TLV CT20 Bedienungsanleitung

172-65742MA-01 (CT20/CT20D) 7 October 2021

Electro-Pneumatic Control Valve

CT20/CT20D

(for Valve Unit)

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Contents

Introduction .......................................................................2

Safety Considerations.......................................................3

Specifications....................................................................5

Configuration.....................................................................6

Installation.........................................................................8

Maintenance....................................................................10

Disassembly/Reassembly...............................................11

Troubleshooting...............................................................20

TLV EXPRESS LIMITED WARRANTY...........................21

Service............................................................................23

Introduction

Thank you for purchasing the TLV electro-pneumatic control valve CT20/CT20D.

This product has been thoroughly inspected before being shipped from the

factory. When the product is delivered, before doing anything else, check the

specifications and external appearance to make sure nothing is out of the

ordinary. Also be sure to read this manual carefully before use and follow the

instructions to be sure of using the product properly.

If detailed instructions for special order specifications or options not contained

in this manual are required, please contact TLV for full details.

This instruction manual is intended for use with the model(s) listed on the

front cover. It is needed not only for installation, but also for subsequent

maintenance, disassembly/reassembly and troubleshooting. Please keep it in

a safe place for future reference.

For details of the actuator and the electro-pneumatic digital positioner, refer to

the respective instruction manuals issued by the manufacturer.

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Safety Considerations

Read this section carefully before use and be sure to follow the instructions.

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

The precautions listed in this manual are designed to ensure safety and prevent

equipment damage and personal injury. For situations that may occur as a result

of erroneous handling, three different types of cautionary items are used to

indicate the degree of urgency and the scale of potential damage and danger:

DANGER, WARNING and CAUTION.

The three types of cautionary items above are very important for safety: be sure

to observe all of them as they relate to installation, use, maintenance and repair.

Furthermore, TLV accepts no responsibility for any accidents or damage

occurring as a result of failure to observe these precautions.

Symbols

Indicates a DANGER, WARNING or CAUTION item.

Indicates an urgent situation which poses a threat of death or

serious injury

Indicates that there is a potential threat of death or serious injury

Indicates that there is a possibility of injury or equipment/product

damage

Install properly and DO NOT use this product outside the

recommended operating pressure, temperature and other

specification ranges.

Improper use may result in such hazards as damage to the

product or malfunctions that may lead to serious accidents. Local

regulations may restrict the use of this product to below the

conditions quoted.

Use hoisting equipment for heavy objects (weighing

approximately 20 kg (44 lb) or more).

Failure to do so may result in back strain or other injury if the

object should fall.

DO NOT use only the actuator eye bolt when hoisting or lifting

the assembled product.

Failure to observe this precaution may lead to product damage.

Take measures to prevent people from coming into direct

contact with product outlets.

Failure to do so may result in burns or other injury from the

discharge of fluids.

When disassembling or removing the product, wait until the

internal pressure equals atmospheric pressure and the

surface of the product has cooled to room temperature.

Disassembling or removing the product when it is hot or under

pressure may lead to discharge of fluids, causing burns, other

injuries or damage.

Continued on the next page

DANGER

WARNING

CAUTION

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Be sure to use only the recommended components when

repairing the product, and NEVER attempt to modify the

product in any way.

Failure to observe these precautions may result in damage to the

product and burns or other injury due to malfunction or the

discharge of fluids.

Do not use excessive force when connecting threaded pipes

to the product.

Over-tightening may cause breakage leading to fluid discharge,

which may cause burns or other injury.

Use only under conditions in which no freeze-up will occur.

Freezing may damage the product, leading to fluid discharge,

which may cause burns or other injury.

Use only under conditions in which no water hammer will

occur.

The impact of water hammer may damage the product, leading to

fluid discharge, which may cause burns or other injury.

Make sure the power supply is OFF before carrying out work

on the wiring or inspections involving disassembly.

If such work is carried out with the power on, there is a danger

that equipment may malfunction or electric shock may occur,

leading to injury or other accidents.

Make sure that wiring work requiring a special license is

carried out by qualified personnel.

If carried out by unqualified personnel, overheating or short

circuits leading to injury, fires, damage or other accidents may

occur.

When using this product, NEVER stand close to, or leave

tools anywhere near, moving parts, such as the shaft.

Contact with moving parts or objects becoming caught in moving

parts could lead to injury or damage or other accidents.

CAUTION

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Specifications

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges.

Improper use may result in such hazards as damage to the product or

malfunctions which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

Use only under conditions in which no freeze-up will occur. Freezing

may damage the product, leading to fluid discharge, which may cause

burns or other injury.

CAUTION

Refer to the product nameplate for detailed specifications.

Valve Section

Actuator Section

*Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are

PRESSURE SHELL DESIGN CONDITIONS, NOT OPERATING CONDITIONS.

**Valve No. is displayed for products with options. This item is omitted from the

nameplate when there are no options.

Model

NominalDiameter

Maximum Allowable*

Pressure*

Maximum Operating

Pressure

Maximum Allowable

Temperature (TMA)*

Maximum Operating

Temperature (TMO)

Valve No.**

Serial No.

Operating Direction

Model

NominalDiameter

Maximum Allowable

Pressure*

Maximum Operating

Pressure

Maximum Allowable

Temperature (TMA)*

Maximum Operating

Temperature (TMO)

Valve No.**

Serial No.

Spring Range Pressure supplied to

Positioner

Valve Material

Valve Characteristic

Stroke Cv Value

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Configuration

CT20

No.

Part

Body

Valve Bonnet

Stem Connector Nut

Locknut

Guide Bushing

Stuffing Box V-ring Packing



Stuffing Box Washer



Stuffing Box Spring



Valve Plug & Stem



Valve Bonnet Gasket



Bolt

Nut

Valve Seat



Nameplate (Valve Section: front / Actuator Section: back)

Travel Indicator Scale

Stem Bracket Clamps

Drain Plug

Actuator Stem

Fixing Nut

*Replacement parts are available only in the following kits:

M = Maintenance Kit

R = Repair Kit

Actuator Section

Positioner Section

Valve Section

Eye Bolt

Actuator area 700 cm2(1.08 in2) only

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

CT20D (Option)

No.

Part

Body

Valve Bonnet

Stem Connector Nut

Locknut

Guide Bushing

Stuffing Box V-ring Packing



Stuffing Box Washer



Stuffing Box Spring



Valve Plug & Stem



Valve Bonnet Gasket



Valve Bonnet Bolt

Valve Bonnet Nut

Valve Seat



Nameplate (Valve Section: front / Actuator Section: back)

Travel Indicator Scale

Stem Bracket Clamps

Drain Plug

Actuator Stem

Fixing Nut

*Replacement parts are available only in the following kits:

M = Maintenance Kit

R = Repair Kit

Actuator Section

Positioner Section

Valve Section

Eye Bolt

Actuator area 700 cm2(1.08 in2)only

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Installation

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges.

Improper use may result in such hazards as damage to the product or

malfunctions which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

Use hoisting equipment for heavy objects (weighing approximately

20 kg (44 lb) or more). Failure to do so may result in back strain or other

injury if the object should fall.

CAUTION

DO NOT use only the actuator eye bolt when hoisting or lifting the

assembled product. Failure to observe this precaution may lead to

product damage.

CAUTION

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids.

CAUTION

Do not use excessive force when connecting threaded pipes to the

product. Over-tightening may cause breakage leading to fluid

discharge, which may cause burns or other injury.

CAUTION

Installation, inspection, maintenance, repairs, disassembly and adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

Check to make sure that the piping where the product is to be installed is constructed

properly. If the piping is not correctly constructed, the valve may not perform optimally.

1. Blowdown

Before installing the product, be sure to blow down all piping thoroughly.

If this is not possible, perform a blowdown using the bypass valve.

Blowdown is especially important for newly installed piping or after the

system has been shut down for a long period of time.

2. Installing the actuator section

The eye bolt welded onto the upper part of the diaphragm housing is

for mounting and removing the actuator. Do not lift the assembled

product using only the eye bolt.

(See Fig. 1)

3. Installing the control valve

Lift the assembled product using hoisting equipment such as cranes

and forklifts. Do not lift the assembled product using only the eye bolt.

(See Fig. 2)

4. Removing protective caps and seals

Before installation, be sure to remove all protective seals and caps.

(Found in two locations, on the product inlet and outlet.)

CT20

CT20D

① ②

Fig. 1

Hoisting the

actuator

Fig. 2

Hoisting the

control valve

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

5. Installation angle

Install the product so that the arrow mark on the valve

body points horizontally in the direction of steam flow, and

it should be installed horizontally in the piping with the

actuator at the top. Allowable inclination is 10 degrees in

the fore-aft direction and 15 degrees in the plane

perpendicular to the steam flow line.

6. Piping support

Install the product, paying attention to avoid excessive

load, bending and vibration. Support the inlet and outlet pipes securely.

CT20

CT20D

7. Maintenance space

Leave sufficient space for maintenance, inspection and repair. (Units: mm (in))

CT20

CT20D

8. Drainage port usage example

The threaded condensate drainage port at the

bottom of the body makes possible installation of a

blow valve or steam/air trap. Because the

condensate drainage port is located on the primary

side of the product, condensate flowing in the

primary side piping can quickly be eliminated,

contributing to prevention of valve seat erosion and

rapid start-up of the equipment.

If there is a problem in operation, determine the cause

using the “Troubleshooting” section in this manual.

300

(12)

400

(16)

400

(16)

400

(16)

400

(16)

300

(12)

100

(4)

100

(4)

100 (4)

100

(4)

100

(4)

100 to 190 (4 to 71/2)110 to 190 (41/2to 71/2)

172-65742MA-01 (CT20/CT20D) 7 Oct 2021

Maintenance

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids.

CAUTION

When disassembling or removing the product, wait until the internal

pressure equals atmospheric pressure and the surface of the product

has cooled to room temperature. Disassembling or removing the

product when it is hot or under pressure may lead to discharge of fluids,

causing burns, other injuries or damage.

CAUTION

Be sure to use only the recommended components when repairing the

product, and NEVER attempt to modify the product in any way. Failure to

observe these precautions may result in damage to the product or burns

or other injury due to malfunction or the discharge of fluids.

CAUTION

Operational Check

An inspection of the following items should be done on a daily basis to determine

whether the product is operating properly or has failed. Periodically (at least

biannually) the operation should also be checked.

In the event of failure (malfunction), also refer to the "Troubleshooting" section for

remedies.

Inspection Item

Inspection Points

Remedy for Failure (Malfunction)

Leakage from valve

(when the valve is

closed)

Visual inspection or stethoscope

inspection; is the outlet side

pressure or temperature elevated,

or is there the sound of the

medium flowing?

Adjust the zero/span; if that does

not solve the problem, replace

with a new valve plug & stem

and valve seat

Leakage from gland

section

Visual inspection; is fluid leaking

from the gap between the guide

bushing and the valve stem, or

are there signs it has leaked

previously?

Coat the guide bushing and the

valve stem with grease; if that

does not solve the problem,

replace with new V-ring packing

Leakage from the

gaskets between

any pressurized

parts

Visual inspection; is fluid leaking

from the gasket areas on

pressurized parts?

Apply additional tightening (refer

to recommended torque) or

replace with new gaskets

Leakage from

pressurized parts

such as body and

valve bonnet

Visual inspection; is fluid leaking

from pressurized parts such as

the body or valve bonnet?

Replace any pressurized parts at

leak locations

Parts Inspection

When parts have been removed, use the following table to inspect the parts and

replace any that are found to be defective.

Inspection Item

Gasket(s): Check for warping and damage (Graphite gaskets MUST be replaced if disassembled)

Stuffing Box V-ring Packing: Check for warping or damage

Valve Plug & Stem, Valve Seat: Check for damage or scratches

Body, Valve Bonnet: Check for damages or corrosion

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