OPERATION AND MAINTENANCE INSTRUCTIONS

505/507/509 SERIES MULTI-PORT BALL VALVES

HIGH CYCLE TYPE

4

 

Thank you for purchasing an Inline Industries 505/507/509 Series Multi-Port Ball Valve. This product has been constructed for maximum system design flexibility. Available in 3, 4, and 5 way configurations, with Schedule 40 (threaded, butt, and socket weld), tube (butt weld and clamp), and flanged (ANSI 150 and 300 Class) end connections, and full or standard L or T port flow patterns, the 505/507/509 product line offers a multitude of solutions for your fluid processing needs.

 

Installation and Operation

Always install your valve according to accepted industry standards and practices and operate only within stated pressure, temperature and fluid media limits. Do not open or disassemble valve unless you intend to replace resilient seat and gasket materials. Repair kits are available from your local Inline representative or call 1-800-568-8998.

Your 505/507/509 valve is available lever operated (standard) or prepared with an ISO 5211 mounting pad (optional) for electric or pneumatic actuation. Product specification sheets and technical drawings are available for dimensional information necessary for proper installation and automation.

 

Maintenance

Resilient seated valve products may wear over time resulting in loosening at component boundaries. If leakage is detected, tighten according to the steps and torque values outlined below. If tightening does not correct the problem, it is time to replace your seats and seals.

 

Repair

Remove and Clean Valve

A.    If valve is in line, make sure system is purged and line, ball and cavity pressure are released before unbolting from piping system.

B.    Remove all add-on components such as actuators and set aside.

C.    Disassemble valve. Remove old seats and seals and discard them. Clean and dry metal components in preparation for reassembly.

Install Repair Kit and Reassemble Valve

Arrange cleaned valve parts on workbench. Position body on its side (top of the valve body facing you) with Side B on the bench and Side A facing up. (See Figure 2.)

A.    Stem Assembly

 

1.     Place thrust washer on stem sliding over threaded end and seating on shoulder at base.

2.     Insert stem into body cavity through side, threaded end first, and glide through the hole in the top of the body until seated.

3.     While holding stem in place, slide stem packing set over threaded end. Stem packing should be stacked with mating concave/convex sides facing each other. Slide over stem, concave piece first, until seated.

4.     Place stem packing bushing over threaded end of the stem and lower over stem packing.

5.     Position two spring washers with concave sides facing each other and lower set over stem bringing them to rest upon stem packing bushing.

6.     Thread stem nut down stem and hand tighten until stem and packing assembly are properly seated, aligned and in a fixed position. Tighten stem nut to the torque specified in Table 2 and rotate slightly more until stem nut flats are perpendicular to stem flats. This will allow you to slide the lock washer down stem and into position over stem nut. Thread second stem nut down over stem until resting on lock washer to keep stem assembly locked in place for further valve assembly and adjustments.

 

B.    End Caps/Ball (3-Way Configuration)

1.     Your 3-way valve has four end caps, three ported end caps (with hole) and one closed end cap (with no hole). Place new seats in all 4 end caps.

2.     Select the closed end cap.

3.     Gently insert one of the four gaskets provided into the step machined into Side A of the body (facing upward).

4.     Gently insert the closed end cap into Side A until it rests against gasket. Align bolt holes.

5.     Using four (4) bolts and washers (8 bolts and washers for 3 and 4 sizes), hand-tighten end cap to body until loosely fixed in place.

6.     Turn body over. Make sure seat is properly positioned in end cap. Orient the axis of the key at base of stem vertically so as to facilitate ball entry. Position the orifices on the ball to match the pattern stamped into the top of the stem. Carefully lower ball into the body cavity gliding ball key way over stem key until cradled on the exposed stop end cap seat.

7.     Select one of the ported end caps and repeat Steps 3-5 above for Side B.

8.     Ball should now be loosely secure. Turn valve body upright and inspect to see that the stem is straight and ball orifice is aligned with end cap bore hole. Use of a cylindrical dowel to properly align the axis of the ball with opposing end caps is highly recommended. Continue hand-tightening according to sequence in Figure 1 until proper alignment is secured.

9.     Repeat Steps 3-8 above for the remaining two sides.

10. Once end caps are on and proper alignment is achieved, tighten end cap bolts on Side A turn with a torque wrench. Tighten each bolt once alternating diagonally across end cap according to Figure 1. Tighten bolts on Side B turn in the same sequence. Repeat this for Sides C and D. Repeat this entire cycle until all bolts are tightened to the values specified in Table 1. This should ensure proper seating and alignment.

 

C. Final Assembly and Test

1.     Your 505/507/509 ball valve is now ready for final assembly, adjustment, and testing. Remove top stem nut. Place stop plate over stem. Slide handle over stem in the orientation desired. (Two positions, 180 to each other, are possible.) Position flow pattern indicator (optional) to match flow pattern stamped on top of stem. Slide indicator over stem and hand-tighten stem nut until handle is fixed in place. Secure with wrench.

2.     Submit valve to qualified valve test facility for pressure test.

 

Your repaired 505/507/509 ball valve is now ready for installation and service.

Inline Industries makes a number of other fluid processing valves which complement this offering. Please consult your local Inline representative for more information about our products or call 800-568-8998 for more details. Thank you for purchasing an Inline product.

 

Table 1. 505/507/509 Suggested maximum torquing values of ball valve bolts.

 

 

Type and size of ball valve

Torques

Bolt Size

505, 507, 509

(in.-lbs.)

M6*P1.0

1/4", 3/8"

90

M8*P1.25

1/2", 3/4", 1"

160

M10*P1.5

1 1/4", 1 1/2"

320

M12*P1.75

2", 3"

550

W 5/8"*11UNC

4"

1150

 

 

 

Table 2. 505/507/509 Suggested torquing values of gland nut.

 

 

Type and size of ball valve

Torques

Gland Nut Size

505, 507, 509

(in.-lbs.)

M10

1/4" - 1/2"

40 - 50

M12

3/4"

70 - 80

M14

1"

85 - 95

M18

1 1/4", 1 1/2"

105 - 115

M20

2"

140 - 155

M28

3" - 4"

170 - 185

 

 

 

Figure 1.

1

4

1

4

7

5

6

8

3

2

1/4" - 2"

3

2

3" - 4"

Figure 2.