Class 1 Valve manual Class 1, Inc. • A Unit of IDEX Corporation 607 NW 27th Avenue • OCALA, FL 34475 USA 800.533.3569 • FAX: 352.629.2902 www.class1.
Table of Contents 1. Introduction & Specifications .................................................................................................... 3 2. Ball Valve Identification ............................................................................................................... 4 3. Ball Valve Actuators .................................................................................................................... 5 i. ii. iii. iv. Remote Handle Direct Handle Rack Linkage Electric 4.
1. Introduction & Specifications The new Class 1 four-piece stainless steel ball valves were created for reliability, corrosion resistance, customization, and ease of maintenance. Class 1 Stainless Steel Ball Valve • The Class 1 stainless steel ball valves are available in 2.0”, 2.5”, and 3.0” sizes. • Ball valves are composed of four main components: valve body assembly, inlet and discharge flange adapters, and actuator.
2. Ball Valve Identification Class 1 Stainless Steel Ball Valve – Center Body Assembly Size 2.0” 2.5” 3.0” A 3.00” 3.50” 3.98” Center Body Assembly Dimensions B C D 4.50” 3/8-16 Threads 3.44” 5.375” 3/8-16 Threads 3.70” 6.115” 3/8-16 Threads 4.
3. Actuators 3.1 REMOTE HANDLE A = valve center to handle length; B = valve center to outside hole; C = valve center inside hole; D = valve center to handle centerline; E = valve center to top of assembly; F = valve center to top of slow close assembly (not shown) Class 1 Valve Manual p/n: 119138 Dimensions A B C Dimensions D E F Short Lever (115164) 4.50” 4.00” 3.25” 2.0” Valve 3.82” 4.65” 5.30” Long Lever (116303) 6.63” 6.13” 4.00” 2.5” Valve 4.08” 4.91” 5.56” 3.0” Valve 4.46” 5.29” 5.
3. Actuators 3.2 DIRECT HANDLE A = valve center to handle length; D = valve center to handle centerline; E = valve center to top of assembly; F = valve center to top of slow close assembly (not shown) Dimensions A Short Handle 9.00” Dimensions D E F 2.0” Valve 3.82” 4.65” 5.30” Long Handle 9.50” 2.5” Valve 4.08” 4.91” 5.56” 3.0” Valve 4.46” 5.29” 5.94” [Use shim 119260 with all direct handle actuators. See Section 6.3 on page 24 for installation details.
3. Actuators 3.3 RACK LINKAGE Rod/Handle Cut-Out Ø1.00” D C Valve Center Class 1 Valve Manual p/n: 119138 Dimensions A B C D E F 2.5” Valve 4.75” 4.90” 4.094” 4.675” 3.0” Valve 5.25” 5.28” 4.469” 4.675” OPEN CLOSED OPEN CLOSED 15.40” 3.93” 8.63” 10.70” 15.40” 3.93” 8.63” 10.
3. Actuators 3.4 ELECTRIC Dimensions A B C D 2.0” Valve 4.29” 9.32” 2.10” 4.35” 2.5” Valve 5.16” 11.20” 2.43” 5.23” 3.0” Valve 5.16” 11.58” 2.43” 5.23” A = width of actuator; B = valve center to top of assembly; C = valve center to actuator short side (length); D = valve center to actuator long side (length) Electric actuators require Class 1 controller 117010 to operate. The 117010 smart switch uses position feedback from the actuator to display the valve’s open/close position.
4. Safety Information The Class 1 ball valves are designed for optimum safety of its operators. For added protection, please follow the safety guidelines listed in this section and adhere to all warning, danger, caution, and important notes found within this manual. ! The following section must be carefully read, understood, and followed by all installers and operators before attempting to install or operate Class 1 Valves.
4. Safety Information • • • • • • o Electric motors and wiring are protected by a circuit breaker. DO NOT remove or bypass the circuit breaker, as severe damage to the electric motor or apparatus wiring could occur. Be careful that NO part of your body (head, feet, arms, legs, fingers, hair, etc.) is in an area of rotating or moving parts. Certain internal parts of the Class 1 valve assembly may be under tension. When servicing the valve, wear eye protection and exercise care when removing these parts.
5. installation Evaluate the best location for the valve installation, taking the following into consideration: • Customer requirements • Discharge location on the vehicle • Maintenance accessibility • Linkage Geometry – Refer to Hale Products service bulletin SB92 for details.
5. installation • Electric actuators – If an electric actuator is used, route the wire harness away from potentially hot and/or moving parts. Secure the harness every 10” – 12” (254mm – 309mm) to prevent excessive movement. • Testing – After installation, verify that the valve cycles properly from fully OPENED to fully CLOSED without excessive effort. If equipped with a hand wheel or electric control, verify that the indicator lights sequence properly, indicating valve OPEN, CLOSE, or in between.
5. installation 5.4 Electric Actuator Installation Actuator Stem Adapter Bottom Plates Shims Lower Bracket Bracket Base 5.4-1 Electric Actuator Assembly Parts 5.4-2 Valve with Stem and Insulator in Place 1. Remove the hex bolt and washer from the valve stem. (These are no longer needed.) Also remove the stop plate, valve stem retainer (bend if necessary), and wave spring (see valve exploded view for part details—Section 6.3). Keep the valve stem and valve stem insulator bushing in place. [Figure 5.
5. installation 5. Add the bottom plates and thread the long bolts into the plates. (Loctite use is recommended.) Orient the bottom plates so that the ridges face down, toward the valve body. Torque four bolts in a criss-cross pattern to a maximum value of 11 ft-lbs. (Discard shims – they are not needed.) [Figures 5.4-6 through 5.4-8] Figure 5.4-5 Lower Bracket with Four Long Bolts Figure 5.4-6 Adding the Bottom Plates Incorrect Orientation – Ridge must face DOWN, toward valve body Figure 5.
5. installation Figure 5.4-9 Valve Stem Adapter Installed Figure 5.
5. installation Upper Bracket & Actuator Long Bolts Base Bracket Short Bolts & Nuts Bottom Bracket Bottom Plate Figure 5.
5. installation 5.4.1 Utilizing the KZCO EH2 Series Electric Actuator (for 2.0” Class1 Valves) The diagram below shows the typical layout using the SPS Electric Valve controller (117010) with KZCO EH2 series electrical actuator (p/n 117234-003). The harness part number is 117593-XX (where XX is the length in feet – 05, 10, 15, 20, 25, 30). Harness p/n 117593-XX (where XX is the length in feet – 05, 10, 15, 20, 25, 30).
5. installation 5.4.2 Utilizing the KZCO EH5 Series Electric Actuator (for 2.5” & 3.0” Class1 Valves) The diagram below shows the typical layout using the SPS Electric Valve controller (117010) with KZCO EH5 series electrical actuator (p/n 117234). The harness part number is 117008-XX (where XX is the length in feet – 05, 10, 15, 20, 25, 30). Harness p/n 117008-XX (where XX is the length in feet – 05, 10, 15, 20, 25, 30).
5. installation 5.4.
5. installation 5.5 Slow Close Assembly Installation 1. Remove the bolt and washer threaded into the valve stem. (If no handle is attached, install a direct or manual handle. 2. Align the slow close assembly so that the two (2) spring pins on the slow close can be pressed into the top of the valve body. There is a 90° slot on the slow close assembly that allows space for a handle. Align the four (4) inner pins, so that they slide into the space between the handle and valve stem (see picture below). 3.
5. installation Inner Pins on Bottom of Slow Close Installing Slow Close Assembly onto Valve & Handle Slow Close Installation – (Upper Piece & Inner Components Removed for Clarity) 5.6 Rack Linkage Installation 1. Remove the bolt and washer threaded into the valve stem. Remove any attached lever or handle. 2. Remove the top two bolts, washer, and lock washer on both valve flange adapters on the valve. 3. Attach the main bracket (Item 2) with these four bolts, washer, and lock washer.
5. installation Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Class 1 Valve Manual p/n: 119138 2.5” Valve P/N C25-0000-00-0 119417 119418 117374 117373 119881 106623 018-1206-02-0 097-0020-02-0 110-1200-11-0 117372 100294 100379 106949 113303 3.0” Valve P/N C30-0000-00-0 117376 117371 117374 117373 119881 106623 018-1206-02-0 097-0020-02-0 110-1200-11-0 117372 100294 100379 106949 113303 Description Valve Center Body Main Bracket Lock Bracket Gear Gear Spacer Brass Bushing Snap Ring Hex Head Bolt 1/4-20 x 0.
6. Maintenance WARNING – Before beginning any inspection, maintenance, or service to the ! equipment, verify that the pressure has been released from the system. Lock out the equipment, in accordance with the manufacturer’s recommendations. Open discharge valves, remove the suction tube caps, and discharge valve caps ! to release any residual pressure. 6.
6. Maintenance 6.3 Valve Exploded Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2.0” Valve P/N 116237 116254 040-2100-00-0 116288 116289 116287 116261 117301 116256 116896 116270 116260 106949 113303 2.5” Valve P/N 116238 116254 040-2100-00-0 116288 116289 116287 116261 117302 116256 116896 116191 116260 106949 113303 3.
6. Maintenance 6.4 Valve Repair Kits Item Part Number QTY 1 2 3 4 5 6 7 040-2100-00-0 116896 116270 116288 116289 116287 117301 1 1 2 1 1 1 1 Item Part Number QTY 1 2 3 4 5 6 7 040-2100-00-0 116896 116191 116288 116289 116287 117302 1 1 2 1 1 1 1 Item Part Number QTY 1 2 3 4 5 6 7 040-2100-00-0 040-1140-00-0 116259 116288 116289 116287 117303 1 1 2 1 1 1 1 Class 1 Valve Manual p/n: 119138 2.
7. Troubleshooting The information in this chapter lists the possible causes and suggested solutions for standard Class 1 valve applications and troubleshooting. Before calling Class 1 or a Class 1 authorized parts service center for assistance, please attempt to eliminate the problem with this information.
7. Troubleshooting Class 1 Valve SIZE 2.0” 2.5” 3.
7. Troubleshooting CONDITION: Valve operation requires excessive effort to OPEN or CLOSE. REMEDY: • If equipped with slow-close actuator, remove the slow-close module and operate the valve. If the valve operates normally, replace the slow-close actuator. • If equipped with the gear actuator, verify that the gear actuator, actuator handle, and drive shaft are not damaged or bent, and are lubricated.
7. Troubleshooting • Remove both valve seals and visually inspect them for foreign debris, deterioration, or damage (cracks, splits, flat spots, etc), especially around the valve ball / seal interface. Replace parts as necessary. • Remove the valve ball and visually inspect the outer surface for scratches or marks that would prevent full contact with the valve seal. Replace the ball if necessary. CONDITION: Valve does not fully OPEN or CLOSE – manual operation.
Class 1, Inc. • A Unit of IDEX Corporation 607 NW 27th Avenue • OCALA, FL 34475 USA 800.533.3569 • FAX: 352.629.2902 www.class1.
