User manual WA KATES L016

INSTALLATION & SERVICE INSTRUCTION MANUAL FOR KATES FLOW RATE CONTROLLER MODEL L016. IMPORTANT 1. THE KATES FLOW RATE CONTROLLER IS DESIGNED TO ACCURATELY REGULATE FLOW RATES AND IS PRECISION BUILT WITH EXACTING TOLERANCES AND FINISHES. TO INSURE SATISFACTORY PERFORMANCE, THE REGULATED FLUID MUST BE CLEAN AND FREE OF DIRT OR SOLIDS. THE INSTALLATION OF A 200 MESH STRAINER OR 75 MICRON FILTER IS RECOMMENDED, JUST UPSTREAM FROM THE CONTROLLER. 2. EQUALLY IMPORTANT: WHEN DIS-ASSEMBLING, SERVICING, OR CLEANING THE CONTROLLER, THE INTERNAL PARTS MUST BE HANDLED WITH CARE TO PREVENT DAMAGING THE SURFACE FINISH IN ANY WAY. 3. OPERATION OF A KATES FLOW RATE CONTROLLER SUPPLIED BY A POSITIVE DISPLACEMENT PUMP, WILL BE SATISFACTORY ONLY IF A PRESSURE-RELIEVING VALVE IS CONNECTED BETWEEN THE PUMP AND THE CONTROLLER TO BYPASS EXCESS FLUID BACK TO THE FLUID SOURCE, OR TO THE INTAKE OF THE PUMP. INSTALLATION 1. 2. 3. 4. 5. The Kates Flow Rate Controller is shipped fully assembled, ready for operation, with all parts in place. It is completely self-contained, requires no outside source of power, no straight piping runs, and is as simple to install as an ordinary angle valve. Upstream and downstream shutoff valves and a bypass valve should be installed so that the controller may be opened for inspection and cleaning without requiring complete system shutdown. (See figure 5) Before installing the controller, be sure to flush out the piping system to remove any foreign material such as dirt, scale, chips, etc. All controllers are constructed substantially, but pipe supports should be located so that the controller is not subject to mechanical load due to piping, or to the expansion or contraction of piping. The controller should be installed at a point in the pipe where it will be completely filled with liquid under all conditions of operation. The preferred axis of the controller is vertical, with the bonnet up. INLET IS AT SIDE and outlet connection is at bottom. On threaded connections, apply pipe thread compound sparingly to male threads only, so that surplus will not get inside the controller. START UP PROCEDURE 1. Turn the flow rate setting handle until the desired flow rate mark on the dial lines up with the pointer on the nameplate. 2. Place controller in service by opening upstream and downstream shutoff valves and closing the bypass valve around the controller. Controller will now regulate the flow rate at the set value. (See figure 5) NOTE: Avoid slamming the controller with pressure. 3. If there is air trapped in the top of the controller, this should be purged by the liquid after a short period. 4. When the flowing fluid temperature is above room temperature, especially with viscous fluids, there may be a "warming up" period until the controller reaches the same temperature as the fluid. During this warming up period, the controller may be somewhat sluggish in action. If desired, this warming up period may be eliminated by the use of a heating coil or jacket. 5. During the first few days of operation, the adjuster shaft packing should be observed and tightened if necessary. 1 BLT 311 - 03 SERVICE INSTRUCTIONS The Kates Flow Rate Controller has only one moving element, and is designed so that there are no complex linkages, delicate bearings, or any failureprone components. Therefore, occasional cleaning may be the only servicing the controller will require. CAUTION: SHUT OFF ALL SUPPLY LINES AND MAKE SURE THAT THE CONTROLLER IS RELIEVED OF PRESSURE BEFORE ATTEMPTING TO SERVICE OR CLEAN. TO CLEAN CONTROLLER CAUTION: in all cleaning operations, be very careful not to scratch, nick or mark any surfaces or edges. 1. The controller operates by downward flowing liquid and is self cleaning for most liquids. Downflow design also will allow drainage on shutdown of many systems if discharge shutoff valve is closed after inlet shutoff valve. 2. It is not necessary to remove the controller from the line to clean. If installation includes proper shutoff and bypass valves, operate these and take controller off stream or control. (See figure 5) 3. Arrange a clean area where internal parts can be placed and kept free of dirt. 4. Score a line on the flanges of the body and bonnet, to insure that the bonnet is oriented the same way when re-assembling. Remove bonnet bolts, lift bonnet assembly straight up, remove body O-ring, place the bonnet in the clean area and discard the O-ring. 5. Lift out the orifice sleeve and place in the clean area. 6. Slowly lift out the impeller, valve sleeve assembly, and spring, and place in the clean area. 7. Remove the orifice cylinder clamp screws and lift out the orifice cylinder and place in the clean area. NOTE: Normally it is not necessary to remove the valve tube to clean it sufficiently. If it must be removed, follow instructions below "TO REMOVE VALVE TUBE". 8. Thoroughly clean all parts that have been removed from the controller by immersing them in a suitable solvent. Clean and flush inside of flow controller body and the valve tube with the solvent, and drain. All surfaces, especially the metering orifice, the valve tube and integral valve ports, must be COMPLETELY CLEAN. Any dirt, sediment, coating or gummy residue must be completely removed. Wipe all parts and surfaces dry with a clean, lint-free cloth. 9. Replace orifice cylinder, and tighten clamp screws; replace the spring, impeller, and valve sleeve assembly on the valve sleeve. Make sure that the valve sleeve will slide freely on the valve tube with no sticking. 10. Replace orifice sleeve, and make sure that the slot faces the inlet of the body. 11. Install a new body O-ring, then lower the bonnet slowly making sure that the scored line is in line with the scored line of the body, at the same time turning the flow rate setting handle until the key on the end of the adjuster shaft fits into the slots in the orifice sleeve, and the shoulder on the lower face of the bonnet fits into the body. When properly assembled, bonnet will seat squarely on the body all the way around. (See figure 1) See that the pointer is in front where set point can be read. Replace and tighten the bonnet bolts (300 ft.lb of torque required). 12. Place controller in service as specified under steps 2-7, "START UP PROCEDURE". TO REMOVE VALVE TUBE 1. 2. 3. 4. 5. If the valve tube must be removed, for cleaning or replacement, first remove all other internal parts of the controller. (Steps 1-7 above) Remove the valve tube screws, lift out the valve tube, and clean with solvent. Before replacing the valve tube, be sure that it is CLEAN. Also be sure that the counter-bore at the bottom of the body is CLEAN, as it forms a seat for the valve tube. Install valve tube, replace valve tube screws, and tighten them securely. Reassemble controller according to steps 9-12 above. TO REPLACE ADJUSTER SHAFT PACKING: 1. The only packing required is between the adjuster shaft and the bonnet. This consists of two rings of woven graphite fiber, three solid graphite rings and a stainless steel packing washer. To replace the packing, remove the bonnet, and then remove flow rate setting handle by removing handle clamp screw and lifting dial and handle assembly upwards. Adjuster shaft assembly can now be removed by pulling it through the bonnet from the inside. CAUTION: Be careful not to scratch the shaft. 2. Remove the existing packing by prying it out of the gland, using a blunt-ended hook. CAUTION: Be careful not to scratch the gland. 3. Slide a new packing into the gland (see figure 3 for proper installation). 4. Carefully push the adjuster shaft assembly through the bonnet from the inside until the flange of the shaft bottoms out on the inside of the bonnet. NOTICE: The packing must be held in place while inserting the shaft. 5. Install the packing retainer and its bolts until the bolts begin to tighten. NOTICE: The packing retainer bolts must tightened in the same order every time and must never be turned more than an eighth turn (45°) at a time. This is meant to ensure the packing is equally tensioned all the way around and the packing ring does not cock to one side in the packing gland. See figure 4, for the recommended tightening scheme. 6. Tighten the packing retainer bolts until the packing is compressed enough to allow for the bearing retainer to sit flush on the bonnet without touching the packing retainer. 7. Install the bearing (see figure 2) and bearing retainer. Tighten the bearing retainer bolts. 8. Tighten the packing retainer bolts as described in step 5 and following the pattern described in figure 4. 9. The packing retainer screws must be tightened to 30 ft.lb to ensure a proper pre-load is made on the packing and the packing makes a seal. NOTICE: The packing may need additional tightening to ensure that the packing seal will have no leakage. 10. Put the controller in service by following Steps 2-7 listed under the heading "START UP PROCEDURE". 2 BLT 311 - 03 Knob Clamp Screw Dial Clamp Screw Clamp Ring Nameplate Screw Bearing Retainer Bearing Packing Retainer Packing Washer Bonnet Nut Adjuster Key Impeller Orifice Sleeve Orifice Assembly Valve Tube Plug Orifice Cylinder Screw Valve Tube Bonnet Bolt Valve Tube Screw Adjuster Knob Handle Nut Adjuster Handle Dial Nameplate Bearing Retainer Screw Packing Retainer Screw Adjuster Shaft Graphite Packing Bonnet Solid Pin Flat Washer Metal O-ring Valve Tube Spring Thrust Washer Body Figure 1 GS1528 TEXT SHOULD FACE UP. THIS WASHER SHOULD HAVE A TIGHT FIT IN THE BEARING RETAINER. WOVEN GRAPHITE STAINLESS STEEL PACKING WASHER NOTICE: THE ROUNDED CORNERS ON THE PACKING WASHER MUST FACE UP (AWAY FROM THE PACKING). SOLID GRAPHITE WOVEN GRAPHITE WS1528 TEXT SHOULD FACE DOWN. THIS WASHER SHOULD HAVE A TIGHT FIT AROUND THE SHAFT. Figure 2 3 Figure 3 BLT 311 - 03 1 4 6 MO DE L 5 3 AL S ER I 2 NOTICE: THE TIGHTENING PATTERN MAY START ON ANY HOLE AS LONG AS THE ORDER IS MAINTAINED THROUGHOUT THE TIGHTENING PROCESS. Figure 4 UPSTREAM SHUT OFF VALVE KATES CONTROLLER FILTER/ STRAINER DOWNSTREAM SHUT OFF VALVE BYPASS VALVE Figure 5 PRODUCT WARRANTY The W.A. KATES COMPANY guarantees every piece of equipment manufactured by it to be inspected, tested, and free from defects in workmanship or material when shipped from its factory. No warranty of corrosion resistance of any parts or assembly is expressed or implied. This guarantee is valid for one year from date of shipment from its plant. Within that time, the W.A. KATES COMPANY will replace free of charge any equipment returned, with shipping charges prepaid, found to have been defective at time of shipment. This warranty does not apply to : (a) damage resulting from misuse or inadequate handling; (b) damage resulting from continued use after defect is apparent; (c) any other damage, loss or liability; or (d) any piece of equipment that is changed, modified or altered in any way after it leaves the factory. The liability of the W.A. KATES COMPANY shall be limited to the replacement, f.o.b. our factory, of any equipment found to have been defective at time of shipment with duplicate or similar equipment of equal performance rating, but such liability shall in no event exceed the contract price for said equipment. W. A. KATES CO. 1363 Anderson, Clawson, Michigan 48017 Tel (248) 435-8225 - Fax (248) 435-8255 E-mail: info@wakates.com Internet: http://www.wakates.com 4 BLT 311 - 03