 9 Debris in water

1 Nozzle will not close
Uneven surface

©CCI
1.4.11 Inspection of spray nozzles

1.4.11.1Disassembly of OP spray nozzles
!!! 1. Unscrew all nuts and washers and remove flange.

2. Loosen and remove nozzle holder, spacer ring and packing by
Before you open any
pressure vessel, you must mounting one of the screws in the center hole of the nozzle holder and
personally make pull it out.
absolutely sure that the
fluid system is completely 3. Spray atomizing nozzle is locked in position by means of lock washer
depressurized! To open a which is bent upwards against one of the flat sides of the nozzle.
valve that contains or is Release the locking by bending back the lock washer and unscrew the
connected to a hot media – nozzle.
even if it is only slightly
pressurized – may lead to 4. Check the nozzle for obstruction caused by dirt particles. Clean if
severe injury! required. Make sure the water channels in the nozzle are open. Check
the condition of the spring as well. If the seat surface is damaged or
the spring is worn – replace the complete nozzle.
Ö The nozzles might have been marked and must in that case be
remounted in the same position.
Ö Cleanliness is very important when working with nozzles.
Fig 10 Cross-section of spray

nozzle
Screw, nut
and washer
Nozzle stud
Gasket
Flange
Nozzle Spacer ring
Lock washer
Nozzle holder Packing

Fig 11 Removing of
nozzle holder

©CCI
1.4.11.2Reassembly of OP spray nozzles

1. Assemble spray atomizing nozzle and nozzle holder and secure the
nozzle with lock washer as previously.
2. Put a new gasket on nozzle holder and insert into nozzle stud. Make
sure that the old gasket is completely removed.
Ö Always change gasket
3. Replace – if necessary – packings, mount them together with spacer

ring and fit flange with screws, nuts and washers.
Fig 12 Cross-section of spray

nozzle
Screw, nut
and washer
Nozzle stud
Gasket
Flange
Nozzle Spacer ring
Lock washer
Nozzle holder Packing
Fig 13 Cross-section of nozzle

head
Pin
Nozzle plug Lock nut
Adjustment nut
Inner nozzle
chamber Spring for
Body pressure control
Water channel

©CCI
1.4.11.3Disassembly of SE spray nozzles
!!! 1. Unscrew all nuts and washers and remove flange.

2. Loosen and remove nozzle holder, spacer ring and packing by
Before you open any
pressure vessel, you must mounting one of the screws in the center hole of the nozzle holder and
personally make pull it out.
absolutely sure that the
fluid system is completely 3. Check the nozzle for obstruction caused by dirt particles. Clean if
depressurized! To open a required. Make sure the water and steam channels in the nozzle are
valve that contains or is open. If the water or steam injection areas are damaged – replace the
connected to a hot media – complete nozzle.
even if it is only slightly
pressurized – may lead to Ö The nozzles might have been marked and must in that case be
severe injury! remounted in the same position.
Fig 14 Cross-section of spray Gasket Steam inlet

nozzle type SE
Screw, nut
and washer
Nozzle holder
Flange
Spacer ring
Nozzle
Nozzle stud
Water inlet Packing
Fig 15 Removing of
nozzle holder

©CCI
1.4.11.4Reassembly of SE spray nozzles

1. Put a new gasket and packings on nozzle holder and insert into nozzle
stud. Make sure that the old gasket is completely removed.
Ö Always change gasket
2. Mount nozzle in the nozzle holder.

3. Replace - if necessary - packings, mount them together with spacer
ring and fit flange with screws, nuts and washers.
Ö See Table 2 for suitable torque.
Fig 16 Cross-section of spray Gasket Steam inlet

nozzle type SE
Screw, nut
and washer
Nozzle holder
Flange
Spacer ring
Nozzle
Nozzle stud
Water inlet Packing

©CCI
2 - Components and parts list
2 Components and parts list
2.1 Configurations
See next spread.
Ö Use BTG original parts or parts of approved material only.

©CCI
Stem/Plug
Gland bush
Gland nut
Stem packing
Lock nut
Stem guide Cover plate
Segment ring
Spacer ring
Inlet
Pressure seal gasket
Bonnet Fig 18 VLB-T. Tight plug.
Body
Outlet
Pressure reduction
unit
Fig 19 VLB-BT. Balanced

and tight plug
OP nozzle
Fig 17 VLB-B. Balanced plug. Fig 20 VLB-BC. Balanced

plug with cage.

©CCI
2.2 Ordering procedure

Important!
When ordering parts, please state data marked with arrows below.
Type of valve:
Manufact.No:
Tag No:
Year:
Inlet:
Outlet:
Water:
Fig 21 Type sign for valve with

marked ordering data

©CCI

©CCI

©CCI

©CCI
INSTALLATION,OPERATION,
MAINTENANCE MANUAL 100D
DRAG®
VELOCITY
CONTROL
ELEMENT
CUSTOMER NAME: Cethar Vessels Limited
PURCHASE ORDER:
PROJECT: Vandana Vidyut Ltd
STATION:
UNIT:
PROJECT NUMBER:
PART NUMBER SERIAL NUMBER TAG NUMBER

A66901 AA66901-01-02 01/02MAN07-AA201
CCI Valve Technology GmbH PH: +43-1-869.27.40

Lemboeckgasse 63/1/2 FAX: +43-1-865.36.03 REV: NC
A-1230 Vienna, Austria EMAIL: CCI@CCIValve.at
TABLE OF CONTENTS
SECTION 1 1
SAFETY IS GOOD BUSINESS 1
IMPORTANT TECHNICAL ASSEMBLY/DIS-ASSEMBLY INSTRUCTIONS ARE INCLUDED IN THE DRAWINGS,
SEE SECTION 8.INTRODUCTION 1
INTRODUCTION 2
SECTION 2 3
HANDLING 3
SECTION 3 13
PNEUMATIC ACTUATOR-YOKE ASSEMBLY 13
SECTION 4 17
TRIM ASSEMBLY 17
SECTION 5 23
ACTUATOR 23
SECTION 6 27
MAINTENANCE 27
SECTION 7 34
SPECIAL VALVE COMPONENTS 34
SECTION 8 35
VALVE DRAWINGS AND BILLS OF MATERIAL 35
SECTION 9 36
VENDOR LITERATURE 36

Lemboeckgasse 63/1/2 FAX: +43-1-865.36.03 REV: NC
SECTION 1
SAFETY IS GOOD BUSINESS
DURING THE COURSE OF MAINTENANCE AND INSPECTION ACTIVITIES ON CCI

EQUIPMENT, YOU ARE CAUTIONED TO ADHERE TO THE INSTRUCTIONS
CONTAINED IN THIS MANUAL AND TO INSIST UPON STRICT ADHERENCE TO YOUR
PLANT SAFETY POLICIES IN ORDER TO AVOID POSSIBLE DAMAGE TO
EQUIPMENT AND INJURY TO PERSONNEL.
OUR SERVICE DEPARTMENT IS PREPARED TO DISCUSS SOLUTIONS TO ANY

PROBLEMS CONCERNING THE MAINTENANCE AND INSPECTION PROCEDURES
APPLICABLE TO CCI EQUIPMENT. PLEASE DIRECT ALL INQUIRIES TO:
CCI Valve Technology GmbH
Lemboeckgasse 63/1/2
A-1230 Vienna, Austria
PHONE: +43-1-869.27.40
FAX: +43-1-865.36.03
EMAIL: CCI@ CCIVALVE.AT
WHILE THIS INFORMATION IS PRESENTED IN GOOD FAITH AND BELIEVED TO BE

ACCURATE, CCI DOES NOT GUARANTEE SATISFACTORY RESULTS FROM
RELIANCE UPON SUCH INFORMATION. NOTHING CONTAINED HEREIN IS TO BE
CONSTRUED AS A WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED,
REGARDING THE PERFORMANCE, MERCHANTABILITY, FITNESS, OR ANY OTHER
MATTER WITH RESPECT TO THE PRODUCTS, NOR AS A RECOMMENDATION TO
USE ANY PRODUCT OR PROCESS IN CONFLICT WITH ANY PATENT. CCI
RESERVES THE RIGHT, WITHOUT NOTICE, TO ALTER OR IMPROVE THE DESIGNS
OR SPECIFICATIONS OF THE PRODUCTS DESCRIBED HEREIN.
IMPORTANT TECHNICAL ASSEMBLY/DIS-ASSEMBLY INSTRUCTIONS ARE

INCLUDED IN THE DRAWINGS, SEE SECTION 8.

Lemboeckgasse 63/1/2 FAX: +43-1-865.36.03 PAGE 1 OF 34
INTRODUCTION
1.1 GENERAL DESCRIPTION

CCI Control Valves are designed to provide
solutions to control valve problems in a wide
range of severe service applications. CCI
DRAG® Technology provides specified
control and shut-off, with longer intervals
between maintenance for increased
plant production.
1.2 PRINCIPLE OF OPERATION

High fluid velocities through the trim are a
principal source of severe service control
valve problems. CCI’s patented DRAG®
disk stack controls flowing velocities through
the valve trim by forcing the process fluid
through a tortuous path of right angle turns.
The resistance to flow provided by these
turns (or stages) limits the trim exit velocity,
regardless of the pressure drop. This
reduction in velocity greatly reduces
cavitation, erosion, high noise, and pipe
vibration. For some applications, CCI offers
custom designed cage trim. The
configuration, size and quantity of passages
in the cage are designed to provide the
required flow capacity and valve
characteristic without loss of velocity control.
1.3 INTRODUCTION
This manual has been prepared by CCI
engineers, designers and maintenance
personnel to assist you in obtaining many
years of satisfactory service from your
control valve.
Before beginning any major work, we

recommend that you read this manual
carefully. If any questions arise please
contact your local representative or call
the customer service manager for
technical assistance.

SECTION 2
HANDLING
2.1 SCOPE by contract, CCI products are packaged for

domestic shipping and indoor storage.
This Section describes recommended
procedures for receiving, storing, handling, and After the shipping container is unloaded at the
installing CCI control valves. site, the container should be inspected for
damage. Joints and seams should be
2.2 INTRODUCTION inspected for signs of separation.
In order to inspect the valve, the container lid

ALL APPLICABLE REGULATIONS AND can be safely removed without reducing the
SPECIFICATIONS SHOULD BE FOLLOWED. structural integrity of the container. If damage
GOOD GENERAL PRACTICE SHOULD BE to any part is suspected, carefully check the
USED FOR ALL INSTALLATION AND equipment against the packing list. Make a
MAINTENANCE ACTIVITIES. note of any loose, damaged, or missing parts.
Notify both the freight company and your CCI
Every CCI control valve is custom designed for
contract administrator.
a specific application and a specific set of
operating conditions. The control valve drawing
in Section 8 provides complete information on
2.4 STORAGE
valve design conditions, dimensions, weight,
and general arrangement. A nameplate The control valve may have been shipped
attached to every control valve lists the design either disassembled, or with spare parts. Valve
conditions for that particular control valve. trim parts, including plug assemblies, seat
rings, disk stacks, cages, spacers, and balance
2.3 RECEIVING AND INSPECTION cylinders should be coated with rust inhibitor,
and placed in a separate container. Seat ring
and plug seating surfaces should be protected
Shipping and packing documents are attached
with tape. These protective coverings are
to or packed in the control valve container.
removable.
Quality assurance documents, operation and
maintenance manuals, and drawings are A desiccant should be added to the container,
packed in the container when specified by the and replaced periodically.
purchaser. THESE DOCUMENTS SHOULD
BE IMMEDIATELY DELIVERED TO THE All parts for the control valve should be stored
APPROPRIATE PLANT MANAGER, PROJECT in a fire resistant, weather-tight, and well-
MANAGER, OR ENGINEER. ventilated building. The parts should not be
exposed to temperatures below -20° F (-29° C)
or above 120° F (48° C). The storage area
WARNING should not be subject to flooding. The floor
THE CONTROL VALVE IS VERY HEAVY. IF should be paved or similarly level, firm,
THE VALVE IS NOT HANDLED PROPERLY, protected, and well-drained. All parts should be
SERIOUS INJURY CAN OCCUR. SUITABLE placed on pallets or shoring to permit air
LIFTING EQUIPMENT MUST BE PROPERLY circulation.
USED AND ATTACHED. DO NOT USE THE
ACTUATOR FOR LIFTING/HANDLING THE To avoid elastomer deterioration, both
VALVE ASSEMBLY. pneumatic and hydraulic actuators must be
cycled at least every six (6) calendar months. A
The container is marked with instructions for minimum of three (3) full strokes is required
handling and storage. These directions should using the normal operating medium.
be strictly followed. Unless specifically required

2.5 REMOVAL FROM SHIPPING The flow direction is indicated by an arrow on
CONTAINER the body. The valve must be installed in the
correct flow direction.
The unit is shipped in a container designed to The control valve is normally installed in a
support both the body assembly and the vertical position, with the valve actuator pointed
actuator assembly. To remove the control straight up. If the assembly is to be installed in
valve from the shipping container, carefully any other orientation, then adequate supports
place appropriate slings around the valve yoke may be required for the valve actuator
or actuator and lift with a hoist. assembly.
For flanged valves, complete the bolting of the

WARNING valve in line. For welded-end valves, see
Section 2.7 below.
Applicable codes, regulations and industrial
practices for handling (hoisting and lifting) loads 2.7 WELDING OF VALVE BODY TO PIPE
must be followed. These include but are not
AND POST-WELD STRESS RELIEF
limited to the following:
A. Slings should be free of kinks and twists.
All welding is to be perfomed in accordance
B. Position the lifting hook over the load so
with the appropriate plant procedures.
that the load does not swing when lifted.
C. The crane operator shall see that the load
is well secured and balanced. CAUTION
D. The crane operator shall avoid carrying The heat of welding and post weld heat
loads over people. treatment can damage valve seals and
compromise hardness and wear capabilities.
Remove ALL valve trim PRIOR to welding. For
CAUTION a valve with pressure test or flushing kit
Use care when lifting or handling the control installed, it is not necessary to remove this kit
valve to ensure that the accessories and lines before welding and stress relief.
are not damaged.
The control valve has been cleaned, inspected, CAUTION

and sealed at the factory prior to shipment. Do not use the plug, stem, or actuator shafts for
Protective covers have been installed in the grounding during welding operations.
valve inlet and outlet. These covers prevent the
entry of foreign matter into the valve. No Before reassembly with valve trim, thoroughly
additional cleaning should be required. After flush the valve body to remove weld slag and
the protective covers are removed, the interior residue, even if a backing strip is used. See
of the body should be inspected in order to section 2.8.
ensure that the valve is free of contaminants. If
cleaning is required, refer to Section 6.
2.8 LINE FLUSHING AND CHEMICAL

CAUTION CLEANING
Do not mar the weld preps of welded-end
valves or the sealing surfaces of flanged valves. During new construction, or major repair of
existing equipment, debris is generated from
2.6 INSTALLATION the processes of cutting, machining, grinding,
welding, erecting and installation. If not
After the control valve has been removed from properly addressed, this debris can result in
the shipping container, lift and rotate the control damage to the control valve trim, improper
valve into its installed position using a hoist and operation of the control valve and improper
sling. operating of the plant. The best time to

address this problem is during the construction the atmosphere. A mirror target at the outlet
or major repair phase. of the pipe is used to check if the pipe is
clean.
Damage from Debris
Since this temporary piping usually creates
The most common debris generated during
a low back pressure, the steam blowing is
construction or major repair is weld slag
performed at a lower pressure than normal
(sharp edged particles) and weld splatter
system operation. The flow rate of steam
(small hard beads of weld or base material).
used for flushing should be one that results
Unaddressed weld slag and splatter can in a slightly higher dynamic pressure than
become trapped between the tightly the normal operation of the system. This
toleranced modulating parts of a control ensures that all foreign matter that can be
valve, resulting in gouges and deep sharp- transported by the steam, is removed prior
edged scratches. Modulating a scratching to commissioning.
surface through a seal can cause the seal to
Equipment which would be sensitive to
fail leading to additional problems such as
damage during flushing, such as tight
trim erosion, loss of guiding and vibration.
toleranced control valve trim components,
Debris trapped between moving parts with should be removed, blocked or isolated. A
hardened or overlaid surfaces can result is list of components to be removed should of
stuck hardware and loss of control. be prepared as part of the flushing
Frequently the damage done by this debris procedure. Ball valves should be flushed in
requires the replacement of parts to restore the full open position.
the control valve’s capabilities.
Following the completion of the flushing, all
pipe work should be free from debris, dirt,
and temporary protective coatings.
Dedicated Flushing Tools

Typically, control valves are used as the
connecting point between the permanent
system piping and the temporary flushing
piping. To protect the permanent control
valve trim during this process, it should be
replaced with a set of dedicated flushing trim
components.
In most cases, the internal parts of the

control valve must be removed before the
valve body is welded into the pipe. After the
valve has been welded to the pipe, the
dedicated flushing components can be
installed. The pipe can then be exposed to
the flushing process.
Following the flushing process, the

Line Flushing temporary piping and dedicated flushing
tools are removed and the valve cleaned
The best way to avoid debris problems is by internally. The permanent trim components
flushing the piping system during of the valve and actuator can then be
construction with steam. Typically, the reinstalled. The functionality and
flushing fluid passes through the pipe performance of the control valve must then
system to be cleaned, passes into a be checked before it’s commissioning.
temporary pipe system, dedicated for the
flushing process, and then vents directly to

Dedicated flushing components for control containing halogens should not be used on
valves can have two configurations: “blow austenitic stainless steel surfaces as they
through” and “blow out.” will contribute to the potential for stress
corrosion cracking.
In a “blow through” configuration, the
flushing medium flows through the control When chemical cleaners that may result in
valve along the same path and in the same adverse reactions are used, sensitive items
direction the normal operating fluid would. that can be damaged by the cleaning
medium should be removed or blanked off.
In a “blow out” flushing configuration, the Removed or blanked off items shall be
piping downstream of the control valve is cleaned separately prior to reinstallation.
blocked and the flushing medium is routed
through the control valve bonnet, which is The systems to be cleaned shall have high
directly connected (by flange or weld) to the and low point vents and drains. Dead legs
temporary flushing piping. shall be avoided.
CCI Valve Doctors are available to provide If chemical cleaning occurs more than 3
expert assistance in reviewing required months prior to start up of commissioning
commissioning and flushing material. activities, the system should be preserved
with nitrogen.
Chemical Cleaning
Dedicated Cleaning Tools
In addition to debris from weld slag and
splatter, oils, grease, preservatives, mill Occasionally, it is desirable to use the
scale and corrosion products will need to be control valve for throttling during the
removed from the boiler and piping systems chemical cleaning process. In these cases,
prior to plant commissioning. To remove adverse reactions between the permanent
these elements, chemical cleaning is trim materials and the cleaning agents may
required. necessitate the use of temporary
expendable trim components of a non-
Chemical cleaning typically contains the reacting material for the throttle process.
following processes: CCI, has and can supply these temporary
expendable trim components.
• Degreasing
• Chemical Cleaning / Descaling

2.9 INSULATING HOT VALVES
• Neutralization
• Passivation
CAUTION
• Water Flushing A valve intended for hot service must have its
valve body and bonnet thoroughly insulated
• Drying before initial use.
The maximum temperatures used during Proper insulation of the valve body and bonnet
these operations should not exceed the will:
maximum design temperature for the
system. a. Protect the actuator and its accessories from
damage due to excessive heat.
Certain chemical cleaners can have an
adverse reaction with pipe material and b. Assist in keeping the valve body adequately
control valve trim materials. For example, warm when the valve is closed.
nitride hardened surfaces may deteriorate in
some chemical cleaners containing acids.
Similarly, degreasing cleaning agents

At least 4 inches (100 mm) of high efficiency
thermal insulation should be applied to all
exterior surfaces of the valve body and bonnet.
CAUTION
Insulation should not be applied to the actuator
yoke legs. The actuator yoke legs must be kept
open to the air for efficient heat removal.
Commissioning of Control Valves

Prior to their initial operation, the condition of
the valve bodies and trim should be
inspected, and the following checks should
be performed.
• Control Valves should be properly stored

FIGURE 2-1 Valve Insulation and handled.
• It may be necessary to disassemble the

2.10 COMMISSIONING CHECKLIST Control Valve prior to welding into the
process line. If so, this should be verified
The commissioning period is a critical point in per the CCI supplied Maintenance
the history of a plant. The commissioning Manual.
period for a Control Valve is no less important.
• Following the welding of the Control Valve
Problems detected during this period can be into the process line, a subsequent stress
resolved with a fraction of the time, effort and relief should have been performed.
most importantly, cost of those problems
detected during plant operation. • It may also be necessary to disassemble
the Control Valve prior to line flushing or
It is always recommended to have CCI Service chemical cleaning of the process line. If
Technicians available during the commissioning so, this step should be verified.*
process.
• Control Valves should be inspected for
surface rust on the internal trim or external
body.
• Control Valves should be inspected to

ensure they are free of trash and debris.
• It should be verified that the Control Valve

is in the proper flow orientation.
• If the Control Valve is in a steam system,

the system piping, both upstream and

downstream of the valve should have Pneumatic Actuator Commissioning Checklist
proper drainage.
The following checks should be performed
NOTE: Refer to Section 2.8: Line Flushing on the air supply line to the CCI Actuator:
and Chemical Cleaning
• The size of the connection from the air
If it is necessary to disassemble a Control supply should be equal to or greater than
Valve, the following checks should be that which is shown on the CCI Top
performed prior to the re-assembly. Assembly Drawing.
• The correct tools for assembly (lifting • The air supply to the CCI actuator should
eyes, torque wrenches) should be be provided via flexible lines or
available compression fittings. No welded
connections should be present.
• Torque wrenches should be calibrated.
• Prior to connection to the CCI actuator, all
• Adequate quantities of CCI’s air lines should have been blown out to
recommended lubricant should be remove any contamination or moisture.
available.
• The supply pressure should not exceed
• Adequate spare parts (soft goods and the pressure requirements listed on the
hard goods) should be available. CCI Top Assembly Drawing. This should
be confirmed with a calibrated gage.
• Disassembly and reassembly of the
Control Valve must be performed • Pressure settings for all filter regulators
according to the supplied Maintenance should be checked against the CCI Top
Manual. Assembly Drawing.
Commissioning of Control Valves with Spray Prior to initial operating, the following checks
Water Injection should be performed on the CCI Actuator
and Control Schematic Accessories:
If the supplied Control Valve includes spray
water injection, or operates in conjunction
with a downstream desuperheater, the
following additional checks should be
performed.
• The water should be properly filtered to

prevent plugging or wear of the spray
water injection nozzle(s).
• The injection nozzles should be inspected

to dirt or debris.
• The control algorithm for the system

should be reviewed to ensure that spray
water injection will not occur prior to the
opening of the Control Valve.**
• Disassembly and reassembly of the spray

injection nozzles must be performed
according to the supplied Maintenance
Manual.
NOTE: Refer to Section 2.16: Control

Algorithms for Turbine Bypass Systems

• If required, anti-contamination (or bug • The positioner linkages should be
screens) should be present and correctly inspected for damage or potential binding
mounted. problems.
• The orientation of all accessories should 2.11 START-UP AND OPERATION

allow for proper drainage and prevent
water or contaminant collection. When reassembling the valve, verify that all
valve body assembly and actuator bolting is
• The electrical signal strength and voltage torqued in accordance with the proper
of any solenoid valves present should be assembly technique outlined in this manual.
verified. The power supply should be
within +/- 10% of required. Verify that all required utilities, including
pneumatic, hydraulic, and electric supplies and
• The operational mode of all present signals, are cleaned and properly sized,
solenoids (fail open, fail closed, fail in connected and adjusted. Refer to the valve
place), should be verified. drawing in Section 8.
• If the Control Valve process fluid (natural Permanent electrical, hydraulic or air supply
gas) is used for the actuator air source, lines should not be installed where they will
ensure component exhaust is vented to a interfere with access to the valve body or
safe location. actuator for maintenance or removal. Flexible
lines with reusable couplings should be used to
If the Control Valves operates at extreme
bring utilities to the valve from the permanent
temperature services (>425oC or <-29oC),
supply lines.
the Control Valve should be sufficiently
insulated to protect the positioner and Verify that all control and accessory
accessories. components are connected and correctly
adjusted. Refer to the valve drawing in Section
If the actuator components will be exposed
8.
to extreme temperature service, CCI should
be notified at the time of order. Clean actuator shaft of all foreign materials.
Functionality Test Checklist Inspect all connections for leakage.
Prior to initial operating, the following Check the tightness of the packing flange nuts.
functionality tests should be performed on After moving the stem up and down, re-tighten
the CCI Control Valve, Actuator and the stem clamp bolts and re-check the packing
Accessories. nut tightness (turn approximately 1/6 turn each
nut). It is also recommended that the packing
• The Control Valve should be stroked to
nut tightness be checked when the valve gets
the fully open and fully closed position.
hot for the first time.
• The opening, closing and trip speed
Stroke the control valve to check for proper
should be verified.
operation, calibration of all controls and
• The operational mode of all present feedback devices.
solenoids (fail open, fail closed, fail in
place), should be verified. 2.12 INSTRUCTIONS FOR ACTUATORS
• If the Control Valve process fluid (natural The installation, set-up and start-up of the
gas) is used for the actuator air source, actuator and controls should be supervised by a
ensure component exhaust is vented to a CCI control and instrumentation technician. For
safe location. information on the actuator and controls see
Sections 5 and 8.

On some pneumatic actuators, a bypass valve 2.13 POSITIONER CALIBRATION
assembly is installed. Verify that the bypass
valve on the actuator is closed (see Figure 2-2). See vendor literature in Section 9 for proper
setup and calibration of the positioner.
Lubrication of the positioner linkage (refer to

Table 5-2) will ensure good modulating control.
CAUTION
The positioner must be properly calibrated in
order to have full seating load when the
actuator is in the closed position. Premature
trim degradation may occur if the calibration is
incorrect.
FIGURE 2-2 Actuator Bypass Valve For positioners that do not auto-calibrate, the
Positions following procedures and signal ranges must be
used during positioner calibration.
If a manual override is installed, verify that it is
in the proper position and is disengaged (refer 1. For “Increasing Signal Opens” valves,
to section 7). move the stem in the closing direction until
the signal is equal to the high end of the
If a Bailey positioner is used, verify that any “low” tolerance band shown in Table 2-1.
bypass valves in the positioner are in the The valve must not be fully closed at this
AUTOMATIC position. point. Decrease signal to the low end of the
“low” tolerance band. The valve shall have
For electric, hydraulic, and manual actuators, closed at or before reaching the low end of
see Section 9 for the manufacturer’s the tolerance band. Increase the signal to
recommended procedures for installation, start- the low end of the “high” tolerance band,
up, and operation. Table 2-1. Ensure that the valve is not fully
open at this point. Increase the signal to the
NOTE: high end of the “high” tolerance band. The
Torque and limit switches are preset at the valve shall be fully open at or before
factory. However, weakening of the reaching the high end of the tolerance
belleville springs may cause the settings to band.
change over time. See actuator
manufacturer’s recommendation for spring 2. For “Increasing Signal Closes” valves,
adjustment. move the stem in the closing direction until
the low end of the “high” tolerance band is
Flush all hydraulic lines and blow all reached. Ensure the valve is not fully
pneumatic lines clean prior to connecting the closed at this signal. Increase the signal to
lines to the actuator and controls. Small the high end of the “high” tolerance band.
particles of debris can clog or damage the The valve shall be closed at or before
controls. reaching the high end of the tolerance
band. Decrease the signal until the high
Verify that the proper hydraulic oil is used end of the “low” tolerance band is reached.
prior to connecting the hydraulic lines to the Ensure the valve is not fully open at this
actuator and controls. The use of an signal. Decrease the signal to the low end
incorrect oil can cause leaks and fouling. of the “low” tolerance band. The valve shall
be fully open at or before the low end of the
tolerance band.

Table 2-1. Positioner Calibration
SIGNAL RANGE LOW BAND HIGH BAND
3 to15 psig 3.1 to 3.6 14.4 to 14.9
3 to 27 psig 3.2 to 4.0 26.0 to 26.8
Full Range 6 to 30 psig 6.2 to 7.0 29.0 to 29.8
4 to 20 mA 4.2 to 4.8 19.2 to 19.8
-10V to +10V -9.8 to –9.1 9.1 to 9.8
3 to 9 psig 3.1 to 3.4 9.0 to 9.3

9 to 15 psig 8.7 to 9.0 14.6 to 14.9
3 to 15 psig 3.2 to 3.6 15.0 to 15.4
Split Range 15 to 27 psig 14.6 to 15.0 26.4 to 26.8
6 to 18 psig 6.6 to 6.2 18.0 to 18.4
18 to 30 psig 17.6 to 18.0 29.4 to 29.8
4 to 12 mA 4.2 to 4.5 12.0 to 12.3
12 to 20 mA 11.7 to 12.0 19.5 to 19.8
2.14 SNAP ACTING RELAY

CALIBRATION
NOT APPLICABLE

SECTION 3
PNEUMATIC ACTUATOR-YOKE ASSEMBLY
3.1 SCOPE
This section describes the procedures for
disassembly and assembly of the actuator-yoke
from the valve.
3.2 DISASSEMBLY
Refer to the valve drawing in Section 8 for valve
actuator information.
CAUTION
To avoid personal injury and damage to the
process system, isolate the actuator from the
system before attempting disassembly.
Isolate the control valve from the system

pressure.
Bleed the air from the utility lines and make

sure that there is no pressure left in the system.
Disconnect all utility lines. The valve should
now be in the fail position as shown on the
valve drawing in Section 8.
Figure 3-1 Actuator / Yoke Assembly Lifting
Attach a sling to the actuator assembly (see
Arrangement
Figure 3-1).
If a bypass valve is installed on the actuator Slowly relieve all air pressure from the actuator
assembly, be certain it is closed. assembly.
If a Bailey positioner is used, be certain the by-

pass valve in the positioner is in the CAUTION
AUTOMATIC position.
Use care to follow normal safety procedures and
Loosen but do NOT remove the bonnet nuts the following instructions when removing tension
(two turns loose from finger tight). on the stem clamp.
Install a temporary air line, with a manually
controlled pressure regulator installed, to the
upper cap air port of the actuator assembly.
Gradually apply sufficient air pressure to the

actuator assembly to break the bonnet loose at
the body assembly. Do not exceed the supply
pressure listed on the valve drawing in Section
8.

FIGURE 3-2 Stem / Actuator Shaft FIGURE 3-3 Yoke / Bonnet Connection
Connection
3.3 ASSEMBLY
Remove the stem clamp. If necessary remove
any linkages. Note the mounting position of Refer to the valve drawing in Section 8 for
linkages for re-assembly. (see Figure 3-2). actuator information.
Disconnect the temporary air line. Attach a sling to the actuator assembly (see
Figure 3-1).
Remove the packing flange. If live-load,
remove belleville springs. If a bypass valve is installed on the actuator
assembly, be certain it is closed.
Remove the yoke clamp, mounting bolts, or
spud nut as supplied (see Figure 3-3). Install an air line to the lower cap air port and
apply sufficient air pressure until the actuator
Lift the actuator-yoke assembly from the body stem goes to the mid-stroke position. Make sure
assembly, taking care not to scratch the stem that the stem does not retract into the end cap.
with the yoke. If required move the actuator
assembly to a clean work area for disassembly. NOTE:
The yoke can be rotated radially to position
the yoke arms as shown on the valve drawing
in Section 8.
Carefully place the actuator assembly on the

bonnet taking care not to scratch the stem with
the yoke.

Attach the yoke to the bonnet using the yoke
clamp and eye bolts, mounting bolts, or spud WARNING
nut as supplied and torque per Table 3-3. The positioner must be properly calibrated in
order to have full seating load when the control
Lubricate the packing flange nuts and the element is in a closed position. Premature trim
threads of the eyebolts or packing flange studs. degradation may occur if calibration is incorrect.
See Table 4-1 for recommended lubrication. Refer to Section 2 for positioner calibration.
Install the packing flange and nuts. Torque the Check for leakage.
nuts per Table 3-2.
Slowly relieve air pressure from the lower cap

air port.
Install an air line, with a manually controlled

regulator installed, to the upper cap air port .
Slowly apply sufficient air pressure to extend

the actuator shaft until it contacts the plug stem.
Install the stem clamp to secure the plug stem

to the actuator shaft and torque per Table 3-1.
Torque the stem clamp bolts evenly in a cross
pattern. As the bolts are tightened, keep the
gap equal on both sides of the stem (refer to
Figure 3-2).
If necessary, install linkages in mounting

positions noted during disassembly.
Slowly relieve air pressure from the actuator

assembly, allowing the internal parts to seek
the relaxed position.
Stroke the valve three times to equalize the

packing compression. Re-torque the packing
flange nuts per Table 3-2.
If live-load packing is used, install the parts as

shown in Section 7.
Install the accessory assemblies in accordance

with the valve drawing in Section 8.
Remove the temporary air lines and install all

permanent utility lines.
Check the operation and calibration of the

actuator.

Table 3-1. Recommended Stem Clamp Torque
STEM SIZE TORQUE BOLT SIZE
(in) (ft-lbs) (N-m) (in)
5/8 5-10 10-15 1/4

1 20-25 25-30 3/8
1-1/2 45-50 60-70 1/2
2 90-100 125-135 5/8
Table 3-2. Recommended Packing Nut Torque

FOR TEFLON PACKING
STEM SIZE BOLT SIZE TORQUE
(in) (in) (lbf-ft) (N-m)
5/8 5/8 - 11 10 15
1 3/4 - 10 15 20
1-1/2 3/4 - 10 25 35
2 7/8 - 9 30 40
Table 3-3. Recommended Yoke Clamp Torque
(in) (ft-lbs) (N-m) (in)

5/8 90-100 125-135 5/8
1, 1-1/2 135-150 185-200 3/4

SECTION 4
TRIM ASSEMBLY
4.1 SCOPE Remove the bonnet from the body. Be sure

that the plug/spindle assembly remains in the
This Section describes the procedures for body. See Figure 4-1.
disassembly and assembly of the valve trim.
Remove the gasket from the body.
4.2 DISASSEMBLY
Disassembly of the actuator-yoke assembly is
required. Please refer to Section 3 for
instructions.
Using the bonnet torque pattern described in

Section 4.3, loosen each bonnet nut 1/8 turn at
a time. Repeat the process until the nuts are
loose.
Attach a yoke clamp and sling to bonnet, as

shown in Figure 4-1.
FIGURE 4-2 Plug assembly lifting

arrangement
Carefully remove the guide bushing and plug

seal from the bonnet or bonnet spacer making
sure the metal parts are not damaged.
Remove the yoke clamp and sling from the

bonnet and place them around the plug stem
with the stem clamp. Using the sling, remove
the plug/spindle assembly from the body (see
Figure 4-2).
FIGURE 4-1 Bonnet lifting arrangement

FIGURE 4-3 Packing removal FIGURE 4-4 Disk stack lifting arrangement
Remove the packing follower. Remove the Refer to Section 6 for cleaning and inspection
packing set using the packing removal tool, see procedures.
Figure 4-3. Be careful not to damage the
stuffing box. 4.3 ASSEMBLY
Remove the spacer, taking care not to damage Prior to assembly, make sure all parts are
the inside diameter of the bonnet. Use a bar clean. Refer to Section 6 for cleaning and
stock of the same diameter as the valve stem inspection instructions.
(see Figure 4-3). An air blast is usually helpful
in removing all loose material.
Lift the disk stack/cage assembly from the

body. If lifting holes are provided, attach two
eye bolts and a sling. (See Section 7 for
disassembly & assembly of separable disk
stack, if applicable).
Carefully remove the seat ring from the body,

taking care not to damage the seating surface.
Remove the seat ring spacer if provided.
Remove the flexitallic gasket(s) from the seat

ring.
FIGURE 4-7 Seat ring gasket installaion

Apply a lubricant (refer to Table 4-1) on the
flexitallic gaskets and place them in the grooves
of the seat ring.
Position the seat ring in the body. Be certain

the seating surface of the seat ring is upward
(see Figure 4-7). Rotate the seat ring several
times to make sure it is fully seated in the body
recess.
If provided, place the seat ring spacer in the

body.
Lower the disk stack/cage assembly into the

body until it registers on the seat. Make certain
the end marked “seat end” is placed on the seat
FIGURE 4-8 Plug seal configuration
ring. If lifting holes are provided, attach two
eyebolts and a sling. Make certain the disk
Apply a thin coat lubricant (refer to Table 4-1)
stack/cage assembly is fully seated on the seat
on the plug seal.
ring by rotating it several times.
Place the plug seal into the bonnet or bonnet
Apply a thin coat of lubricant (refer to Table 4-1)
spacer cavity as shown in Figure 4-8.
on the outside diameter of the plug/spindle
assembly (do not apply to the seating angle). Apply a light coat of lubricant (refer to Table 4-
1) to the body bonnet bore and the outside of
Using the yoke clamp, stem clamp, and sling,
the bonnet or bonnet spacer (see Figure 4-9)..
carefully lower the plug/spindle assembly into
the disk stack/cage assembly until it contacts
the seat ring.
Remove the stem clamp, sling, and yoke clamp

(see Figure 4-2).
Place the guide bushing on the disk stack/cage

assembly.
CAUTION
Do not use a pointed tool to install the plug seal

as damage to the sealing capacity of the seal
will result. The plug seal is easily broken if
uneven pressure is applied when installing.
FIGURE 4-9 Bonnet or Bonnet spacer

lubrication

Attach a yoke clamp and sling to bonnet, as
shown in Figure 4-1. CAUTION
Do not use a pointed tool to install the packing
Lubricate and install the gasket seal into the
as damage to the sealing capability of the
body groove.
packing will result.
Lower the bonnet onto the disk stack assembly,
Place the Teflon v-rings in the stuffing box
cage or bonnet spacer using care to prevent
between the male and the female adapters.
damage to the balance seal.
See Figure 4-11 for proper orientation.
Remove the yoke clamp or eye bolts and sling.
Reference the valve drawing in Section 8 for

the required bonnet bolt torque. Refer to Table
4-2 for recommended bonnet torquing
increments based on the required bonnet bolt
torque.
Be certain that the plug stem is centered in the

bonnet cavity while tightening the nuts
alternately by the increments shown in Table
4-2 and using the torque pattern in Figure 4-10.
The packing follower may be used as a
centering device. Wrap friction tape around the
top of the packing follower so that it will not fall
into the bonnet. Slip the packing follower into
the bonnet while tightening the nuts and make
sure it slips in and out freely. Tighten the
bonnet flange nuts accordingly. Remove the
sling from the bonnet.
FIGURE 4-11 Packing Installation
Slide the packing follower over the plug stem

until it is seated on the packing set.
For actuator-yoke assembly and packing flange

installation, refer to Section 3.
FIGURE 4-10 Bonnet bolt torque pattern
Install the packing spacer over the plug stem,

making sure it is fully seated in the bottom of
the packing box as shown in Figure 4-11.

FIGURE 4-12 Body assembly exploded view
Table 4-1. Recommended Lubricants

DESCRIPTION NON-NUCLEAR NUCLEAR
Never-Seez * Never-Seez (Nuclear Grade Nickel) *

Packing and Seals Dow Corning 111 Dow Corning 111
Bostik NS-160 Bostik NS-160
Body & Internals
Dow Corning 111 Dow Corning 111
Bolting Felpro Felpro N-1000 or N-5000
Blasolube 315
* To be used when temperature is greater than 400 deg. F.

Table 4-2. Recommended Bonnet Torque Increments
REQUIRED TORQUE (T) TORQUE INCREMENTS
(lbf-ft) (N-m) (lbf-ft) (N-m)
T < 100 T < 136 25 34

100 < T < 300 136 < T < 407 50 68
300 < T < 800 407 < T < 1085 100 136
T > 800 T > 1085 200 272

SECTION 5
ACTUATOR
5.1 SCOPE When operating the actuator with the

actuator shaft disconnected from the valve
This section provides instructions for the stem, the following precautions must be
disassembly and assembly of the actuator observed to avoid the possibility of serious
assembly. injury or product damage.
5.2 INTRODUCTION 1) Do not let any object, including fingers, get

between the end of the actuator shaft and
the end of the valve stem.
The actuator assembly is pneumatically
operated, connected to the body assembly with 2) When stroking actuators, do not apply more
a yoke, and to the plug stem with an actuator than 20 psig (140 KPa) air pressure to move
shaft. The actuator assembly extends or the piston in either direction.
retracts the plug assembly within the body
assembly by pressure applied to either side of 3) When checking the actuator static o-rings for
the piston. In the event of air supply failure, the leaks, apply equal pressure simultaneously
air tank or springs when supplied, will force the to both end caps using a maximum air
piston to move the plug into the specified fail supply pressure of 100 psig (700KPa).
position (see Figure 5-1).
4) When checking for a torn or “rolled” piston
o-ring, do not apply more than 20 psig (140
WARNING KPa) to the piston.
CCI pneumatic piston actuators are designed
for use when properly attached to the stem of a 5) Manual override rim pull should not exceed
CCI valve. 20 pounds (9kg) for springless actuators.
FIGURE 5-1 Actuator section view

Apply lubricant (refer to Table 5-2) to all o-rings
5.3 DISASSEMBLY and install them.
Refer to section 3 for removal of the actuator Assemble the manual override if applicable
from the valve. (Refer to section 7 for instructions).
Secure the actuator shaft by the milled flats. If

the shaft does not have milled flats install the
WARNING stem clamp onto the shaft and clamp the stem
Damage to the equipment and personnel could clamp in a vise equipped with soft brass jaws.
occur if the pressure has not been relieved from Secure the piston to the actuator shaft.
the actuator assembly.
Insert the actuator shaft assembly into the lower
Make certain there is no pressure in the cap.
actuator.
Replace the stem guide bushing on the lower
If a manual override is installed, remove it from cap (cylinder casing) by turning it clockwise.
the actuator. (refer to section 7 for instructions)
For sizes SC/V 300, 400, and 500, apply a light
Remove all nuts and tie rods (screws) from the coat of lubricant (refer to Table 5-2) to the
uper cap. interior surface of the cylinder. Carefully install
the cylinder onto the lower cap.
Remove the upper cap.
Place the upper cap onto the cylinder. Align the
For sizes SC/V 300, 400, and 500, tilt the
air ports in the lower cap and upper cap.
cylinder at the top to break the sealing tension
at the lower cap. Remove the cylinder. Lubricate and install tie rods, nuts, and washers
(screws).
Remove the actuator shaft, with the piston
attached, from the lower cap (cylinder casing).
Remove the stem guide bushing by turning it CAUTION

counter-clockwise. Tighten the nuts (screws) evenly by increments
to prevent canting the upper cap. Use care to
Remove all o-rings, guide rings, and wiper ring. prevent damage to o-rings while installing the
Take care not to damage the o-rings during upper cap.
disassembly.
Continue to tighten the nuts (screws) until the
Secure the actuator shaft by the milled flats. If end caps are seated against the cylinder
the shaft does not have milled flats install the (casing).
stem clamp onto the shaft and clamp the stem
clamp in a vise equipped with soft brass jaws. Torque all studs and nuts to ensure the end
Separate the shaft(s) and piston. caps are seated properly against the cylinder
(casing).
Refer to Section 6 for cleaning and inspection
procedures. 5.5 TESTING
5.4 ASSEMBLY Connect an air line to the lower cap air port and
slowly apply 80 psi (5.5 kPa) air pressure.
Prior to assembly, make sure all parts are Check for leakage at the bottom seal. Check
clean. Refer to section 6 for cleaning and for air flow at the upper cap air port, indicating
inspection instructions. piston seal leakage. Vent the air pressure.
Replace all o-rings, guide rings, and wiper ring. Remove the air line from the lower cap air port
Contact CCI for replacement parts. Inspect all and connect to the upper cap air port. Repeat
o-ring grooves for cleanliness and smoothness. procedure above to text for upper cap leakage.

FIGURE 5-2 Actuator assembly exploded view

Table 5-1. Actuator Stud Torque

Actuator
Stud Size
Size Stud Qty Required Torque
(lbf-ft) (N-m)
SC/V 200 M8 8 10 14
SC/V 320 M10 12 15 20
SC/V 300 M16 8 38 52
SC/V 400 M16 8 38 52
SC/V 500 M16 8 38 52
Table 5-2. Recommended Lubricants

DESCRIPTION LUBRICANTS
Positioner Linkage WD-40
All o-rings and Cylinder Kluber Altemp QNB 50

SECTION 6
MAINTENANCE
6.1 SCOPE 6.2 PREVENTATIVE MAINTENANCE

This Section presents procedures for CCI control valves are designed to provide long
preventative maintenance, fault finding, service life with proper preventative
inspection, repair, and cleaning of CCI control maintenance. Preventative maintenance is
valves and pneumatic actuators. Instructions limited to periodic replacement of seals and
for control devices and accessories provided packing, and periodic inspection and cleaning
with the valve are provided in Section 9. of the valve trim. Preventative maintenance
Detailed instructions for electric and hydraulic schedule (see Table 6-1) should be observed.
actuators are provided in Section 9. Valve and A CCI Factory Recommended Installation and
actuator drawings are provided in Section 8. Service Record is attached (see Table 6-4).
NOTE NOTE
NOTIFY CCI FIELD SERVICE THE REQUIRED MAINTENANCE
ENGINEERING (949)858-1877, OF ANY SCHEDULE MAY VARY DEPENDING
PROBLEMS WHICH ARISE DURING UPON APPLICATION AND DUTY CYCLE.
MAINTENANCE.
TABLE 6-1: PREVENTATIVE MAINTENANCE SCHEDULE
Schedule Activity
Every 1.5 year Inspect the packing follower, plug/spindle assembly, seat ring, and disk
stack/cage for damage. Rework or replace as required.
Replace flexitallic gaskets, balance seal, metal seal if damaged, stem
packing, and packing spacer. Check the operation and calibration of all
valve instruments, control devices, and the actuator.
Every 3 years Replace the actuator bushing, all actuator and manual override o-rings.
See section 9 for electric and hydraulic actuator maintenance
requirements.
Every 4.5 years Replace accessory soft-goods.

6.3 FAULT-FINDING AND RECOMMENDED REPAIR
Since CCI control valves are designed to Table 6-2 identifies potential problems, possible
provide long service life when properly causes, and recommended repairs. The
maintained, the fault-finding and corrective potential problems and recommended repairs
maintenance procedures for CCI control valves listed are intended primarily for CCI control
are limited. If factory recommended valves fitted with CCI pneumatic actuators. If
maintenance schedules are observed, then the an electric or hydraulic actuator is installed on
need for unscheduled maintenance and repair the valve, also see Section 9. Please contact
should be infrequent. CCI, Field Service Engineering for assistance in
resolving any maintenance problems.
TABLE 6-2: FAULT-FINDING AND REPAIR
Problem Possible Cause Item Recommended Repair

Packing leakage. Incorrect packing flange 1 Torque the packing flange nuts to the limits
torque. specified in Table 3-2.
Packing damaged or 2 Replace the packing following the procedures
incorrectly installed. given in Section 4.
Valve stem scratched. 3 Disassemble the valve and inspect the stem.
Replace the stem and plug, if necessary.
Reassemble the valve with new packing
following the procedures given in Section 4.
Valve leaks Problems with actuator 4 Check the system supply pressure. Compare
internally when shut- supply pressure. measured supply pressure to requirements
off. given on the Top Assembly drawing. Check the
setting and operation of all supply regulators
and needle valves. Check filters for excessive
dirt accumulation.
Incorrect positioner 5 Check the positioner outputs and actuator
calibration. inputs. At shutoff, full supply pressure should
be measured at the top port of the actuator, and
zero supply pressure should be measured at
the bottom port of the actuator. If not,
recalibrate the positioner.
6 Disassemble the valve and inspect the balance
Damage to or wear of valve seals, flexitallic gaskets, and the plug and seat
trim has occurred. ring seating surfaces for damage or wear.
7 See item No. 6
Improper assembly
8 See item No. 6
Debris in valve
Leakage class ordered 9 Consult CCI Field Service Engineering for
doesn’t meet expectations assistance.
Bonnet leakage. Incorrect bonnet bolt torque 10 Depressurize and cool the valve. Check the
or bolt torque procedure. bonnet bolt torque following the procedure
given in Section 4. The torque requirements
are specified on the Top Assembly drawing.
Incorrect gasket or metal 11 Depressurize and cool the valve. Remove the
seal installation, damaged bonnet and replace the gasket or seal. See
gasket or seal. Section 4.

TABLE 6-2: FAULT-FINDING AND REPAIR (continued)
Problem Possible Cause Item Recommended Repair

Bonnet leakage. (con’t) Large temperature 12 Very large thermal transients in the valve fluid
gradients. can cause leakage. Check the start-up and
operating procedures for the valve. Disassemble
the valve and inspect the valve trim for damage.
Contact Control Components Inc. for
recommendations.
Plug / Stem jumps or Problems with actuator 13 See item No. 4.
sticks while in travel. supply pressure
Positioner calibration is 14 See item No. 5.
not correct.
Control devices 15 Check the setting and operation of all control
misadjusted or devices, including supply regulators, needle
malfunctioning. valves, volume boosters, and solenoid valves.
Incorrect packing flange 16 See item No. 1.

torque.
Valve trim is galling. 17 Disassemble the valve. Check the plug and disk
stack / cage for signs of galling or wear. Check
the stem and packing box for scratches and
damage. Check for foreign material or loose
particles caught between moving parts in the
valve. Check disk stack / cage passages for
clogging or accumulation of debris or particles
Debris in valve 18 See item No. 6.
19 Sticking or jumping due to lack of lubrication will

No seal lubrication or likely go away or be significantly reduced during
wrong lubrication used normal operation. Lubrication is only a
temporary substitution for the system fluid.
Trim misalignment 20 See item No. 6.
Valve plug / stem does not Problems with actuator 21 See item No. 4.
follow input signal. supply pressure.
Positioner calibration is 22 See item No. 5.
not correct.
Leaking valve actuator 23 Disassemble the actuator assembly and replace
seals. all o-rings.
Control devices 24 Check the setting and operation of all control
misadjusted or devices, including supply regulators, needle
malfunctioning. valves, volume boosters, and solenoid valves.
None of the above. 25 Call CCI.
Reduced flow through Valve operating conditions 26 Check the valve inlet temperature, inlet pressure,
element. incorrect. outlet pressure, and flow rate.
Potential problem with 27 Observe valve operation to see if the valve is
valve trim. responding properly to its input signal. See item
No. 17.

TABLE 6-2: FAULT-FINDING AND REPAIR (continued)
Reduced flow through Valve not fully open 28 See item Nos. 34-36.
element. (con’t)
Debris blocking flow 29 See item No. 6.
passages
Leakage from valve Leaking valve actuator 30 See item No. 23.
actuator. seals.
Stroke time too slow. Problems with actuator 31 See item No. 4.
supply pressure.
Incorrect packing flange 32 See item No. 1.
torque.
Control devices 33 See item No. 24.
misadjusted or
malfunctioning.
Valve doesn’t open fully. Manual override is limiting 34 Re-Position manual override so it does not
stroke interfere with the stroke.
Improper positioner 35 See item No. 5.
calibration
Major debris in valve 36 See item No. 6.
Valve doesn’t close fully Improper positioner 37 See item No. 5.
calibration
Major debris in valve 38 See item No. 6.
Valve doesn’t maintain Loose feedback linkage 39 Check that all linkage nuts and bolts are tight.
stable position Positioner gain too high 40 Decrease positioner gain if adjustable.
Booster sensitivity is too 41 Decrease booster sensitivity
high
Positioner loses calibration Loose adjustments in 42 Re-calibrate and tighten zero and span lock nuts.
positioner
Valve doesn’t respond Positioner gain too low 43 Increase positioner gain if adjustable.
consistently to small signal Desired change to 44 Consult CCI Field Service Engineering for
changes measured variable is assistance.
smaller than valve can
accommodate
Wrong signal action or fail Misunderstanding 45 Consult CCI Field Service Engineering for
direction between end user and assistance.
specifier

6.4 INSPECTION AND REPAIR A complete record of all maintenance and

repairs should be maintained. A CCI Factory
The following inspection and repair procedures Recommended Installation and Service Record
are recommended for the valve and actuator is attached (see Table 6-4).
components (Table 6-3). Replace all parts
which cannot be repaired by these procedures. Defects refer to galling, burrs, nicks, scratches
If an electric or hydraulic actuator is installed on or other imperfections resulting in material
the valve, also see Section 9. being raised above the normal surface which, if
not removed, would prevent proper mating of
Contact CCI, Field Service Engineering for parts and sealing surfaces. Minor defects
recommended wear tolerances and maximum would not affect the mating of parts and sealing
allowable surface flaw depths, especially for surfaces.
seat rings, plugs, spindles, stems, and other
valve trim components.
TABLE 6-3: INSPECTION AND REPAIR

ACCEPTABLE
ACCEPTABLE
NOT
COMPONENT INSPECTION CRITERIA RECOMMENDED REPAIR
GENERAL
Threaded surfaces Galling, burrs, nicks X Chase all threads with a correct tap or die.
Sealing surfaces Burrs or corrosion X Polish using 400 grit crocus cloth
Burrs, nicks, scratches on sealing surfaces X Contact CCI for replacement or repair
Seat ring Minor defects on inside diameter X
Minor defects on outside diameter X
Minor defects on top or bottom X
Disk stack/cage Honing may be possible – contact CCI for
Defects on inside diameter X
replacement or repair
Damaged disks X Replace disk stack
Disks
Clogged passages X Refer to cleaning methods
Defects on stem in area contacting packing X Contact CCI for replacement or repair
Defects on seating surface of plug X Contact CCI for replacement or repair
VALVE
Spindle/plug assembly Pitted or galled plug outside diameter X Replace

Worn surface overlay material X Replace
Minor linear defects on plug outside diameter X
Plug seal Any defects X Replace
Belleville springs Cracking or chipping X Replace
Defects on inside diameter X Contact CCI for replacement or repair
Balance cylinders Defects on seal contact surfaces X Contact CCI for replacement or repair
Minor defects on outside diameter X
Defects on packing area inside diamter X Contact CCI for replacement or repair
Bonnet
Defects on inside/outside diameter X
Guide bushing Defects on inside/outside diameter X
Defects on o-ring groove X Contact CCI for replacement or repair
Upper/lower caps
ACTUATOR
Defects on inside/outside surfaces X

o-rings Any defects X Replace
Shaft Defects on outside diameter X Replace
Scoring and fiber separation on inside
Cylinder X Replace
diameter

6.5 CLEANING MATERIALS REQUIRED Direct compressed air through each disk
passage, in the reverse direction of flow.
The following materials should be used to
comply with CCI recommended cleaning Dry parts with cleaning cloths and/or
methods. Materials and methods may be compressed air
changed to meet local conditions and
requirements. 6.7 RECOMMENDED SPARE PARTS
• crocus cloth, 400 grit When ordering spare parts, please refer to the
• cleaning cloths information listed on the cover sheet of this
• brush, S.S. wire manual.
• brush, non-metallic
Flexitallic gaskets
• solvent
Balance seal
• methyl alcohol, anhydrous purified Stem packing
• ethyl alcohol, anhydrous denatured Packing spacer
• acetone, technical grade Packing follower
Balance seal spacers
NOTE Metal seal
RE-DISTILLED SOLVENTS MUST BE Actuator soft-goods Kit or o-rings and bushing
EQUIVALENT TO NEW SOLVENT.
6.8 LONG LEAD TIME ITEMS
WARNING When ordering parts, please refer to the

SOLVENTS MAY BE TOXIC AND information listed on the cover sheet of this
FLAMMABLE. REFER TO THE manual.
MANUFACTURER'S INSTRUCTIONS
BEFORE USING. EYE PROTECTION IS Plug assembly or spindle
REQUIRED WHEN SOLVENTS OR Disk stack assembly
COMPRESSED AIR IS USED. Seat ring
Piston rings
6.6 CLEANING METHODS .
The following procedures should be used for

cleaning CCI control valve and CCI pneumatic
actuator components. If an electric or hydraulic
actuator is installed on the valve, see Section 9.
CAUTION
DO NOT USE ABRASIVES TO CLEAN VALVE
COMPONENTS.
Immerse parts in solvent.
Remove stubborn accumulations of dirt from

the sealing surfaces with a non-metallic brush.
Remove scale, rust, and minor pitting from the

interior of the body using 400 grit crocus cloth
or a S.S. wire brush.
Rinse parts with clean solvent.

TABLE 6-4: FACTORY RECOMMENDED INSTALLATION AND SERVICE RECORD
Customer:
Site:
Valve Tag:
CCI Serial No.:
Description:
Installation Record Date By Notes
Valve Assembly & Test
I&C Assembly & Test
Schedule Activity Date By Notes
1.5 years Inspect packing follower, plug assembly, seat ring, & disk
stack/cage for damage. Replace flexitallic gaskets, balance
seal, metal seal if damaged, stem packing, & spacer. Check
the operation and calibration of all valve instruments, control
devices, and the actuator. Rework or replace as required.
3 years Inspect packing follower, plug assembly, seat ring, & disk stack
/ cage for damage. Replace gaskets, balance seal, metal seal if
damaged, stem packing, & spacer. Check the operation &
calibration of instruments, control devices, & actuator. Rework
or replace as required. Replace actuator bushing and o-rings.
4.5 years Inspect packing follower, plug assembly, seat ring, & disk stack
or replace as required. Replace accessories soft-goods
Replace accessories soft-goods.

SECTION 7
SPECIAL VALVE COMPONENTS
NOT APPLICABLE

SECTION 8
VALVE DRAWINGS AND BILLS OF MATERIAL

SECTION 9
VENDOR LITERATURE

INSTALLATION AND MAINTENANCE
INSTRUCTIONS
G
MODEL 840G/H/TBS & 860G/H/TBS
SERIES CAGE GUIDED AND CAGE
RETAINED SEAT VALVES WITHOUT
ACTUATOR FOR VERTICAL MOUNTED
COMPILED BY: PROJECT ENGINEER
APPROVED BY: ENGINEERING MANAGER
1/30
SAFETY IS GOOD BUSINESS
DURING MAINTENANCE AND INSPECTION ACTIVITIES ON CCI EQUIPMENT, YOU ARE CAUTIONED
TO ADHERE TO THE INSTRUCTIONS CONTAINED IN THIS MANUAL AND TO INSIST UPON STRICT
ADHERENCE TO YOUR PLANT SAFETY POLICIES IN ORDER TO AVOID POSSIBLE DAMAGE TO
EQUIPMENT AND INJURY TO PERSONNEL.
WHILE THIS INFORMATION IS PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE, CCI
DOES NOT GUARANTEE SATISFACTORY RESULTS FROM RELIANCE UPON SUCH INFORMATION.
NOTHING CONTAINED HEREIN IS TO BE CONSTRUED AS A WARRANTY OR GUARANTEE, EXPRESS
OR IMPLIED, REGARDING THE PERFORMANCE, MERCHANTABILITY, FITNESS, OR ANY OTHER
MATTER WITH RESPECT TO THE PRODUCTS, NOR AS A RECOMMENDATION TO USE ANY
PRODUCT OR PROCESS IN CONFLICT WITH ANY PATENT. CCI RESERVES THE RIGHT, WITHOUT
NOTICE, TO ALTER OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF THE PRODUCTS
DESCRIBED HEREIN.
OUR SERVICE DEPARTMENT IS PREPARED TO DISCUSS SOLUTIONS TO ANY PROBLEMS

CONCERNING THE MAINTENANCE AND INSPECTION PROCEDURES APPLICABLE TO CCI
EQUIPMENT. PLEASE DIRECT ALL INQUIRIES TO:
CCI CCI KOREA, Ltd.

22591 AVENIDA EMPRESA 81-21, ONGJEONG-RI, TONGJIN-EUP
RANCHO SANTA MARGARITA, GIMPO-SI, GYEONGGI-DO
CALIFORNIA 92688 USA REPUBLIC OF KOREA
PHONE:(949) 858-1877 PHONE: (031) 985-9430
FAX:(949) 858-1878 FAX: (031) 985-0552~3
2/30
TABLE OF CONTENTS
Section I General Description PAGE
1-1 Introduction ..................................................................................................................... 5

1-2 Principle of Operation ..................................................................................................... 5~9
1-3 Design Features ............................................................................................................. 9~11
Section II Installation
2-1 Introduction ..................................................................................................................... 12
2-2 Receiving & Inspection ................................................................................................... 12
2-3 Storage ........................................................................................................................... 13
2-4 Handling.......................................................................................................................... 13
2-5 Flushing .......................................................................................................................... 14
2-6 Installation....................................................................................................................... 14~15
2-7 Start-Up and Operation .................................................................................................. 15
Section III Control Element

3-1 Disassembly ................................................................................................................... 16~18
3-2 Assembly ........................................................................................................................ 18~19
3-3 Remark ........................................................................................................................... 19~20
Section IV Body Assembly

4-1 Disassembly ................................................................................................................... 21~22
4-2 Assembly ........................................................................................................................ 23~27
Section VI Preventative Maintenance and Problem Solving

6-1 Preventative Maintenance ............................................................................................. 35
6-2 Problem Solving ............................................................................................................ 35~36
3/30
FIGURES AND TABLES
Page
Figure 1.1 CCI Cage Trim ................................................................................................................ 6
Figure 1.2 CCI Control Valve, Over-the-Plug Flow.......................................................................... 7
with Drilled Hole Cage and Teflon Balance Seal
Figure 1.3 CCI Control Valve, Under-the-Plug Flow........................................................................ 8
with Contoured Plug Assembly
with Multi-Step Plug Assembly
with Gasket Bonnet Seal and long Cage
Figure 1.6 CCI Valve with Pressurized Seat Plug Assembly .......................................................... 11
Figure 3.1 Control Elements with Diaphragm Actuator ................................................................... 17
Figure 3.2 Stem & Actuator Shaft Connection ................................................................................. 20
Table 3-1 Recommended Stem Clamp Torques ............................................................................ 20
Figure 4.1 Typical Valve Construction ............................................................................................. 22
Figure 4.2 Packing Removal............................................................................................................ 22
Table 4-1A Alloy Steel Bolting Torques ............................................................................................ 24
Table 4-1B Stainless Steel Bolting Torques .................................................................................... 24
Table 4-2 Recommended Packing Nut Torques ........................................................................... 25
Table 4-3 Recommended Lubricants ............................................................................................ 25
Figure 4.3 Lower Gasket Installation ............................................................................................... 26
Figure 4.4 Torque Pattern ................................................................................................................ 26
Figure 4.5 Packing Arrangement ..................................................................................................... 27
Table 6.1 Problem Solving ............................................................................................................. 35~36
4/30
SECTION I
GENERAL DESCRIPTION
1-1. INTRODUCTION
CCI Control Valves are custom selected to fit application and piping requirements,
and to eliminate the problems of cavitations, noise, erosion, and vibration by
effectively controlling fluid velocity. CCI Control Valves are engineered for easy
maintenance, and quick-change trim, with no screwed or welded seats.
The CCI Control Valve trim is built for long, trouble-free service. The key to good
service life is proper installation and routine maintenance during use.
The key features of a CCI Control Valve are the valve body, which is sized to fit
piping requirements; the cage, which provides velocity control; the body assembly,
which includes the seat ring, bonnet, plug assembly, and bonnet spacer or balance
cylinder; the actuator assembly, which regulates the valve trim; and accessory
components and controls selected to meet or exceed valve performance
requirements.
1-2. PRINCIPLE OF OPERATION
Velocity Control
High fluid velocities through the trim are a principal source of severe service control
valve problems. Cavitations, erosion, high noise, and pipe vibration are typical signs
that the fluid velocities are not being controlled. Velocity control problems are
eliminated with multi-staged Control Valves.
CCI Cage Trim
In some applications, CCI offers custom designed cage trim. The configuration,
size, and quantity of passages in the cage are designed to provide the required flow
capacity and valve characteristic without loss of velocity control (see Figure 1.1).
5/30
CCI CAGE TRIM
FIGURE 1.1
Flow Direction: Over-the-Plug / Flow-to-Close
Over-the-plug flow is typically specified for liquid flow applications, or for

applications in which exceptional shutoff is important. When the flow through the
control element is over-the-plug, the flow enters into the valve body, flows through
the cage, past the plug, and out through the seat ring bore. In some applications,
the valve trim can be used as a protective strainer, preventing particles from
damaging the seating surfaces of the plug and seat ring (see Figure 1.2). A tag on
the valve body indicates the valve flow direction.
6/30
Bonnet
Packing
Set
Gasket
Plug Ass’y
Balance
Cylinder
Balance
Seal Cage
Seat Ring Body
CCI CONTROL VALVE, OVER-THE-PLUG FLOW

WITH DRILLED HOLE CAGE AND TEFLON BALANCE SEAL
FIGURE 1.2
Flow Direction: Under-the-Plug / Flow-to-Open
Under-the-plug flow is typically specified for steam or gas flow applications, or for
applications in which exceptionally low noise or velocity control is important. When
the flow through the control element is under-the-plug, the flow passes up through
the seat ring bore and under the plug, decelerates through the cage, and exhausts
7/30
through the valve outlet. The valve trim can be designed to provide very precise
outlet velocity control (see Figure 1.3, 1.4, 1.5).
CCI CONTROL VALVE, UNDER-THE-PLUG FLOW

WITH CONTOURED PLUG ASSEMBLY
FIGURE 1.3

WITH MULTI-STEP PLUG ASSEMBLY
FIGURE 1.4
8/30
Packing
set Bonnet
Plug
Assy Long
Cage
Gasket
Body
Seat Ring

WITH GASKET BONNET SEAL AND LONG-CAGE
FIGURE 1.5
1-3. DESIGN FEATURES
The CCI Control Valve features five major elements: the valve body, the disk stack
or cage, the bonnet assembly, the plug assembly, and the actuator and controls
assembly. The bonnet assembly includes the seat ring, bonnet spacer or balance
cylinder, bonnet, plug assembly, seals, and packing seals. The plug assembly
9/30
includes the plug and stem, or spindle. The actuator is bolted to the yoke, and the
yoke is clamped or bolted to the valve bonnet.
All CCI Control Valve trim components are designed for quick change and long life.
Screwed and welded seat rings are not fitted. The bonnet seal style, plug assembly
style, and plug seal style are selected to suit the application and service
requirements.
Bonnet Seal Design
Gasket Seal
This seal type is used primarily in smaller control valve sizes and in high
temperature service. The pressure boundary seal is obtained by compressing a
gasket seal between the bonnet and body. The gasket seal is manufactured from
several layers of stainless steel and graphite that are wound in even spirals around
the axis of the gasket seal. The compressed graphite provides excellent sealing.
The stainless steel supports the graphite, and provides resilience to temperature
changes (see Figure 1.3, 1.4, 1.6). CCI has over 20 years of experience in high
temperature, high-pressure service with this proven design.
Plug Assembly and Plug Seal Design
Unbalanced Plug Assembly
The unbalanced plug is typically selected for very small plug sizes, when large
actuator loading is not required to either lift or seat the plug. This design does not
feature balance holes, balance seals, or pilot trim. The unbalanced plug provides
exceptional shutoff in the flow over-the-plug configuration, since the shutoff
pressure acts to close the valve.
Balanced Plug Assembly
The balanced plug design is used to reduce actuator loading. Axial holes are drilled
through the plug or spindle. A seal is placed at the top of the plug, isolating the
bonnet cavity above the plug from the upstream pressure. The axial holes in the
plug balance the pressure above and below the plug, greatly reducing the loading
required to lift the plug.
Pressures energized seals, manufactured from materials such as Teflon, are used
in lower temperature services. In higher temperature services, graphite-based
balance seals are used. In some applications, a piston ring is used as a balance
seal.
CCI Pressurized Seat Plug Assembly
The CCI Pressurized Seat Plug Assembly is used in high temperature service
requiring tight control valve sealing. The CCI Pressurized Seat Plug Assembly
provides the shutoff of an unbalanced plug with the low actuator force requirements
of a balanced plug.
10/30
The CCI Pressurized Seat Plug Assembly features a pilot plug, a main plug, and a
piston ring balance seal. The piston ring allows a small, controlled leak of pressure
from the valve inlet to the bonnet cavity (see Figure 1.6).
When the control valve is closed and the pilot plug is seated, the Pressurized Seat
Plug Assembly provides exceptional shutoff. The shutoff pressure builds in the
bonnet cavity above the plug, acting to close the valve. The actuator needs only to
provide sufficient thrust to seat the pilot plug against the pilot seat in the main plug.
When a signal to open the control valve is received, the actuator lifts the stem,
opening the pilot seat. The pilot rapidly exhausts the bonnet cavity pressure. The
plug assembly is now balanced. As the stem continues to move in the opening
direction, a shoulder on the stem engages a retaining plate on the main plug. The
stem lifts the main plug off the main seat. The actuator needs only to provide
sufficient thrust to lift the balanced plug.
Packing Bonnet
Set
Balance
Cylinder
Piston
Ring
Pilot
Plug
Cage
Seat Ring
Body
CCI VALVE WITH PRESSURIZED SEAT PLUG ASSEMBLY

FIGURE 1.6
11/30
SECTION II
INSTALLATION
2-1. INTRODUCTION
This section describes recommended procedures for receiving, storing, handling, and
installing CCI control valves. Good general practice should be used for all maintenance
and installation activities. All applicable regulations and specifications should be followed.
Every CCI control valve is custom designed for a specific application and a specific set of
operating conditions. The control valve drawing provides complete information on valve
design conditions, dimensions, weight, and general arrangement. A nameplate attached
to every control valve lists the design conditions for that particular control valve.
2-2. RECEIVING AND INSPECTION
a. Shipping and packing documents are attached to or packed in the control

valve container. Quality assurance documents, operation and maintenance
manuals, and drawings are typically packed in the container. THESE
DOCUMENTS SHOULD BE IMMEDIATELY DELIVERED TO THE
APPROPRIATE PLANT MANAGER, PROJECT MANAGER, OR ENGINEER.
b. The container is marked with instructions for handling and storage. These
directions should be strictly followed. Unless specifically required by contract,
CCI products are packaged for domestic shipping and indoor storage.
WARNING
The control valve is very heavy. If the valve is

not handled properly, serious injury can occur.
Suitable lifting equipment must be properly
used and attached.
c. After the shipping container is unloaded at the site, the container should be
inspected for damage. Joints and seams should be inspected for signs of
separation.
d. Unless the container is damaged, it should not be opened until the control
valve is required for installation. In order to inspect the valve, the container
lid can be safely removed without reducing the structural integrity of the
container. If damage to any parts is suspected, carefully check the
equipment against the packing list. Make a note of any loose, damaged, or
missing parts. Notify both the freight company and your CCI contract
administrator.
12/30
2-3. STORAGE
a. The control valve may have been shipped either disassembled, or with spare
parts. Valve trim parts, including plug assemblies, seat rings, disk stacks,
cages, spacers, and balance cylinders should be coated with rust inhibitor,
and placed in a separate container. Seat ring and plug seating surfaces
should be protected with tape. These protective coverings are removable.
Desiccant should be added to the container, and replaced periodically.
b. If the control valve was shipped completely assembled, a desiccant should

be added to the container, and replaced periodically.
c. All parts or the control valve should be stored in a fire resistant, weather-tight,
and well-ventilated building. The parts should not be exposed to
temperatures below -20° F (-29° C) to 120° F (48° C). The storage area
should be safe not be subject to flooding. The floor should be paved or
similarly level, firm, protected, and well drained. All parts should be placed
on pallets or shoring to permit air circulation.
d. To avoid elastomer deterioration, both pneumatic and hydraulic actuators

must be cycled at least every six (6) calendar months. A minimum of three
(3) full strokes is required using the normal operating media.
2-4. HANDLING
The unit is shipped in a container designed to support both the body assembly and the
actuator assembly. To remove the control valve from the shipping container, place
appropriate slings and lift with a hoist.
CAUTION
CAREFULLY WRAP THE SLING AROUND THE

VALVE YOKE OR OPERATOR.
WARNING
Applicable codes, regulations and industrial

practices for handling (hoisting and lifting)
loads must be followed. These include but are
not limited to the following precautions:
a. Slings should be free of kinks and twists.
b. Position the lifting hook over the load so that the load does not swing when
lifted.
c. The operator shall see that the load is well secured and balanced.
d. The operator shall see that the slings are not handled on the winch head
without the knowledge of the operator.
e. The operator shall avoid carrying loads over people.
13/30
2-5. FLUSHING
a. When the control valve is installed in a system suspected to be contaminated,

the system should be flushed to prevent possible damage to the control valve.
The control valve trim should not be used during flushing. The control valve
trim must be removed prior to flushing. Remove the actuator assembly and
valve trim from the body assembly as described in Sections III and IV.
b. Flushing trim can be obtained from CCI. Install the flushing trim, complete
flushing, and reassemble the valve as described in Sections III and IV.
CAUTION
For 3-way valve, do not remove control valve trim
from body for flushing. Once 3-way valve is installed
in the pipe line, trim components can not be
removed due to its unique design feature. In order to
do flushing for 3-way valve, it shall be done with the
valve trim fully open or fully closed as required by
the user intention.
2-6. INSTALLATION
a. The control valve has been cleaned, inspected, and sealed at the factory
prior to shipment. Protective covers have been installed in the valve inlet
and outlet. These covers prevent the entry of foreign matter into the valve.
No additional cleaning should be required. After the protective covers are
removed, the interior of the body should be inspected in order to ensure that
the valve is free of contaminants. If cleaning is required, refer to Section VI.
CAUTION
Use care when lifting or handling the control valve to
ensure that the accessories and lines are not
damaged.
CAUTION
Do not mar the sealing surfaces of flanged valves.
CAUTION
The heat of post weld heat treatment can damage
valve seals. Remove ALL valve trim PRIOR to
welding. The valve may require disassembly if post
weld heat treatment will be performed. In case the
valve have to be welded with it’s end pipe as a valve
assembly, valve position should be open to avoid
possible damage.
Contact CCI , for additional instructions.
14/30
CAUTION
Do not use the plug, stem, or actuator shafts for

grounding during welding operations.
b. After the control valve has been removed from the shipping container, lift and
rotate the control valve into its installed position using a hoist and sling.
c. The direction flow is indicated by an arrow on the body. The valve must be
installed in the correct flow direction.
d. The control valve is normally installed in a vertical position, with the valve
operator pointed straight up. If the assembly is to be installed in any other
orientation, then adequate supports may be required for the valve operator
assembly.
e. Verify that all required utilities are available.
f. Complete the welding or bolting of the valve in line. For welded-end valves,
which require post weld heat treatment, Post-weld Heat Treatment should be
completed prior to reassembly of the valve.
2-7. START-UP AND OPERATION
Instructions for the assembly, disassembly, and maintenance of the valve operator are
provided in Section V. Drawings for the actuator assembly and for manual override
assemblies are provided in Section VIII. Information on controls, accessories, by-pass
valves, and manual overrides are provided in Section VII.
a. If the valve has been reassembled, verify that the proper assembly technique
and bolt torque has been applied to the valve bonnet studs, packing, yoke
connection, and stem connection. See Sections III and IV for details.
b. Verify that all required utilities, including pneumatic, hydraulic, and electric
supplies and signals, are connected and properly adjusted. Refer to the Top
Assembly drawing for applicable instructions.
c. Verify that all control and accessory components are connected and correctly
adjusted. Refer to the Top Assembly drawing and Section VII for applicable
instructions.
d. Clean the actuator shaft of foreign material and Inspect all connections for
leakage.
15/30
SECTION III
CONTROL ELEMENT
3-1. DISASSEMBLY
CAUTION
To avoid personal injury and damage to the

process system, isolate the control element from
the system pressure and release all pressure from
the control element body and actuator assembly
before attempting disassembly.
a. Bleed all of the air from the lines and make sure that there is no pressure left in
the system. Disconnect all the utility lines.
b. Attach a sling to the actuator assembly (See Figure 3.1).
c. Untie the bonnet bolts from the body.
d. If applicable, be certain the by-pass valve on the actuator assembly is closed.
e. If manual override is provided, make certain it is disengaged. In case of the fail

closed actuators, to set the neutral position of manual override, move the
manual override to the bottom of its stroke; In case of the fail open, to set the
neutral position of manual override, move it to the top of its stroke.
f. Install a temporary air line with a manually controlled pressure regulator installed
in the line to the air port of the actuator assembly.
WARNING
The actuator assembly is spring loaded. Use

care to follow normal safety procedures and the
following instructions when removing tension on
the stem clamp.
g. Using the actuator, move the valve 50% open. Do not exceed the supply
pressure listed on the top assembly drawing in section VIII.
WARNING
Do not allow the plug to drop or turn against the

seat ring. This could cause damage to the seat
ring and the plug.
16/30
SLING
ACTUATOR
STEM
ACTUATOR
CLAMP
SHAFT
PACKING
FLANGE
BONNET
BODY
301 048
CONTROL ELEMENT WITH DIAPHRAGM ACTUATOR
FIGURE 3.1
h. Remove the stem connector or stem clamp from the stems. Measure and
record the gap between the two stems, for future reference.
i. Remove packing flange nuts.
j. Loosen and remove bolts connecting yoke to bonnet.

k. Lift actuator off body using sling.
17/30
l. Slowly relieve all air pressure from the actuator assembly.
m. Disconnect the temporary air line.
3-2. ASSEMBLY
Refer to the control element drawings for torque values and other data applicable to a
particular control element in Section VIII.
a. If the valve is fail closed, install an air line with a manually controlled regulator
installed to the actuator air port.
CAUTION
Do not exceed supply pressure indicated on

the identification tag.
b. Slowly apply sufficient air pressure to fully retract the actuator shaft. Connect a
sling to the actuator assembly and mount to the bonnet (see Figure 3.1).
c. There are two (2) yoke mounting configurations as see Figure 3.2. One has
several hex bolts holding the yoke to the bonnet, the second has two half
clamps that are bolted together. All three designs require that the yoke be
placed on the bonnet and aligned to the drawing requirements before tightening.
HEX BOLTS HOLDING TYPE HALF CLAMPS TYPE
YOKE MOUNTING CONFIGULATIONS

FIGURE 3.2
18/30
NOTE
The yoke can be rotated radially to position

the yoke arms as required for the pneumatic
connection to the positioner.
d. Connect yoke to the bonnet as appropriate per paragraph 3-2c.
e. Install the packing flange.
f. If the valve is fail open, install an air line with a manually controlled regulator
installed to the actuator air port.
WARNING
Do not allow the plug to drop or turn against

the seat ring. This could cause damage to the
seat ring and the plug.
g. Slowly apply sufficient air pressure to move the actuator shaft until it is the
distance from the plug stem measured in paragraph 3-1g. If that was not
recorded, start with a gap of about 0.2 inches (5 mm) from the valve stem.
h. Install the stem connector or stem clamp to secure the plug stem to the actuator
shaft.
NOTE
Torque the stem clamp bolts evenly in a cross

pattern (refer to Table 3.1). As the bolts are
tightened keep the gap equal on both sides of
the stem (refer to Figure 3.3).
i. Slowly relieve all air pressure from the actuator assembly, allowing the internal
parts to seek the relaxed position.
j. Install the accessory assemblies in accordance with instructions described in

Section VII.
k. Remove the temporary air lines and install all permanent utility lines
l. Stroke the valve from fully closed to fully open, noting the ends of travel.
Adjustment may be required to achieve the full valve stroke, without going over
the required travel. The correct valve travel is stated on the valve tag. To
correct the stroke, rotate the valve stem: clockwise to reduce the valve travel,
counter-clockwise to increase the valve travel.
19/30
WARNING
The positioner must be properly calibrated in

order to have full seating load when the
control element is in a closed position.
Premature trim degradation may occur if the
calibration is incorrect.
m. Verify that the plug is firmly pressed against the seat in the closed position.
n. Check the operation and calibration of the control element.
o. Check for leakage.
p. Tighten the Yoke mounting bolts for the hex bolts holding type per 79~94 ft-lb
(107~127 N-m) and the Half clamp type per 17~22ft-lb (24~30 N-m).
TABLE 3-1
RECOMMENDED STEM CLAMP TORQUES

(Refer to Page 8-1 for stem size)
(mm) FT-LBS (N-m)

16 3.7~4.4 (5~6) M6 x 1.0P
20 3.7~4.4 (5~6) M6 x 1.0P
25 8.6~10.8 (11.7~14.7) M8 x 1.25P
32 8.6~10.8 (11.7~14.7) M8 x 1.25P
3-3. REMARK
In case an actuator should be rotated because of an obstacle or a barrier, follow chapter 3-1,
Disassembly procedure and rotate actuator assembly in order not to intervene in that
obstacle and then follow chapter 3-2, Assembly procedure.
Contact with CCI, if additional instructions are required.
20/30
STEM & ACTUATOR SHAFT CONNECTION
FIGURE 3.3
21/30
SECTION IV
BODY ASSEMBLY
(Refer to Figure 4-1 for typical construction)
4-1. DISASSEMBLY
CAUTION: To avoid personal injury or damage to the system, isolate and relieve
the valve from the system pressure prior to any disassembly.
a. With the actuator, move the valve to 50% open. Then, remove the stem connector
from the stems. Measure and record the gap between the two stems, for future
reference.
b. There are three yoke mounting configurations. One has several hex bolts holding
the yoke to the bonnet, the second has two half clamps that are bolted together,
and the third has a spud nut. All three designs require that the yoke be placed on
the bonnet and aligned to the drawing requirements before tightening. There is a
set screw on the clamp design that is to be tightened to prevent yoke rotation in
service.
c. Lift the actuator off the valve body assembly, without damaging accessories or
tubing.
d. Slowly relieve all air pressure from the actuator assembly. If an air
accumulator/volume/storage tank is attached to the actuator, this must be safely
vented to the atmosphere.
e. Push the valve stem down, to put the plug on the seat. Loosen the stem packing.
Remove the bonnet nuts, and remove the bonnet from the body, leaving the valve
trim in the body.
f. Remove the plug assembly, cage, seat ring, and the valve gaskets from the body.
If the valve is fitted with a “U” shape balance seal, note the orientation upon
removal from the valve. The seal must be replaced in this same direction.
g. Remove the stem packing from the bonnet. (Fig 4.2)
h. Clean each piece, and review for damage. Ensure parts are available for
replacement.
22/30
PACKING
FOLLOWER
PACKING
SET
PACKING
FLEXITALLIC SPACE
GASKET
PLUG
BONNET
ASSEMBLY
SEAT RING
CAGE
FLEXITALLIC
GASKET
BODY FLEXITALLIC
GASKET
FIGURE 4-1: TYPICAL VALVE CONSTRUCTION
PACKING
SET
PACKING REMOVAL
TOOL
PACKING
SPACER
BONNET
(REF)
GRAFOIL
PACKING
BAR STOCK SET
PACKING
SPACER
BONNET
(REF)
FIGURE 4-2: PACKING REMOVAL
23/30
4-2. ASSEMBLY
Inspect and replace worn parts as needed before reassembly. It is recommended

that all soft goods such as stem packing, gaskets, balance seals, and soft seats be
replaced before each reassembly.
a. If applicable, snap the new soft seat insert onto the seat ring.
b. Apply lubricant (refer to Table 4-3 for suitable selection) to the seat ring gasket and
insert the seat ring gasket, and then the seat ring into the body. (Fig 4.3)
c. Place the lower cage gasket on the body ledge. Insert the cage into the body.
NOTE: If a two-piece cage assembly is used (when the seal is not on the plug),
install the seal between the two cage pieces, with the original orientation. For valves
that are flow to open, the open side of the U faces the bonnet; flow to close valves,
have the open side face the seat ring.
d. Install the plug seal on the plug (if so designed). Install the plug assembly into the
cage.
e. Install the upper cage gasket.
f. Place the bonnet on the valve, and lightly tighten the bonnet bolting.
g. Install the packing as shown in Figure4-1. (Refer to Figure 4-5 for packing
arrangement.) For graphite packing, install two rings at a time, and compress them
to the torque values in Table4-2, before adding additional packing.
h. Torque the bonnet bolting, using a cross-body torque pattern (Fig 4-4). Apply only
half the torque value specified on each bolt, before reaching the final torque value.
Torque values are in Table 4-1. Use table 4-1B for stainless steel bolting, used with
stainless steel (unpainted) valves. Table 4-1A applies to carbon steel valve
materials.
i. Torque the stem packing to the values in Table 4-2.
j. Apply air to the actuator, moving the stem to about the 50% open position.
k. Place the yoke and actuator to the control valve body, and reconnect the mounting
hardware.
l. Move the actuator stem to the gap measured in step 4.1.b., above. If that was not
recorded, start with a gap of about 5 mm (0.2 inches) of the valve stem, and install
the stem connector.
m. Stroke the valve from full closed to full open, noting the ends of travel. Adjustment
may be required to achieve the full valve stroke, without going over the required
travel. The correct valve travel is stated on the valve tag. To correct the stroke,
rotate the valve stem: Clockwise to reduce the valve travel, counter clockwise to
increase the valve travel.
n. Calibrate the positioner, and check the performance of any other valve-mounted
equipment.
24/30
TABLE 4-1A: ALLOY STEEL BOLTING
BONNET BOLT TORQUE VALUE RANGES
ANSI 150 and
ANSI 600 ANSI 900 ANSI 1500
300
VALVE SIZE N-m Ft-lb N-m Ft-lb N-m Ft-lb N-m Ft-lb
107-
25 NB 1” 79-87 107-119 79-87 107-119 79-87 107-119 79-87
119
107-
40 NB 1.5” 79-87 107-119 79-87 107-119 79-87 207-229 153-169
119
107-
50 NB 2” 79-87 107-119 79-87 107-119 79-87 284-314 209-231
119
107- 153-
75 NB 3” 79-87 207-229 784-867 578-639 784-867 578-639
119 169
207- 153- 209- 1043- 1043-
100 NB 4” 284-314 770-851 770-851
229 169 231 1153 1153
207- 153- 302- 1128- 1128-
150 NB 6” 409-452 832-920 832-920
229 169 333 1247 1247
284- 209- 616- 1128- 1128-
200 NB 8” 835-923 832-920 832-920
314 231 681 1247 1247
450- 330- 616- 1487- 1097- 1487- 1097-
250 NB 10” 835-923
500 370 681 1643 1212 1643 1212
835- 616- 616- 1909- 1408- 1909- 1408-
300 NB 12” 835-923
923 681 681 2110 1556 2110 1556
835- 616-
350 NB 14” --- --- --- --- --- ---
923 681
TABLE 4-1B: STAINLESS STEEL BOLTING

BONNET BOLT TORQUE VALUE RANGES
ANSI 150 and 300 ANSI 600 ANSI 900 ANSI 1500
VALVE SIZE N-m Ft-lb N-m Ft-lb N-m Ft-lb N-m Ft-lb
25 NB 1” 93-103 68-76 93-103 68-76 93-103 68-76 93-103 68-76
40 NB 1.5” 93-103 68-76 93-103 68-76 --- --- --- ---
50 NB 2” 93-103 68-76 93-103 68-76 --- --- --- ---
133-
75 NB 3” 93-103 68-76 180-199 --- --- --- ---
147
180- 133- 182-
100 NB 4” 246-272 --- --- --- ---
199 147 201
180- 133- 261-
150 NB 6” 354-392 --- --- --- ---
199 147 289
246- 182- 538-
200 NB 8” 730-806 --- --- --- ---
272 201 595
246- 182- 538-
250 NB 10” 730-806 --- --- --- ---
272 201 595
538-
300 NB 12” --- --- 730-806 --- --- --- ---
595
350 NB 14” --- --- --- --- --- --- --- ---
25/30
TABLE 4-2: RECOMMENDED PACKING NUT TORQUES
STEM SIZE TEFLON GRAPHITE
mm inch N-m Ft-lb N-m Ft-lb
16 0.63 13 10 24 18
20 0.79 13 10 34 25
25 0.98 20 15 38 28
32 1.26 27 20 54 40
TABLE 4-3
RECOMMENDED LUBRICANTS
Non Nuclear Nuclear
Dow Corning 111 Dow Corning 111
For Packing and Seals:
Bostik NS-160 Bostik NS-160
Never-seez Never-seez (Nuclear Grade Nickel)
For Bolting:
Felpro Felpro N-1000 or N-5000
26/30
SEAT RING SEATING SURFACE
LUBRICANT
FLEXITALLIC
GASKET
LOWER GASKET INSTALLATION
FIGURE 4.3
1
8 5
4 9
10 3
6 7
2
408xx010
FIGURE 4-4: TORQUE PATTERN
27/30
(In many cases, Garlock Style 98 doesn’t be used)
PACKING ARRANGEMENT
FIGURE 4.5
28/30
SECTION VI
PREVENTATIVE MAINTENANCE AND PROBLEM SOLVING
6-1. PREVENTATIVE MAINTENANCE
Every 3 years the stem packing, and if applicable, balance seal and or soft seat
should be replaced. The actuator diaphragm and O-ring should be replaced every
6 years. Other parts are to be replaced when they show wear, to prevent additional
damage to the equipment.
6-2. PROBLEM SOLVING
Table 6-1 gives some general ideas to solve some typical field problems that may
occur during the lifetime of the control valves. More significant problems should be
referred back to the factory for assistance.
TABLE 6-1: PROBLEM SOLVING
PROBLEM CORRECTIVE ACTION

1. Torque the packing flange to the limits specified in Table
4-2. Check for leakage.
2. If damage to the stem is suspected, go to step 3.
Otherwise, following all site safety precautions, replace the
STEM PACKING
packing. In case O-rings are installed on the packing
LEAKAGE
follower, check the O-rings first.
3. Disassemble the valve. Visually inspect the stem and
replace the plug assembly if it is damaged. Also, replace
the stem packing.
1. Check the system air supply pressure to the valve.
2. For spring open valves (DA), ensure that the upper
diaphragm pressure is equal to the filter regulator set
EXCESSIVE pressure, to ensure full shut off.
INTERNAL 3. Try to rotate the plug assembly clockwise, while the valve
LEAKAGE WHEN is seated. This will ensure that the valve is on seat. If
THE VALVE IS unsure, lift the plug assembly off seat, and rotate 1/4 turn
SHUT OFF clockwise.
4. Disassemble the valve and check the gaskets, and the
plug, and seat ring (seating surfaces), and the balance
seal if so supplied.
1. Cool the valve and torque the bonnet to the limits specified
on the table 4-1.
BONNET LEAKAGE
2. Disassemble the valve and check the parts for damage.
Reinstall the bonnet and torque evenly, as specified in this
29/30
PROBLEM CORRECTIVE ACTION
1. Check the system air supply pressure to the valve and the
filter regulator operation.
2. Check the operation of all the accessories such as volume
PLUG ASSEMBLY
boosters.
JUMPING OR
3. Torque the packing flange to the limits specified in table 4-
STICKING
2.
4. Disassemble the valve and check the plug assembly and
cage for galling.
VALVE DOES NOT
FOLLOW
2. Check the positioner calibration and performance.
POSITIONER INPUT
3. Disassemble the actuator and inspect the diaphragm.
SIGNAL
1. Check the valve inlet pressure and flow rate.
2. Visually check to see if the valve is responding to the
REDUCED FLOW
signal.
THROUGH VALVE
3. Confirm that the valve is traveling the full rated stroke.
Re-calibrate if full stroke is not reached.
ACTUATOR 1. Check torque on the diaphragm case bolts.
ASSEMBLY 2. Disassemble the actuator. Replace the diaphragm and o-
LEAKAGE ring.
2. Torque the packing flange to the limits specified in Table
4-2
SLOW STROKE
3. Check the operation of the filter regulator. Clean the
TIME
positioner nozzle.
4. Check the adjustments of the accessories such as
boosters and solenoids.
POSITION
OVERSHOOT OR
2. Check the calibration of the positioner.
HUNTING AT A
3. Check that the booster adjustment is not too sensitive.
STROKE POSITION
z ACCESSORY COMPONENTS AND RECOMMENDED SPARE PARTS, ASSEMBLY

DRAWINGS & BILLS OF MATERIAL WILL BE ATTACHED WITH THIS MANUAL
30/30
Mounting instructions
Blow out tool
©CCI 2010
S025748 en rev.E
Mounting Instructions Blow Out Tool
Pos. Description
01 Blow out house
Before opening any 02 Stem
pressure vessel, make 03 Seatcover
absolutely sure that the 04 Plug
fluid system is completely 05 Slotted nut
depressurized! Opening 06 Gasket
an only slightly pressur- 07 Set screw
ized valve or being linked 08 Nut
to hot fluid may lead to
09 Lock washer
severe injury or even
death! 10 Drift hole bolt
11 Drift hole nut
12 Nut
13 Lock washer
14 Spring
1 S025748 en rev. E
Mounting Instructions
1. Remove the trim. (Acc. To Technical book)
Bolt and nut

Fig.A
2. Seal the drift holes in the autoclave seal of the valve with attached bolts (10) and nuts (11) as shown
in Fig. A
Gasket
Fig. B
3. Place the gasket (06) on the Blow out tool flange. Push the Stem (02) into the Blow out tool
completely as shown in Fig. B.
Fig.C
3. Push the Blow out tool with Stem (02) and Seatcover (03) into the valve body. Fix the tool with the
bolts (07), washers (09) and nuts (08). See Fig. C.
2 S025748 en rev. E
Torque Specifcation (Nm)
Screw (07) 8.8 21CrMoV57

Dimension Lubricated/Dry Lubricated/Dry
M10 35 / 39
M12 34 / 39
M16 87 / 101
M20 169 / 196
M24 285 / 331
M27 414 / 481
Avoid mounting the screws without a lubricant.
Plug
Fig.D
4. Push the Stem (02) so that the Seatcover (03) reaches the seat. See Fig. D.
Fig. E
5. Insert the Spring (14) in the tube so that the spring is facing the Stem (02). Measure the distance S
as shown in Fig. E.
6. Fit the Plug (04) to compress the Spring (14). Compress the Spring 8 mm, use the Plug (04) length
and the measured distance S to measure the compressed length. Lock the Plug (04) with the slotted nut
(05).
3 S025748 en rev. E
USER MANUAL
ST2
User manual
Referred to :
Fw revision starting from 2.00

RC software revision starting from 2.00
_____________________________________________________________________________________
STI s.r.l. via pascoli 10 A/B 24020Gorle (Bg) – ITALY www.stiactuation.com
IOM 4029 - ST2 User manual - rev.2 08/2010 -1-

USER MANUAL
ST2
Description.......................................................................................................................................................................... 5
CONTROLLER MOUNTING ................................................................................................................................... 5
Manufacturer’s identification : ................................................................................................................................... 6
GENERAL SAFETY INSTRUCTIONS ............................................................................................................................ 8
Installation .................................................................................................................................................................. 8
Maintenance ................................................................................................................................................................ 8
Controller sw upgrade......................................................................................................................................................... 9
RemoteControl sw installation......................................................................................................................................... 11
RemoteControl sw connection ......................................................................................................................................... 11
USB connection : ...................................................................................................................................................... 11
Starting the sw .................................................................................................................................................................. 12
The Main page .................................................................................................................................................................. 13
Quick Buttons ................................................................................................................................................................... 14
Download button .......................................................................................................................................................... 14
Graph button ................................................................................................................................................................. 14
Password button ............................................................................................................................................................ 14
‘Tuning window’ .............................................................................................................................................................. 15
‘Travel Control’ area .................................................................................................................................................... 15
Definitions : .................................................................................................................................................................. 15
0 Ctrl Signal : ............................................................................................................................................................ 15
0 Position : ................................................................................................................................................................ 15
Low [0..50 %]: .......................................................................................................................................................... 15
High [50..100 %]: ..................................................................................................................................................... 15
Tuning :......................................................................................................................................................................... 15
Kp IN/OUT [0 .. 100]: .............................................................................................................................................. 16
Stroke Time IN/OUT [0,0 ..3000,0 sec]: .................................................................................................................. 16
Approach IN/OUT [0..100]: ..................................................................................................................................... 16
Dead Band [0..10] : ................................................................................................................................................... 16
‘IN/OUT window’ ............................................................................................................................................................ 17
Fail/Trip settings ........................................................................................................................................................... 17
Mode C1/C2 : ........................................................................................................................................................... 17
Ack END MODE ..................................................................................................................................................... 17
On St. ........................................................................................................................................................................ 17
SOV .............................................................................................................................................................................. 18
SOV ASSIGNEMENT ............................................................................................................................................. 19
SOV BOOSTER FUNCTION .................................................................................................................................. 20
Analog Outputs ................................................................................................................................................................. 24
Temperature .................................................................................................................................................................. 25
Date & Time ................................................................................................................................................................. 25
History and Diagnostic ..................................................................................................................................................... 26
Counters : .................................................................................................................................................................. 26
Example of Diagnostic Report :................................................................................................................................ 27
Historic event log ...................................................................................................................................................... 29
Periodic log (SD Card) ............................................................................................................................................. 30
SDCard : ................................................................................................................................................................... 30
Main vars and status ......................................................................................................................................................... 32
ActPos [%] :.............................................................................................................................................................. 32
ReqPos [%]: .............................................................................................................................................................. 32
Input [mA]: ............................................................................................................................................................... 32
Status : ...................................................................................................................................................................... 32
Errors: ....................................................................................................................................................................... 32
Service State / Mode : ............................................................................................................................................... 33
Channel 1 CFG window (Channel 2 CFG window) ..................................................................................................... 34
CALIBRATION ....................................................................................................................................................... 34
_____________________________________________________________________________________

USER MANUAL
ST2
INPUT SIGNAL : Split range .................................................................................................................................. 34

INPUT SIGNAL : Calibrate 4mA ............................................................................................................................ 35
INPUT SIGNAL : Calibrate 20mA .......................................................................................................................... 35
Change Description .................................................................................................................................................. 35
Position excess Fail....................................................................................................................................................... 37
Signal Fail ................................................................................................................................................................. 37
Probe Fail .................................................................................................................................................................. 38
HART panel ...................................................................................................................................................................... 39
HART PARAMETERS ................................................................................................................................................ 39
Tag : .......................................................................................................................................................................... 39
Date :......................................................................................................................................................................... 39
Descriptor : ............................................................................................................................................................... 39
Message : .................................................................................................................................................................. 39
Polling address: ......................................................................................................................................................... 39
Dev. ID : ................................................................................................................................................................... 39
HART Protocol ............................................................................................................................................................. 39
HART Communication ................................................................................................................................................. 39
Hart Mode : ............................................................................................................................................................... 39
The Graph window ........................................................................................................................................................... 40
The Graph Menu ............................................................................................................................................................... 41
File : Save Image ...................................................................................................................................................... 41
File : Save Snapshot.................................................................................................................................................. 41
File : Load Snapshot ................................................................................................................................................. 41
File : Load History File ............................................................................................................................................. 41
File : Convert History File ........................................................................................................................................ 41
STI Advanced Panel ......................................................................................................................................................... 42
Probe (STI Advanced Panel) ............................................................................................................................................ 43
Proportional valve (STI Advanced Panel) ........................................................................................................................ 44
FB Current Value :.................................................................................................................................................... 44
Manual control : ........................................................................................................................................................ 44
Calibration type : ...................................................................................................................................................... 44
SOV (STI Advanced Panel) .............................................................................................................................................. 45
Feedback : ................................................................................................................................................................. 45
Manual Settings ........................................................................................................................................................ 45
4-20mA (STI Advanced Panel) ........................................................................................................................................ 46
An. Inputs (STI Advanced Panel) ..................................................................................................................................... 47
General (STI Advanced Panel) ......................................................................................................................................... 48
‘Erase calibration’ :................................................................................................................................................... 48
‘Set as default’ : ........................................................................................................................................................ 48
Reset to default’: ....................................................................................................................................................... 48
‘Upload’ : .................................................................................................................................................................. 48
‘Reset factory default’ : ............................................................................................................................................ 48
‘Save parameters’ : ................................................................................................................................................... 48
‘Memory test’ : ......................................................................................................................................................... 48
Trips detection time: ................................................................................................................................................. 48
SD CARD : Pre Trigger Time .................................................................................................................................. 48
SD CARD : Log Time .............................................................................................................................................. 48
The Menu.......................................................................................................................................................................... 49
Menu : File.................................................................................................................................................................... 49
Load: ......................................................................................................................................................................... 49
Save : ........................................................................................................................................................................ 49
Report : ..................................................................................................................................................................... 49
Exit : ......................................................................................................................................................................... 49
Menu : Device............................................................................................................................................................... 49
Download.................................................................................................................................................................. 49
_____________________________________________________________________________________

USER MANUAL
ST2
Example of Configuration Report............................................................................................................................. 50

SYSTEM INFORMATION............................................................................................................................................ 50
TRAVEL CONTROL ....................................................................................................................................................... 50
TUNING ........................................................................................................................................................................... 50
Parameter ...................................................................................................................................................................... 50
Channel 1 ...................................................................................................................................................................... 50
Channel 2 ...................................................................................................................................................................... 50
FAIL TRIP SETTINGS .................................................................................................................................................... 52
SOV STATUS ................................................................................................................................................................. 52
Channel 1 ...................................................................................................................................................................... 56
Channel 2 ...................................................................................................................................................................... 56
Menu : Password........................................................................................................................................................... 60
Login......................................................................................................................................................................... 60
Change ...................................................................................................................................................................... 60
Menu : ? Info ................................................................................................................................................................ 60
Electrical connections: ...................................................................................................................................................... 61
Application example : ................................................................................................................................................... 61
Terminal Board : wiring specification and electrical rating .......................................................................................... 62
Terminal board from 1 to 50 and from 100 to 113 : ................................................................................................. 63
Terminal board from 51 to 70 ................................................................................................................................... 63
Terminal Board : pinout ................................................................................................................................................ 64
Terminal board from 1 to 50 ..................................................................................................................................... 64
Terminal board from 100 to 113 ............................................................................................................................... 66
Position Feedback Probe............................................................................................................................................... 67
Analog Input ( pressure sensors)................................................................................................................................... 68
4-20mA IN : Request position ...................................................................................................................................... 69
4-20mA OUT ................................................................................................................................................................ 70
Digital output ................................................................................................................................................................ 71
TRIP : Digital Input ...................................................................................................................................................... 72
ON/OFF SOV ............................................................................................................................................................... 73
Proportional Valve ........................................................................................................................................................ 74
Power supply ................................................................................................................................................................ 75
AC universal input (standard solution) : ................................................................................................................... 75
DC 24V= input : ....................................................................................................................................................... 75
DC 24V= input without isolation :............................................................................................................................ 75
Options...................................................................................................................................................................... 75
How To (advanced user configuration guide)................................................................................................................... 76
Configure SOV and TRIP ............................................................................................................................................. 76
Setting the the Trip signal Type :.............................................................................................................................. 77
Setting the Activation Status : .................................................................................................................................. 77
Setting the SOV : ...................................................................................................................................................... 78
Configure Power reduction and test the SOV ........................................................................................................... 79
Configure the Proportional Valve ................................................................................................................................. 80
Select the type of proportional valve ........................................................................................................................ 80
TROUBLE SHOOTING .................................................................................................................................................. 81
ST2Mono : single channel version ................................................................................................................................... 83
Differences : ................................................................................................................................................................. 83
ST2Mono Power supply : ............................................................................................................................................. 83
ST2Mono : terminal board............................................................................................................................................ 84
_____________________________________________________________________________________

USER MANUAL
ST2
Description
The “Smart Trak” controller is used as a positioning system for proportionally-driven hydraulic actuators.
Fast stroke and superior resolution allow the unit to be applied on severe service hydraulic actuators demanding fast
stroking and precise positioning. Smart Trak system covers a wide range of actuator size and stroke length
requirements.
Smart Trak 2 is able to drive two fully independent actuators.
The Smart trak controller must be connected to the following devices:

1. feedback probe (for each actuator) which detects the hydraulic actuator's actual position
2. One modulating valve ( for each actuator)
3. Up to 3 on-off solenoid ( for each channel)
4. Optional pressure/temperature (4-20mA signal) sensors
On the customer's side power supply, 4-20mA signal (request position) and if required trip signal and output signal
must be connected.
CONTROLLER MOUNTING
The controller enclosure is rated for NEMA4 (NEMA4X when the Stainless Steel) / IP66 environment, which is
watertight to “wash down”, such as a water hose. Outdoor mounting is acceptable, however, the controller should be
protected from direct sunlight by a suitable sun shield (see temperature ratings).
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USER MANUAL
ST2
Manufacturer’s identification :
Every controller Smart Trak is provided with a name plate with its serial number. The year of
manufacturing is indicated by the first two numbers of the serial number.
Do not remove it and/or replace with other name plates
The decoder of the

manufacturer’s model can be made by means of the following table :
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USER MANUAL
ST2
ST2
Housing
O – Standard
I – Stainless steel
H – Hazardous
S – Special
Output port
1 – Blank
2 – Standard dwg. ……
3 – Standard dwg. ……
4 – Special
5 – Hazardous dwg. ……
Supply
1 – Universal AC / 110 Vdc
2 – 24 Vdc DC/DC
3 – None
4 – Special
Communication
D – Nr. 2 digital
C – Nr. 2 digital + CANBUS + 485/422
N – None
S – Special
Display
0 – Blind cover
1 – With display
Certification
A – American (UL)
E – European CE
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GENERAL SAFETY INSTRUCTIONS

The non-observation of the following safety instructions and of the instruction manuals can result in
serious injury.
Installation
- Must be done by qualified person trained to operate
- A ground tap is necessary
- The electrical and hydraulic connections must be done according to the diagram and label
- The supply circuit must be protected in case of current exceeding the limit fixed
- The equipment must be provided with cable entries and filler plugs certified according to the
required certification
- The actuator must be installed and used according to the project design specification.
- The fluid must be chemically compatible with the used gaskets and lubricant
Maintenance
- Must be done by qualified person
- Cleaning must be done with a humid cloth
- Greases and oils must be used according to the manufacturer’s instructions, however their
flammability point must be > 140°C
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USER MANUAL
ST2
Controller sw upgrade
The software is factory installed in the controller. For a new installation, a "Loader" program is necessary. It can be
installed selecting the file SETUP.exe from the supplied LOADER software cd.
A shortcut should appear in the program selection of start menu. Select the “Loader” access program:
Program » Loader » Loader
Or select it directly:
C:\Program Files\STI s.r.l\Loader\Loader.exe
The following window will appear:
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Configure the PC COM port selecting: “Configuration” from EDIT menu for “Texas 2812 DSP”.
Copy the DSP software to be installed to a folder on the laptop. File extension should be “.hex”.
Perform the following steps on the Smart Trak controller to prepare it for software loading.
- Turn off the controller by the main power switch
- Change the switches SW1 as showed in SW Upgrade mode
NORMAL
SW UPGRADE mode
Attach the USB cable to the CN1 connection block

- Launch the loader program
- Select the down arrow next to the “OPEN” quick select button
- Select “Texas 2812 DSP File”
- Locate the .HEX file, and select OPEN
- Turn on the controller
- Select the “Program” quick select button
-
The program should run to completion
- Upon completion select File » Exit
- Turn off the controller
- Change the switches SW1 as showed in Normal mode.
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IOM 4029 - ST2 User manual - rev.2 08/2010 - 10 -

USER MANUAL
ST2
RemoteControl sw installation
• Insert the CD ( or download the installation file)
• Run setup.exe
• Follow the instruction on the desktop
RemoteControl sw connection
USB connection :
Connect a standard USB ‘A’ to ‘B’ cable from your computer to the ST2 USB port
CN1
When the USB connection is used a specific USB driver is required.

The USB driver is usually provided with the RemoteControl installation file or can be
download from http://www.ftdichip.com/Drivers/VCP.htm with reference to FT232R device.
If communication problems are recognized check the ‘latency timer’ in the advanced properties of the COM port
assigned and set it to 1ms.
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ST2
Starting the sw
• Run the sw starting from the desktop icon or from the Windows Start menu.
The ‘Select Communication’ page is displayed.
• Select the right communication port
Only the available communication

ports are displayed in the combo box.
• Select the Communication mode (RS232or

HART)
• Press the ‘OK’ button
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ST2
MAIN VARS
The Main page
QUICK
BUTTONS
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Quick Buttons
Download button
Download all the parameters from ST2.
At the end of the download the values displayed on the RC sw are the same of the ST2 positioner
Graph button
Open the Graph window
Password button
Open the Login window
In order to change the parameters value or to access the various configuration windows a login is request.
The default standard password is : 12345
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‘Tuning window’
‘Travel Control’ area
Definitions :
Limit : when a limit is configure the Request position is limited at this value
Example : Set the Limit at 95%. Even if the signal input is 20ma and the theoretical Request position is 100%, the
applied Request position is 95%
CutOff : When a cutoff is configured if the Actual position falls inside the Cutoff area the Request position is fixed at
the min ( or max) value.
Example : Set the cutoff at 5%. When the Request position is less of 5% and the Actual position is less of 5% a fixed
pressure is applied in order to put the actual position at 0%.
WARNING_
On some type of valves it is mandatory to enable a cutoff to ensure that the valve works properly ( to ensure full trust
on sit)
0 Ctrl Signal :
Specify the relationship between 4-20mA signal input and stem position.
‘Stem in’ means that you want that the Stem is in ‘in position’ when you apply 4mA
‘Stem out’ means that you want that the Stem is in ‘out position’ when you apply 4mA
0 Position :
Specify the relationship between 0-100% indication ( a 4-20mA Out) and stem position.
‘Stem in’ means that 0% position is when the Stem is in ‘in position’
‘Stem out’ means that 0% position is when the Stem is in ‘out position’
Low [0..50 %]:

Specify if a Limit or a CutOff is configurated in the close direction.
High [50..100 %]:

Specify if a Limit or a CutOff is configurated in the open direction.
Tuning :
A lot of parameter are configurable with a different value in the Open direction and in the close one. This is to
maximize the performance of the system.
If the Mono flag is checked the first value of each parameter is automatically copied in the second one.
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Kp IN/OUT [0 .. 100]:
Proportional gain is the multiplier of the error (difference between input signal and actuator actual position) and it is
expressed in percent. It is active only for an error which is bigger than dead band value.
A different gain for each stem direction can be imposed.
Stroke Time IN/OUT [0,0 ..3000,0 sec]:

The value expressed in seconds of the stroking time for each direction
Approach IN/OUT [0..100]:

Special parameter, similar to a derivative factor, used to control overshoot.
Dead Band [0..10] :

Dead band prevents (at expense of the accuracy) that the valve, in the controlled condition, keeps continuously hunting
for the target position
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ST2
‘IN/OUT window’
Fail/Trip settings
Configure the digital input for TRIP function.
Up to 6 digital input are available.
For each digital input you can configure :
Mode C1/C2 :
Error mode for channel 1 and channel 2.
It is possible to define the action to do when the TRIP input is
ON.
Normally a TRIP is related only to one channel, but it is

possible to set an error mode for both the channels.
• Off/DirectDriveMode/Booster Enabled Mode :

The TRIP is not used or it is assigned for Direct Drive
function ( See SOV configuration)
• SafetyShutdown :
Up to 3 different Safety mode for each channel.
The SOV activation in each SafetyShutdown mode is
define in the SOV configuration panel
• Modulation valve :
The actuator is driven to a specific position specified in
the ‘Pos’ field that is showed when ‘Modulation Valve’
is selected
• Freeze :
Actuator freezes in the last position
• Ack :
Trip is used for the error acknowledgment
in remote mode.
• External SOV :
External safety shut down valve has been
activated.
Ack END MODE

The end mode option allows to configure the action to be executed at the end of the error conditions.
On St.
This option allows to configure the ON status for the selected trip.
‘E’ means : when the input is energized ( contact is closed or voltage is applied)
‘nE’ means : when the input is de-energized ( contact is open or voltage is not applied)
For safety reason the best choice is ‘nE’ : if a wire is cut off you are able to recognize this potential problem
Err : Led used to show if a trip is activated (trip status , energized or not, is equal to ‘On St’ and a function , Mode
C1/C2) is defined.
Hw : Led used to show if a trip is energized or not
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SOV
SOV1 SOV2 SOV3 SOV4 SOV5 SOV6
Yellow Led : SOV On

Red led : SOV disconnected or short circuit
Black led : SOV off
Configuration
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SOV ASSIGNEMENT
Select if a SOV is assigned to Channel 1 or Channel 2 or if it is reserved for DirectDrive.
Selecting DirectDrive a SOV is not assigned to a specific channel and can be activated from a trip. This mode is used
typically to drive ON/OFF Valve without feedback.
When a specific trip is assigned to a SOV for direct drive, a warning is showed if the trip is already assigned for other
functions.
Channel 1 :
Only the SOV assigned to channel 1 are active and configurable in this panel.
The matrix specify if a SOV is activated or not in a specific Running/SafetyShutdown status.
Refer to “Configure SOV and TRIP” at the end of this instruction manual to understand how to set the SOV.
Channel 2 :
Only the SOV assigned to channel 2 are active and configurable in this panel.
The matrix specify if a SOV is activated or not in a specific Running/SafetyShutdown status.
Refer to “Configure SOV and TRIP” at the end of this instruction manual to understand how to set the SOV.
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SOV BOOSTER FUNCTION
This feature come with sw release 2.0 .

The ON/OFF valves can be used in order to speedup the movement of big actuators.
Two operative modes are available :
- With enable
- Normal
When Booster ‘with enable’ is selected a specific TRIP signal is used like ENABLE of the booster : it means that you
can have a big error and that the movement can happens only with the proportional valve ( if the TRIP is not activated )
or also with the ON/OFF valve.
When Booster ‘normal’ is selected every time the error is greater than the activation threshold the ON/OFF valve is
used.
The Booster function is related to a SafetyShutdown mode and not to a specific SOV because in order to move in one
specific direction the status of more than one SOV must be changed.
Configuration parameters :
Mode :
No : booster function is disabled
Normal : booster function is enabled all the time based on the other configuration parameters
With Enable : booster function is enabled based on the status of the TRIP channel specified on the same row
Target :
We need to specify if this ‘safety shutdown’ mode move the actuator in the ‘Stem IN’ or ‘Stem OUT’ direction. Make
attention : a wrong settings can cause an hydraulic short circuit ( if the proportional valve is used with the booster)
Activation Threshold :
Is the minimum error that can start the booster activation
Disactivation Threshold :
Is the residual error ( when we are approaching the target) that stop the booster activation
Use PV :
If this caption is selected the proportional valve works helping the movement during the booster action
Trip Nr :
This parameter is used only when the mode is ‘With enable’ and specify the TRIP channel used to enable the booster
function.
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The TRIP signal is evaluated ‘on the edge’ and not ‘on the level’ , it means that in order to enable the booster the TRIP
status must change from ‘not active’ to ‘active’. It cannot be ‘active’ all the time, if you need the booster all the time
you need to select mode=’Normal’
When the Mode is ‘With Enable’ the SafetyShutdown mode related to a booster cannot be used like in the previous sw
versions for a Quickopen or QuickClose function because it is automatically disactivated when the error is less than the
‘disactivation threshold’.
Examples of movement :
Booster ‘with enable’, PV not used.
The slope changes because the

The setpoint is changed BOOSTER is activated
TRIP is activated
and the
BOOSTER are
fired
PV is used at the beginning ( PV is used at the end when the

before the enable that come from booster is disactivated
the TRIP)
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USER MANUAL
ST2
Booster ‘with enable’, PV used.
The setpoint is changed
TRIP is activated
and the
BOOSTER are
fired
PV is used all the time The slope changes because the

BOOSTER is activated
The slope changes again because

the BOOSTER is disactivated
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Digital Output
Digital Output 1 Digital Output 2 Digital Output 3
Yellow led : Digital Output ON

Configuration
Three Digital Output are available, for each one it is

possible to select different activation options.
When a Digital Output is configured it is Turned ON

( the normally open contact of the relay is closed) if
the error condition is not present and it is turned off
when the error condition is true.
Selecting more than one error condition in one

column the output is turned off when at least one
condition is verified.
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ST2
Analog Outputs
Two analog outputs are available.
It’s possible to choose the required parameter, in order to

associate it to the selected output channel for the
reproduction of the indicated signal in a range from 4mA to
20 mA.
• ReqPosCh1 : required position of CH1 , between

4÷20 mA
• ReqPosCh2 : required position of CH2 , between
4÷20 mA
• ActPosCh1 : actuator position of CH1 , between
4÷20 mA
• ActPosCh2 : actuator position of CH2 , between 4÷20 mA
• InputCh1 : input signal of CH1 , between 4÷20 mA
• InputCh1 : input signal of CH2 , between 4÷20 mA
• Temperature :temperature in the controller box , between 0÷100°C
• AI1 : Analog input 1 , between 4÷20 mA
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Temperature
Show the temperature inside the enclosure.
Date & Time

Show Date & Time of the controller.
This information is used for diagnostic purposes.
With a double-click it is possible to change the

date&time ( when you double-click a panel with actual
date&time –taken from the laptop - is opened, pressing
‘OK’ this information is sent to the controller).
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History and Diagnostic

Different level of diagnostic data are available.
COUNTERS
• Counters
• Historic event log Historic Event Log
• Periodic log (SD Card)
• Event log (SD Card)
Counters :
The controller record the number of time that an event happens and the last time and date of this event.
Events are grouped in three main groups : Channel 1, Channel 2 and Alarm Counters
Press the ‘download’ button to get data from the positioner
Press the ‘Report’ button to make a file (in .rtf format) with all the data
Press the ‘Exit’ button to close the window

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Example of Diagnostic Report :
Report Date : 13/10/2008 15.20
CHANNEL 1
Error Counter Date
Signal <min : 0
Pos.Exc.Error : 0
Pos.Exc.Warn. : 0
Probe : 2 10/10/2008 18:31:11
Hard Limits : 0
Calib. Erased : 0
Calibr. Aborted : 0
System Counter Date
Calibration : 0
In Service : 0
Out Of Service : 0
Position History
Total Stroke (Stroke nr.) : 0h 00m 12s

Time in [0,1) : 6h 07m 30s
Time in [1,25) : 0h 04m 25s
Time in [25,50) : 0h 00m 00s
Time in [50,75) : 0h 00m 00s
Time in [75,99) : 0h 00m 00s
Time in [99,100) : 0h 00m 05s
In Service Time : 0h 00m 00s
CHANNEL 2
Error Counter Date
Signal <min : 0
Pos.Exc.Error : 0
Pos.Exc.Warn. : 0
Probe : 2 10/10/2008 18:31:11
Hard Limits : 0
Calib. Erased : 0
Calibr. Aborted : 0
System Counter Date
Calibration : 0
In Service : 0
Out Of Service : 0
Position History
Total Stroke (Stroke nr.) : 0h 00m 06s

Time in [0,1) : 6h 12m 00s
Time in [1,25) : 0h 00m 00s
Time in [25,50) : 0h 00m 00s
Time in [50,75) : 0h 00m 00s
Time in [75,99) : 0h 00m 00s
Time in [99,100) : 0h 00m 00s
In Service Time : 0h 00m 00s
Alarm Counter Date
Trip 1 : 0
Trip 2 : 0
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Trip 3 : 0
Trip 4 : 0
Trip 5 : 0
Trip 6 : 0
Error on SOV 1 : 0
Error on SOV 2 : 0
Error on SOV 3 : 0
Error on SOV 4 : 0
Error on SOV 5 : 0
Error on SOV 6 : 0
EEPROM 0 : 0
EEPROM 1 : 0
Temperature [°C]
Min : 23.2
Max : 36.0
Average : 33.7
Events Log
10/13/2008 15:18:20 Log Time: 10 --> 2

10/13/2008 15:16:11 Log Time: 0 --> 10
10/13/2008 12:27:41 System Turned ON
10/10/2008 18:31:11 Ch1 Probe Error
10/10/2008 18:31:11 Ch2 Probe Error
10/10/2008 18:26:46 System Turned ON
10/10/2008 18:26:00 Ch2 Probe Error
10/10/2008 17:19:11 SOV3: Channel 1 --> Channel 2
10/10/2008 17:18:42 SOV2: Channel 1 --> Channel 2
10/10/2008 17:01:41 Trip 2 Err Mode: Off --> SSD1
10/10/2008 16:53:47 Ch1 Operation Mode: Stem Out --> Stem In
10/10/2008 16:53:41 Ch1 Operation Mode: Stem In --> Stem Out
10/10/2008 16:46:38 Ch1 HighLimit: 95,0 --> 96,0
10/10/2008 16:46:33 Ch1 LowLimit: 5,3 --> 5,0
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Historic event log
Up to 500 events can be stored in the internal eeprom

of the positioner.
The events are stored in a circular queue , so when
the limit is reached the older elements are deleted to
free space for the new elements.
Each element is recorded with : date, time , event
specification.
Press the ‘Start Read’ button to

download the events from the
positioned.
Events are downloaded starting from the most recent

one.
Press the ‘Stop Read’ button to stop

the download.
Filter options are available to show only :

- Errors
- Warning
- Info
It is also possible to select a filter related to the
channel : only Ch1, only Ch2, Ch1 & Ch2
Types of event :
- Ch x Signal < min

- Ch x Signal > max
- Ch x Position Error
- Ch x Position warning
- Ch x Probe Error
- Ch x Hard Limit
- Ch x Calibration Erased
- Ch x Calibration Aborted
- Ch x Calibration Completed
- In Service
- Out Of Service
- Trip x
- Error On SOV x
- Eeprom x
- System Startup
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Periodic log (SD Card)
Inserting an SD Card in the slot an automatic process of data

collection is activated.
The time between two consecutive recording is defined in the

SDCARD LogTime parameter in the advanced STI menu.
Typically the LogTime is equal to 10 minutes.
A file is created for each month of the year, the name of the file is
DIAGyymm (where ‘yy’ is the year and ‘mm’ is the month).
The Graph Tool allow :

- To open the History file and show the most important data
- To convert the History file in a .csv file ( compatible with
Excell and other spreadsheet)
Converting the History file you have access up to 30 different data

to monitor the status of a positioner.
SD Card slot
SDCard :
ST is able to manage standard SDCard formatted in FAT16 (storage capacity up to 2Gbyte).
In the STI advanced panel it is possible to check if the SD is recognized or not.
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Event log (SD Card)

- Every time an event happens a SnapShot is saved on the SD card
- SnapShot is 20 seconds lenght with a sample rate of 100Hz
- SnapShot is centered around the event (pretrigger is configurable in the advanced STI menu)
- The RemoteControl Graph tool is able to open and show a SnapShot file
- SnapShot are saved with a name related to date/time/event_type in order to find the data in an easy way
Events that start a snapshot are :

- Ch x Signal < min
- Ch x Signal > max
- Ch x Position Error
- Ch x Position warning
- Ch x Probe Error
- Ch x Hard Limit
- TRIP x
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Main vars and status

This window report a collection of information about the status of the positioner.
You can select 3 different views :

- Channel 1 : only the information of the channel 1
- Channel 2 : only the information of the channel 2
- Channel 1 and 2 : the information of both the channels
ActPos [%] :
Actual position measured by the positioner.
ReqPos [%]:
Request position evaluated ( the request position take in account the ‘Service State’, the 4-20ma input signal or manual
setup, the transfer function and the split range)
Input [mA]:
Current read at the 4-20ma Loop current Input channel.
The user can align the value showed using the commands available in the ‘CFG’ area
Status :
The calibration status is showed
Errors:
Show , for each channel, the actual and the last error. More detailed information are available in the ‘history and
diagnostic’ window.
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Service State / Mode :

Allow the selection of the Service State.
- In Service : the Request Position is evaluated continually by the positioner starting from the 4-20ma signal
value
- Out Of Service (Manual) : the Request Position come from the manual set in the window. When the Service
Mode become ‘Out Of Service (Manual)’ the first manual setpoint is equal to the last ‘Actual position’ in order
to minimize the movement of the system
- Out of Service : special mode selected automatically when the system is not calibrated. In this mode port B is
fully pressurized and port A is depressurized
WARNING_
Changing from ‘Out of Service’ to ‘In Service’ the system can move
The ‘Main vars’ window can show information in two ways :

Channel 1 & 2 : reduced set of information concerning the two channels in one page
Only one channel : detailed information for one channel at a time
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Channel 1 CFG window (Channel 2 CFG window)
CALIBRATION
Start the calibration procedure.
WARNING_
When the ‘Start Calibration’ button is pressed the system can move.
INPUT SIGNAL : Split range

Enable the split range function.
The values in Lower range value and Upper range value are referred to the 4-20mA input.
A minimum distance of 20% is required between Lower and Upper value, so up to 5 split range area can be configured
in different concatenated positioners.
The result of the split range is then evaluated by the ‘Transfer Function Curve’.
If the Low range value is equal to 0% and Upper range value is equal to 100% the positioner interpret 4ma like the 0%
Request position and the 20ma like 100%.
If the Low range value is equal to 0% and Upper range value is equal to 50% the positioner interpret 4ma like the 0%
Request position and the 12ma like 100%.
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INPUT SIGNAL : Calibrate 4mA
Read the actual value of the input current and assume it like 4ma value.
CAUTION_
Be sure that you are supplying the positioner with a stable, real 4ma
INPUT SIGNAL : Calibrate 20mA

Read the actual value of the input current and assume it like 20ma value.
Change Description
Each channel can have a description used to identify it in an easy way.
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INPUT CHAR.
The Characterization specify the relationship between the Input signal and the Request Position.
Selecting ‘Customer’ you have the chance to draw a specific

characterization curve.
Table button :
Open the Transfer Function Curve window
- The ‘Stem In’ and ‘Stem Out ’ label in the ‘Requested position’ axis show the effect of the ‘0 Ctrl Signal’ and ‘0
Ctrl Position’ selection
- The ‘4.0ma’ and ’20.0ma’ in the ‘Signal Position’ show the effect of the ‘Split Range’ setup
- The effect of ‘Limit’ and ‘CutOff’ are

showed on the graph
- To ‘Send’ a ‘Customer Curve’ to the

Positioner press the ‘OK’ button.
- You can change a value in the
table or click_&_move the dot in
the graph
- Keeping hold the shift key and
clicking on two dots,
automatically the system make a
linear interpolation between these
two points.
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ST2
Position excess Fail

Selecting this command, it’s possible to configure the max admissible position error and warning (difference
between the required and the actual position) and the actions to be executed, if these limits are exceeded.
• Mode : configure the action that will be taken when the

error happens.
• Warning Tolerance : it's possible to set the max error
position value (tolerance) that cause a warning
• Warning Time : In case of warning condition, this
parameter defines the waiting time before the alarm is
activated
• Error Tolerance : it's possible to set the max error
position value (tolerance) that cause an error
• Error Time : In case of error condition, this parameter defines the waiting time before the alarm is activated
To set the value, double click on the corresponding cell, click the option and press “OK” to confirm it or
“CANCEL” to exit.
Signal Fail
This command allows to configure the minimum and maximum admissible inlet signal (mA), the actions to be
executed if these limits are reached and the error clearing condition.
Mode : The first line allows to configure the action to be executed in case of an out of range or fail signal.
To set the value, double click on the corresponding cell, click the option and press “OK” to confirm it or
Ack : The end mode option configures the action to be executed at

the end of the error conditions.
The available options are:
OPTION EXECUTED ACTION
• AUTO Automatic return to normal working
condition without waiting for confirmation.
• WAIT ACK A confirmation is required before
returning to normal working condition.
• WAIT NOERR Automatic return to normal working condition only if all
Position :
This function is active only if the “Spool” selection has been made for the “Error mode” option; by this function
it’s possible to define the actuator position in case of signal fail.
The value of the position (expressed in percentage of the stroke) can be adjusted between -10 and 110% of the
stroke,
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Probe Fail
Mode : The first line allows to configure the action to be

executed in case of an out of range or fail of the probe.
To set the value, double click on the corresponding cell,
click the option and press “OK” to confirm it or
Ack : The end mode option configures the action to be executed at the end of the error conditions.
The available options are:
OPTION EXECUTED ACTION
• AUTO Automatic return to normal working condition without waiting for confirmation.
• WAIT ACK A confirmation is required before returning to normal working condition.
• WAIT NOERR Automatic return to normal working condition only if all
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HART panel
HART PARAMETERS
Tag :
The Tag is a 8 character label assigned
by the end user based on the location
and use of the field device. It’s a 8
character (6 byte) Packed ASCII string
used to identify the field device. The term
originated when physical tags were
attached to instruments for this purpose.
Date :
The date is represented by three 8-bit binary unsigned integers representing, respectively, the day, month and
year (minus 1900). It’s a date code, used by the Master for record keeping (e.g. last or next calibration date).
Descriptor :
The Descriptor is a 16 character (12 byte) Packed ASCII string used by the Master for record keeping.
The default value is a blanked string, 16 bytes long.
Message :
The Message is a 32 character (24 byte) Packed ASCII string used by the Master for record keeping.
The default value is a blanked string, 32 bytes long.
Polling address:
In the HART Protocol, the polling address is an integer used to identify the field device. It is used to construct the
Short Frame Address. The Polling Address is set to 0 in point to point installations.
Dev. ID :
This number is different for every device manufactured with a given Manufacturer ID and Device Type.
HART Protocol
Show some communication parameters used for debug
HART Communication
Hart Mode :
‘Time management’ and ‘Time management (performance)’ are two different way to manage the Hart modem. If you
have experience of communication problems try to change this option.
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USER MANUAL
ST2
The Graph window
Event Line : moving with the

mouse on the line, specification
about the event are showed ( i.e.
Ch1 TRIP1)
Begin a movement (if

in manual mode)
Start & Stop the
recorder
Specify the CH1 Required position

Channel 2 information selector. for a manual movement
Specify the CH2 Required position

Channel 1 information selector.
for a manual movement
Double Click on the painted area to

change the color.
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USER MANUAL
ST2
The Graph Menu

File : Save Image
Save the actual showed picture like a .bmp file
File : Save Snapshot

Save the actual picture in binary file
File : Load Snapshot

Load the graph stored in a binary file
File : Load History File

Load an History file previously stored in a SD card
Opening the file you can select the portion of the graph that you want to
see.
In the right-bottom side of the graph appear a selection box with a list of
the records available. Select the desidered one and click Load to open.
File : Convert History File

Open an History file previously stored in a SD card in a .csv file. It is possible open the file with a spreadsheet like
Excel and analyze the data.
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USER MANUAL
ST2
STI Advanced Panel

This panel is for expert user only.
Inserting the password ‘23456’ the ‘STI’ button appear in the top left part of the main window.
Pressing the ‘STI’ button different windows are available
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USER MANUAL
ST2
Probe (STI Advanced Panel)

For each channel is possible :
- Select the type of the probe
o Micropulse
o 4-20mA
- Check the actual values
- Verify calibration limits
It is possible to change the type of the probe

only if the channel is NOT calibrated.
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USER MANUAL
ST2
Proportional valve (STI Advanced Panel)
The P.V.Type allow the

selection of different types of
proportional solenoid valve.
Choosing a value the PWM
min and max limits are
loaded.
If it is needed to use a
proportional valve not listed ,
it is possible to evaluate the
min and max value with
manual control and then put
the value in the min and max
field ( select calibration type
equal to ‘Manual’ to disable
the self evaluation of the
current limits).
FB Current Value :
Show the current ( in
ampere) that flow in the
solenoid valve.
Manual control :
(only if the channel is not
calibrated)
Drive manually one proportional valve.
Write a value in the field (between the PWMmin and max values) and press the ‘+’ or ‘-‘ button to energize the
proportional valve in one direction or in the other).
Check the current that energize the solenoid in the ‘FB Current Value’ field.
Calibration type :
Manual : during calibration only the minimum current needed to move the valve is evaluated
Autosearch : during calibration not only the minimum current is evaluated but also the PWM needed to reach the
nominal current value ( if you select an ATOS 12V 2,2A the ST2 search for the PWM that is necessary to drive 2,2A in
the coil).
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USER MANUAL
ST2
SOV (STI Advanced Panel)
Feedback :
The ‘SET’ column show if the ST2
want to energize a specific
solenoid valve( The yellow led is
turned ‘ON’).
The ‘F.back’ column show if a

solenoid valve is connected
without errors ( the GREEN led is
turned ‘ON’ if a solenoid valve is
recognized).
‘Pw Red.’
Select the power level for the SOV.
A solenoid valve is energized with
the full power (24V=). After 1
second the power applied is equal
to the percentage specified in the
field. Reducing the power ( for
example at 80%) the life of a
solenoid valve is longer, the
heating is reduced and the total
power used for the device is less.
In case of long cables between ST2
and SOV it is important to check
that the voltage on the coil is
enought)
‘Use Feedback Control’

Checking the box if an error happens on a SOV it is managed by the ST2
Manual Settings
If the SOV is not assigned to a calibrated channel it is possible to turn ON and OFF it.
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USER MANUAL
ST2
4-20mA (STI Advanced Panel)
4-20mA INPUT :
It is possible to check the
calibration limits and the
current value
It is possible to calibrate the 4-

20mA input in the standard
channel CFG panel.
4-20mA OUTPUT :
It is possible to calibrate the
4mA and the 20mA signal
level of each output.
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USER MANUAL
ST2
An. Inputs (STI Advanced Panel)
For each analog input ( 6

channels are available) it is
possible :
- Calibrate the 4mA
limit
- Calibrate the
20mA limit
- Assign a Name of
4 digit ( for
example ‘Pi’)
- Assign a label like
measuring unit (
for example ‘bar’)
- Specify the
relationship
between the 4-
20mA signal and
the measured
value ( for
example :
4mA=0bar,
20mA=400bar)
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USER MANUAL
ST2
General (STI Advanced Panel)
‘Erase calibration’ :
For each channel it is possible to remove the calibration
‘Set as default’ :
Save the actual configuration data like a default in the ST2
memory.
Reset to default’:
Load a stored configuration. It is possible to select a partial set of
data to load.
‘Upload’ :
Send the actual data in the Remote Control to the ST controller. It is
possible to select a partial set of data to load.
‘Reset factory default’ :

Reset the ST2 to the factory default data.
‘Save parameters’ :
Start to save the parameters that are in RAM in the eeprom (this action is
only for diagnostic, the parameters are saved automatically when changed
in the RemoteControl interface.
‘Memory test’ :
With the ‘check memory’ button it is possible to check if the stored configuration is equal to the one used. This option
is for diagnostic purpose
Trips detection time:

Specify the delay (filter) in milliseconds for TRIP detection.
SD CARD : Pre Trigger Time

Position of the event in the 20 seconds snapshot. Selecting 8 sec the snapshot starts 8 second before the event.
SD CARD : Log Time

Period between two consecutive record in the Periodic Log
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USER MANUAL
ST2
The Menu
Menu : File
Load:
Load a saved set of parameters in the RC interface
Save :
Save the current set of parameters in a .qtp file
Report :
Make a document in .rtf format with the actual parameters ( It is similar to the Save command but the file format is
compatible with editor software)
Exit :
Close the application
Menu : Device
Download
It is the same of the quick button
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USER MANUAL
ST2
Example of Configuration Report
SYSTEM REPORT
SYSTEM INFORMATION
Date (PC) 08/20/2010 09.02.00
Date (Smart Trak) 08/20/2010 08:03:33
Channel 1 Description Channel 1
Channel 2 Description Channel 2
Device Unique ID 01D1FCC41100009F
DSP SW Version 9,09
Temperature 26,0
Channel 1 Channel 2
Calibration Status Not Calibrated Calibrated
Service State Out Of Service Manual
TRAVEL CONTROL
Parameter Channel 1 Channel 2
0 Ctrl Signal Stem In Stem In
0 Position Stem In Stem In
Low Limit 5,0 % 5,0 %
Low Limit Mode Off Off
High Limit 95,0 % 95,0 %
High Limit Mode Off Off
TUNING

Kp IN 10,0 0,2
Kp Out 10,0 0,2
Stroke Time IN 0,0 sec 0,0 sec
Stroke Time OUT 0,0 sec 0,0 sec
Approach IN 0 0
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USER MANUAL
ST2
Approach OUT 0 0
Dead Band (%) 0,50 % 0,50 %
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USER MANUAL
ST2
FAIL TRIP SETTINGS

Trip
Mode Ch1 Mode CH2 Ack “On” Status
Number
1 Off Safety Shut Down 4 Auto Energized
2 Off Off Auto Energized
SOV ASSIGNEMENT
SOV Number Assigned to:
1 Channel 2
2 Channel 2
3 Channel 2
4 Disconnected
5 Disconnected
6 Disconnected
SOV STATUS
Channel 1
SOV 1 SOV 2 SOV 3 SOV 4 SOV 5 SOV 6
Running -- -- -- -- -- --
Safety Shut Down 1 -- -- -- -- -- --
Safety Shut Down 2 -- -- -- -- -- --
Safety Shut Down 3 -- -- -- -- -- --
Channel 2
Running On Off Off -- -- --
Safety Shut Down 4 Off Off Off -- -- --
Safety Shut Down 5 On On Off -- -- --
Safety Shut Down 6 Off Off Off -- -- --
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USER MANUAL
ST2
BOOSTER CONFIGURATION
Channel 1
Mode Target Act. Tresh Dis. Tresh. Use PV Trip
Safety Shut Down 1 No Stem In 50,00 20,00 Yes Trip 1
Channel 2
Mode Target Act. Tresh Dis. Tresh. Use PV Trip
Safety Shut Down 4 With Enable Stem Out 50,00 5,00 Yes Trip 1
Safety Shut Down 5 With Enable Stem In 50,00 5,00 No Trip 1
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USER MANUAL
ST2
DIGITAL OUTPUT CONFIGURATION

OUT 1 OUT 2 OUT 3
Waiting Ack CH 1 Off Off Off
Waiting Ack CH 2 Off Off Off
Out Of Service CH1 Off Off Off
Out Of Service CH1 Off Off Off
Trip 1 Off Off Off
Trip 2 Off Off Off
Trip 3 Off Off Off
Trip 4 Off Off Off
Trip 5 Off Off Off
Trip 6 Off Off Off
General Error CH 1 Off Off Off
General Error CH 2 Off Off Off
Signal Fail CH 1 Off Off Off
Signal Fail CH 2 Off Off Off
Position Excess Error CH 1 Off Off Off
Position Excess Error CH 2 Off Off Off
Position Excess Warning CH 1 Off Off Off
Position Exce ss Warning CH 2 Off Off Off
Probe Error CH 1 Off Off Off
Probe Error CH 2 Off Off Off
ANALOG OUTPUTS CONFIGURATION

OUT A Off
OUT B Off
CHANNELS CONFIGURATION

Split Range Low 4,0 mA 4,0 mA
Split Range High 20,0 mA 20,0 mA
Position Excess Error Fail Mode Off Off
Position Excess Error Tolerance 10,0 % 10,0 %
Position Excess Error Time 10 sec 10 sec
Position Excess Warning Tolerance 10,0 % 10,0 %
Position Excess Warning Time 10 sec 10 sec
Signal Fail Mode Off Off
Signal Fail Ack Auto Auto
Signal Fail Min Value 3,0 mA 3,0 mA
Signal Fail Position 0,0 % 0,0 %
Probe Fail Mode Safety Shut Down 1 Safety Shut Down 4
Probe Fail Ack Wait Ack Wait Ack
Input Char Linear Linear
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USER MANUAL
ST2
CUSTOMER CURVE DATA

Channel 1 Channel 2
Signal % Req. Pos % Signal % Req. Pos %
0,00 0,00 0,00 0,00
10,00 10,00 10,00 10,00
20,00 20,00 20,00 20,00
30,00 30,00 30,00 30,00
40,00 40,00 40,00 40,00
50,00 50,00 50,00 50,00
60,00 60,00 60,00 60,00
70,00 70,00 70,00 70,00
80,00 80,00 80,00 80,00
90,00 90,00 90,00 90,00
100,00 100,00 100,00 100,00
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USER MANUAL
ST2
ADVANCED PARAMETERS
PROBE PARAMETERS
Channel 1 Channel 2
Probe Type MicroPulse 4-20mA
Probe Limit Inf. 4160 735
Probe Limit Sup. 11988 3473
PROPORTIONAL VALVE
Channel 1 Channel 2
Valve Type Atos 12V 2.2/2.6A Atos 12V 2.2/2.6A
Side 1
PWM_min 1000 1100
PWM_Max 3500 3500
PWM_1A 0 0
Side 2
PWM_min 1000 1100
PWM_Max 3500 3500
PWM_1A 0 0
SOLENOID VALVE

PWM Reduction 100% 100% 100% 100% 100% 100%
Use Feedback Control Off
INPUT 4-20 mA
Channel 1 Channel 2
AD Converter at 4 mA 12177 12177
OUTPUT 4-20 mA
OUT 1 OUT 2
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USER MANUAL
ST2
_____________________________________________________________________________________

USER MANUAL
ST2
USER ANALOG INPUTS
Analog Input 1
Name AI1
Measure Unit
AD Converter at 4 mA 761
Value at 4 mA 0,0
Value at 20 mA 400,0
Analog Input 2
Name AI2
Measure Unit
Value at 4 mA 0,0
Analog Input 3
Name AI3
Measure Unit
Value at 4 mA 0,0
Analog Input 4
Name AI4
Measure Unit
Value at 4 mA 0,0
Analog Input 5
Name AI5
Measure Unit
Value at 4 mA 0,0
Analog Input 6
Name AI6
Measure Unit
Value at 4 mA 0,0
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USER MANUAL
ST2
GENERAL PARAMETERS
Channel 1 Channel 2
Camera Mode Normal Inverted
SD CARD
Pre Trigger Time 8,0 sec
Log Time 60 min
TRIPS
Trips Detection Time 40 mSec
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USER MANUAL
ST2
Menu : Password
Login
It is the same of the quick button
Change
To change the password
Menu : ? Info
Information panel with different sw version data.
“Device Unique ID” is an hardware identifier used to identify a specific electronic hw.
_____________________________________________________________________________________

USER MANUAL
ST2
Electrical connections:
Application example :
_____________________________________________________________________________________

USER MANUAL
ST2
Terminal Board : wiring specification and electrical rating
_____________________________________________________________________________________

USER MANUAL
ST2
Terminal board from 1 to 50 and from 100 to 113 :

Phoenix Contact UKK3 (2770011)
Double-level terminal block with a screw connection, cross section: 0.2
mm2 - 2.5 mm2, AWG: 28 – 12
Rated surge voltage 6 kV
Nominal current IN 32 A
Nominal voltage UN 500 V
Type of connection Screw connection
Tightening torque, min 0.5 Nm
Tightening torque max 0.6 Nm
Terminal board from 51 to 70

Phoenix Contact UK 2,5 N (3003347)
Universal terminal block with screw connection, cross section: 0,2- 2.5
mm², AWG: 24- 12
Nominal voltage UN 800 V
Phoenix contact UK 6,3-HESI (3004171)

Fuse terminal block for cartridge fuse insert, cross section: 0.5 - 16
mm², AWG: 26 - 8,
Fuse G / 6,3 x 32
Nominal voltage UN 500 V (As a fuse terminal block)
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USER MANUAL
ST2
Terminal Board : pinout

_____________________________________________________________________________________

USER MANUAL
ST2
AC Power supply :
80 = Line
81 = Neutral
DC Power supply :
80 = Positive input
81 = Negative input
_____________________________________________________________________________________

USER MANUAL
ST2
_____________________________________________________________________________________

USER MANUAL
ST2
Position Feedback Probe

You can use two different type of position feedback probe :
Micropulse transducers or 4-20mA.
- BTL5-P1 Balluff Micropulse transducer ( or equivalent)

o The probe is powered at 24V=.
o Shield of the cable can be connected in the ST2 earth connection bar. Depending on the quality of the
earth connection in the field could be necessary remove the earth connection of the probe or connect it
at the gnd terminal board.
- 4-20mA signal transmitter (for example STI2030)

- The position transmitter is energized with a 24V= power supply.
- The measurement resistor inside ST2 is equal to 120 ohms.
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USER MANUAL
ST2
Analog Input ( pressure sensors)

6 input for 4-20mA ( or 0-5V) are available.
SW3 dip switch select if the input is for 0-5V ( dip in OFF position) or 4-20mA ( dip in ON position).
SW3_1 is for Analog IN1, SW3_2 is for Analog IN2 and so on.
4-20mA input (preferred solution) :

Terminal board 9 : +24V= for sensor excitation
Terminal pin 12, 36, 11, 35, 10, 34 : input signal from the sensor
Burden resistor : 227 ohms
Analog Input 0-5V :

Terminal board 33 : 5V to energize the sensors ( max 100mA)
Terminal board 8 : GND
Terminal pin 12, 36, 11, 35, 10, 34 : input signal from the sensor
Resolution : 12 bits
Sampling rate : 1KHz with moving average filter.
Isolation : Analog input are not isolated and designed for local use. Take care of electrical noise effect.
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USER MANUAL
ST2
4-20mA IN : Request position

CH1 : Terminal board 14 (+) and 38 (-) . With HART communication channel
CH2 : Terminal board 13 (+) and 37 (-)
Burden resistor : 474 ohms
Sampling Rate : 1KHz with filter
Hardware LowPass filter present.
Isolation : the two channels are isolated respect other electronic (microprocessor) and themselves
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USER MANUAL
ST2
4-20mA OUT
Two isolated independent channels are available.
The function is configurable.
The output is energized from the loop.
CH1 : Terminal board 16 (+) and 40 (-) . CH2 : Terminal board 15 (+) and 39 (-)
Output current (nominal) 4-20ma
Burden 750 Ω max ( power supply = 24Vdc)
External power supply 24V ( 12..30V)
Refresh frequency : 1KHz
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USER MANUAL
ST2
Digital output
3 indipendent digital output is available.
Material Gold overlay silver alloy

Rating (resistive) 3 A 250 VAC or 3 A 30 VDC
Maximum Carrying Current 5A
Maximum Switching Power 750 VA, 90 W
Maximum Switching Voltage 270 VAC, 150 VDC
Maximum Switching Current 5A
For each digital output the Normally Open contact is available (i.e. DigitalOutput 1 : pin 19 and 43)
When a DigitalOutput is configured the relè is energized ( and the contact become closed) when the error condition is
false, and is deenergized ( and the contact return to open condition) when the error condition is true.
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USER MANUAL
ST2
TRIP : Digital Input

6 indipendent isolated TRIP digital input are available.
Each trip can be drived from a ‘free contact’ or from a 24V= or 24Vac signal.
SW2 dip switch must be set in a proper way based on the type of driving signal.
Trip function is configurable in the sw.
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USER MANUAL
ST2
ON/OFF SOV
Up to 6 ON/OFF SOV are available.
Nominal voltage : 24V=
Nominal current : up to 2A ( continuos mode, ambient = 70°C)
Power reduction : It is possible to specify for each solenoid valve a different power reduction value.
Solenoids are energized at full power, after 1 second the pwm circuit reduce the power at the specified value
Solid state driver with :

- Over temperature shutdown (with auto-restart)
- Short circuit protection (current limit)
- Full diagnostic capability
- Active clamp
- Open load detection in On and Off state
Number and power of the SOV depends on the supply unit and the number of SOV that must be energized at the same
time.
Connect earth of SOV at the earth connection bar inside the ST2.
_____________________________________________________________________________________

USER MANUAL
ST2
Proportional Valve
ST2_Channel 1 : Proportional Valve A1 and A2
ST2_Channel 2 : Proportional Valve A3 and A4
Voltage output : 24V (pwm circuit allow the use of 12V solenoid)
Current output : hardware limit at 2,7A
Tested with ATOS 12V , ATOS 18V, Wandfluh 24V, Bosch
Selection of the type of proportional valve, minimum and maximum current is made by sw.
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USER MANUAL
ST2
Power supply
Different solutions are available.
AC universal input (standard solution) :

The power supply module is fitted inside the controller enclosure.
Power supply module is a PhoenixContact QUINT-PS/1AC/24DC/20 able
to supply 24V= with a current up to 20A.
Input range :
Nominal 100 V AC ... 240 V AC
AC range 85 V AC ... 264 V AC
DC range 90 V DC ... 350 V DC
DC 24V= input :
The power supply module is fitted inside the controller enclosure.
Power supply module is a PhoenixContact QUINT-PS-24DC/24DC/10
Check that the total power required ( depending from the number of solenoid and from the schematic) is less than 240W
DC 24V= input without isolation :

No power supply module is fitted inside the enclosure. The power supply is provided from the customer. Care must be
taken in the selection of cable size and length (possible problems : voltage drop, heating, noise).
We suggest to use a dedicated 24V= for each SmartTrak.
Options
(must be fitted in an external enclosure) :
Phoenix contact 2938963 Redundancy Module QUINT-DIODE/40

Phoenix contact 2866239 Uninterruptible Power Supply Unitfor Universal Use QUINT-DC-UPS/24DC/20
Phoenix contact 2866213 QUINT-BUFFER/24DC/20
_____________________________________________________________________________________

USER MANUAL
ST2
How To (advanced user configuration guide)

Configure SOV and TRIP
You must have a clear picture of what you want the SOV do.
Referring to the standard schematic showed you have :
SOV1 Related to channel 1 , function Quick Close

SOV2 Related to channel 1 , function Quick Open
SOV3 Not used
SOV4 Related to channel 2 , function Quick Close
SOV5 Related to channel 2 , function Quick Open
SOV6 Direct drived from TRIP for ON/OFF water valve
TRIP1 Quick Close command input for channel 1

TRIP2 Quick Open command input for channel 1
TRIP4 Quick Close command input for channel 2
TRIP5 Quick open command input for channel 2
TRIP6 ON/OFF water valve command
_____________________________________________________________________________________

USER MANUAL
ST2
For each TRIP signal you must know :

- The type of the TRIP signal ( 24Vac, 24Vdc, Free
contact)
- The activation status of the TRIP (Energized,
NotEnergized)
In our example we can consider the most standard configuration :
Trip Signal type = Free Contact
Activation Status = Not Energized
Setting the the Trip signal Type :

Set the SW2 and SW6 DIP-SWITCH all in the ON position like
described in the ‘TRIP : Digital Input’ paragraph ( If you have
some Trip signal powered at 24Vdc or 24Vac you must turn the
specific dip-switch in the off position).
Setting the Activation Status :

For TRIP1,2,4,5 select ‘NotEnergized’ in the RemoteControl panel.
Select the proper SafetyShutdown mode for each trip :
TRIP1=SSD1/OFF , ‘NotEnergized’ =SafetyShutdown1CH1when NOTEnergized
TRIP2=SSD2/OFF , ‘NotEnergized’ = SafetyShutdown2CH1 when NOTEnergized
TRIP3=OFF/OFF It is not used
TRIP4=OFF/SSD4 , ‘NotEnergized’ = SafetyShutdown4CH2 when NOTEnergized
TRIP5=OFF/SSD5 , ‘NotEnergized’ = SafetyShutdown5CH2 when NOTEnergized
TRIP6=OFF/OFF , Energized Must Be configured for DirectDrive in the SOV configuration panel
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USER MANUAL
ST2
Setting the SOV :
Set the SOV like showed in the picture.
Explanation :
Channel 1
When the SmartTrak channel 1 is in running ( normal operation mode when the system is calibrated), SOV1 is
energized and SOV2 is deenergized. The two ON/OFF valves are in the ‘close’ position, so the only valve that can
control the actuator is the proportional one.
If TRIP1 is activated SOV1 is deenergized (and also SOV2) : the quick close on/off SOV drive the actuator in the
CLOSE position.
If TRIP2 is activated SOV1 is energized (‘close’) and SOV2 is energized (‘open’) : the quick open on/off SOV drive
the actuator in the OPEN position.
Channel 2
Same of channel 1 but with SOV4, SOV5, TRIP1, TRIP2
SOV6 : This SOV is directly drived from TRIP6. When TRIP6 is activated (‘Energized’) it turns on the SOV6 that open
the ON/OFF valve
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USER MANUAL
ST2
Configure Power reduction and test the SOV
To reduce the power consumption of the solenoids, power reduction can be configured. With that on the one hand the
power dissipation of the power supply and the solenoids can be reduced, on the other hand the life time is going to be
increased. The power reduction is by means of pulse-width-modulation.
With longer lines between the SmartTrak and the solenoids, pay attention that the control voltage on the solenoid
through the voltage drop on the lines must not under 17 V.
When the solenoid is turned on , full power is applied for 1 second, after this time the power is reduced to the value
specified ( in %) in the specific configuration field.
Default value is 100% that means that power reduction is not applied.
If you specify a value of 75% it means that after 1 second the pwm circuit works at 75% with an equivalent voltage of
24V*75%=18V
Test the SOV :

Manual Setting allow to Turn ON and OFF
the SOV for diagnostic purpose ( this
feature is available only when the related
channel is not calibrated)
The Feedback led indicates if the

SOV is connected and works properly
( the electronic circuit is able to recognize if
the SOV is not connected or if it is in short
circuit)
The Set led indicates if the required SOV

status made by the sw.
‘Use feedback control’ enable error

management of the SOV.
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USER MANUAL
ST2
Configure the Proportional Valve

Select the type of proportional valve
You can select from different types of proportional valves.
Each proportional valve has a specific minimum and maximum current.
When you select a specific proportional valve, default values for this valve are loaded.
During the calibration the positioner use these

values for reference and find proper
configuration for :
- PwmMin : minimum driver power
able to move slowly the actuator
- PwmMax : default value if
‘Calibration Type = manual’ or pwm
value able to drive the theoretical max
current
FB CURRENT VALUE : Show the current

applied at the proportional valve
MANUAL CONTROL :
Allow to drive manually a proportional valve
for diagnostic purpose ( only when the channel
is not calibrated)
Tips & Tricks:

If you have a very little actuator but you have a big size proportional valve you can modify manually the PWMmax
parameter in order to increase the performance of the system.
Reducing the PWMmax value you can use big Kp :
- Kp is bigger : the system is quick and able to reduce the residual error ( reduce the deadband)
- PWMmax is lower : the proportional valve can’t be open at full flow rate ( even if you have a big kp you can
reduce overshoot and instability)
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USER MANUAL
ST2
TROUBLE SHOOTING
Problem description Cause Solution
1. The controller doesn’t 1.1 The power is not connected 1.1 Connect the power
switch on 1.2 the power supply voltage is out of 1.2 check the power supply voltage
the admissible range (+/-10%) value with a multimeter
1.3 the fuses are blown 1.3 replace the fuses
1.4 some wiring is not properly done 1.4 check the wiring using the
either inside the controller electrical diagram
1.5 there is a short circuit on some of 1.5 disconnect all the terminal boards
the devices connected to the connected to these device and check
controller whether the controller switches on.
2. Probe error 2.1 some wiring is not properly done 2.1 check the wiring
2.2 the software selection in STI 2.2 check that the software setting
menu of the used probe is not correct corresponds to the used probe
2.3 the probe has been calibrated 2.3 erase the previous calibration and
with a shorter stroke process valve perform a new calibration
2.4 the probe is damaged 2.4 replace the probe
3. Proportional valve is 3.1 the proportional valves connectors 3.1 check the connector plug
not working properly are not properly plugged 3.2 check the wiring
3.2 the wiring is not properly done
4. A change in the valve 4.1 the oil pressure value is too low 4.1 check the oil pressure value
position set point doesn’t 4.2 the proportional valve is sticking 4.2 check that the proportional valve
affect the actuator’s 4.3 the parameters configuration is can slide smoothly
position not correct 4.3 check gain and dead band values
4.4 actuator and/or jammed valve 4.3 check that the actuator can move
4.5 signal wires are not properly in a continuous way and not in steps
connected 4.5 check signal wires
4.6 circuit boards are defective 4.6 replace circuit boards
4.7 calibration and tuning have not 4.7 perform a calibration and make
been carried out the proper tuning
4.8 device is in “manual” or “out of 4.8 set the system in “in service”
service” mode mode
4.9 device is in fail safe status 4.9 check whether the solenoid valve
making the fail safe mode is
energized
5. Overshooting or 5.1 incorrect tuning in terms of dead 5.1 change the dead band and gain
positioning too slow band and gain values
5.2 the proportional valve is sticking 5.2 check that the proportional valve
5.3 too small oil tubing or dirty oil filter can slide smoothly
5.4 leakages in oil tubing and 5.3 check oil tubing size with the
manifold connections factory and inspect oil filter
5.5 process valve is sticking 5.4 check leakages in oil tubing and
manifold connections
5.5 check process valve
6. Low signal fail limit 6. Low signal fail limit 6.1 check that the signal wires are
properly connected to the terminal
board
6.2 check with a multimeter the value
of the signal
7. Position excess error 7. Position excess error 7. see point 4. of this table
_____________________________________________________________________________________

USER MANUAL
ST2
8. Position excess warning 8. Position excess warning 8. see point 4. of this table
9. Hard limits error 9. Hard limits error 9.1 check the probe is working
properly
9.2 check that the oil supply value is
not too low
10. Error on solenoid valve SOVx 10. Error on solenoid valve SOVx 10.1 check that the solenoid valve’s
coil is not burnt
10.2 check the wiring between the
solenoid valve and the controller
11. Calibration erased 11. Calibration erased 11. This is a warning message used
to inform that a calibration parameters
reset has been performed by the
operator
12. Waiting ACK 12. in order to go back to normal

operation an “ack” command must be
provided
13. External SOV warning 13. this is a warning message

showing that a solenoid valve not
energized by the controller has taken
the system into the fail safe position
_____________________________________________________________________________________

USER MANUAL
ST2
ST2Mono : single channel version

Based on the same electronic, a single channel version is available.
The electronic is partially mounted , the terminal board is different, the sw is the same and is able to recognize if the
electronic is suitable for a double channel or for a single one.
Differences :
ST2 ST2Mono
TRIP digital Inputs 6 4
SOV 6 3
Proportional valve driver 2 1
4-20mA Analog Output 2 2
Digital Output 3 3
Start/Stop Feedback Probe 2 1
4-20mA Feedback Probe 2 1
Analog inputs 6 3
4-20mA inputs ( setpoint) 2 1
Hart
RemoteControl
SD Card
ST2Mono Power supply :

When the power supply selected is the 24Vdc the power supply adapter is the same for the ST2 and the ST2Mono ( see
chapter ‘Power Supply’ of this IOM).
When the power supply selected is ‘AC Universal Input’ a specific unit is used for the single channel version (Phoenix
QUINT-PS/1AC/24DC/10 ) able to delivery up to 10A.
_____________________________________________________________________________________

USER MANUAL
ST2
ST2Mono : terminal board
_____________________________________________________________________________________

USER MANUAL
ST2
_____________________________________________________________________________________

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Manual

Double acting electro hydraulic actuators

Figure 1 – EHC-VC ......................................................................................................................... 16

The EHC actuators are available in three versions:

EHC* -VC: double-acting, no spring.

1.2 Cleaning and installation instructions

2.1 Disassmebly and reassembly

Actuators with spring close or spring open function contains prestressed

• Make sure the system is depressurized.

2.1.1.1 EHC – VSC (spring close)

1. Make sure the actuator piston rod is fully extracted.

2.1.1.2 EHC – VSO (spring open)

1. Make sure the actuator piston rod is fully retracted.

2.1.2 Disassembly of actuator

NOTE! Damaged or corroded parts must be replaced.

2.1.2.2 EHC – VSC (spring close)

NOTE! Damaged or corroded parts must be replaced.

2.1.2.3 EHC – VSO (spring open)

NOTE! Damaged or corroded parts must be replaced.

2.1.3 Reassembly of actuator

NOTE! Assembling dirty components will lead to hydraulic system failure or

• Wash all components carefully in a suitable solvent.

5. Reinstall position transducer (if any).

2.1.4 Spring house reassembly

2.1.4.1 EHC – VSC (spring close)

1. Install actuator, insert screws with new lock washers.

2.1.4.2 VSO (spring open)

1. Install actuator, insert screws with new lock washers.

Table 1: Torque specification, [Nm]

3 Components and spare parts

NOTE! Use CCI original parts or parts of approved material only.

1 Cable 10 Actuator stem

1 Position transducer 15 Upper guiding ring

Figure 3 – EHC-VSO (spring open)

1 Position transducer 14 Hydraulic cylinder

CCI Valve Technology AB Box 603, 661 29 Säffle - SWEDEN

Connection Material Design p/t Test p

Figure 4 – Type sign for valve with marked ordering data

1 Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2 Components and parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M573.02/4en Service instructions VLB I

Fig 1 Pressure seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

M573.02/4en Service instructions VLB III

1 Service and maintenance

Ö Due to thermal stresses it is very important that any replaced part

M573.02/4en Service instructions VLB 1

1.3 Trouble Shooting

Symptom Probable Cause and Action

2. Foreign particles in the valve. If yes, the

Temperature control does not function. 1. Temperature transmitter or temperature

2. Check that the water valve and its

3. Check the condition of the spray

4. If the water is contaminated we

The valve is not tightly closing. Inspect plug and seat.

Ö Plug all openings immediately.

Vertical installation: Connect the hoist hook to the sling ropes

2 Service instructions VLB M573.02/4en

Caution: The centre of the gravity can be above the strapping

M573.02/4en Service instructions VLB 3

Pressure seal gasket

4 Service instructions VLB M573.02/4en

Fig 2 Valve stem, dimensions

Table 1: Valve stem, dimensions Diameter (D) Diameter (d)

M573.02/4en Service instructions VLB 5