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    MOOG   INDUSTRIAL CONTROLS DIVISION    MOOG  Industrial Controls Report CDS6700 INSTALLATION AND MAINTENANCE MANUAL FOR PROCESS VALVE ASSEMBLY Revision A: 14 September 2001 Location of Original: Dept. 366 Admission Steam Control Valve Model 80-507-X   CAUTION DISASSEMBLY, MAINTENANCE, OR REPAIR OTHER THAN IN  ACCORDANCE WITH THE INSTRUCTIONS HEREIN OR OTHER SPECIFIC WRITTEN DIRECTIONS FROM MOOG INC., WILL INVALIDATE MOOG INC’S OBLIGATIONS UNDER THE WARRANTY. REFER TO THE MOOG INC., INDUSTRIAL CONTROLS DIVISION WARRANTY FOR COMPLETE PROVISIONS THEREOF.    MOOG  CDS6700   Industrial Controls Division Revision: A INSTALLATION AND MAINTENANCE MANUAL  ________________________________________________________________________________________________________________________________________________________________________ TABLE OF CONTENTS Section or Page Paragraph Title No. 1.0   CONTROL VALVE ASSEMBLY INSTALLATION ....................................................1 2.0   CONTROL VALVE ASSEMBLY MAINTENANCE ...................................................4 3.0   GENERAL DISASSEMBLY AND ASSEMBLY INSTRUCTIONS ...........................5 4.0   TROUBLESHOOTING THE HARDWARE .............................................................22 5.0   FACTORY PARTS AND SERVICE .........................................................................24 6.0   WARRANTY ..............................................................................................................26 A31A HIGH PERFORMANCE BUTTERFLY VALVE, MARCH 1998 FORM 5291 A31D ERRATA SHEET FOR A31A, JUNE 1995 A41 POSI-SEAL HIGH PERFORMANCE BUTTERFLY VALVE, MAY 1999 FORM 5344    MOOG  CDS6700   Industrial Controls Division Revision: A INSTALLATION AND MAINTENANCE MANUAL  _______________________________________________________________________________________________________________________________________________________________________ -1-   SECTION 1.0 - CONTROL VALVE ASSEMBLY INSTALLATION CAUTION !! DO NOT CONTAMINATE !! Assembly is shipped CLEAN and sealed BYPASS THIS ASSEMBLY DURING ALL FLUSHING PROCEDURES Connect only to a hydraulic and/or process system which meets, or exceeds, ISO 4406 (SAE J1165) Solid Contamination Code 19/16/13 APC ? m(c) (18/16/13 micr ? m). Connection to a contaminated system voids all warranties. This unit is NOT intended to provide system filtration. 1.1 HYDRAULIC SYSTEM CONTAMINATION CONTROL The life of active hydraulic components (pumps, hydraulic actuators, solenoid valves and cartridge valves), is determined by the cleanliness of the hydraulic system fluid. The fluid should be maintained at a cleanliness level of ISO 4406 (SAE J1165) Solid Contaminant Code 16/14/11 or better. In no case should Solid Contaminant Code 18/16/13 be exceeded. A continuously operating, side circulation filtration system is recommended as the most effective means for maintaining fluid cleanliness level. This design utilizes an auxiliary low volume, low pressure pump to continuously circulate oil from the sump through a low pressure 3 micron absolute ( ? 3   ?  75) filter and back. Changing filter elements does not require shut down of the main hydraulic system. 1.2 INSTALLING THE CONTROL VALVE ASSEMBLY Note:  Installation drawings are available from: the supplier’s document control center or from Moog Inc., Industrial Controls Division; 8:00 am to 5:00 pm EST Phone: (716) 655-3000; Fax. (716) 655-1803 or E-mail: application_support.icd @ moog.com Ask for Customer Support and provide the Valve Assembly Model No. (80-507-X) from the large MOOG  nameplate on the side of the hydraulic actuator. a. Consider the following when deciding the orientation of the control valve assembly. The flow arrow on the process valve must agree with the direction of fluid flow in the process line (the orientation of the valve flow centerline to the actuator can be changed 90 ?  per section 3.4). Changing the hydraulic filter element is much easier with the filter bowl oriented downward (horizontal or below). Good design  practice dictates that the valve shaft of a steam valve not be oriented downward. b. Clear the area surrounding the installation site. c. Flush the process fluid line of all dirt, welding chips, scale, or other foreign material prior to installing the valve.    MOOG  CDS6700   Industrial Controls Division Revision: A INSTALLATION AND MAINTENANCE MANUAL  _______________________________________________________________________________________________________________________________________________________________________ -2- d. Whenever possible, install the actuator in an upright position with the rotary valve stem oriented horizontally. Vertical actuator installation permits easier valve maintenance. 1.2 INSTALLING THE CONTROL VALVE ASSEMBLY (con't) e. Provide adequate side and overhead clearance around the actuator to allow for disassembly of the actuator assembly from the valve assembly. f. Verify the valve flow direction, as shown by the arrow on to the rotary valve, agrees with the intended flow direction in the pipeline. g. Verify that the flange gasket inner diameter covers the seat retaining ring. This is essential for meeting seat leakage requirements. h. Flush the hydraulic supply and return lines of foreign material by inter-connecting the pressure and return lines around the servoactuator assembly. Moog Flushing Manifold, model 50-956-1, is available for this purpose. Circulate hydraulic fluid through the interconnected lines at full pump flow. Replace hydraulic system filter elements as indicated by their contamination alarms. Install hydraulic lines to the control valve actuator only after the system runs for four to six hours, at full flow, without tripping a filter element contamination alarm on the hydraulic system filters. i. Connect hydraulic supply pressure to the P port (on the filter assembly) and the tank line to the T port. Return pressure should not exceed 10% of system pressure. i.  Connect the instrument signal lines per the electrical schematic provided on the Control Valve Assembly Installation drawing. Close all unused electrical conduit ports with approved metal conduit plugs. Close electrical cavities with covers and seals were provided. Where explosion-proof conduit sealing hubs are  provided, seal the conduit hubs with the sealing compound supplied in order to comply with electrical code  NFPA #70 and CSA C22.2, #30 hazardous area requirements. Follow the instructions supplied in the sealing compound package. WARNING: FAILURE TO INSTALL CONDUIT PLUGS AND SEAL THE CONDUIT HUBS ADJACENT TO THE ELECTRICAL ENCLOSURE CAN RESULT IN SERIOUS PERSONAL INJURY AND EQUIPMENT DAMAGE. 1.3 QUICK-CHECK Prior to start-up, check the Control Valve assembly as follows: a.  Verify that the rotary valve is installed with the flow arrow in the same direction as the intended flow in the process line. b.  Adjust the two valve packing nuts just sufficient to stop leakage past the valve stem. CAUTION:
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