OPERATION AND
MAINTENANCE INSTRUCTIONS
505/507/509
SERIES MULTI-PORT BALL VALVES
HIGH
CYCLE TYPE
¼”—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 ¼ turn with a
torque wrench. Tighten each bolt once
alternating diagonally across end cap according to Figure 1. Tighten bolts on Side B ¼ 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 |
|
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