A.

Hock MSR- und Electronic Service GmbH Valve Division

Wörth am Main

SERIES 2000
Single seated top guided control valve

SERVICE

Preventive maintenance
Preventive maintenance consists of making a periodic visual
inspection of the valve assembly. This will reveal packing box leaks,
loosening of air connections due to vibration and other visible
failures of valve parts and accessories. A suggested inspection
includes the following actions:
1. Check packing box for leakage. If leakage is evident, do not
tighten packing flange nuts beyond point required to stop
leakage. If packing box is too tight (this can very easily happen
when a wrench is used), excess stem friction is created due to
the pressure of packing against stem. The excess stem friction
may cause the diaphragm top to require several additional
pounds of air to stroke the valve. If tightening the packing flange
nuts fails to stop the leakage, box requires either additional
packing or removal of the old packing and installation of a new
one.
Periodic cleaning of the valve stem will keep dirt and grit from
being carried into packing.
2. Check all mechanical and air connections. In some applications,
e.g. where the valve is located in a line near a pump, vibrations
may cause both, mechanical and air connections to work loose.
3. If possible, stroke the valve through several cycles, noting the
operation, the pressure required for stroking and normal action
of the valve.
4. Check tightness of diaphragm case (seal and o-ring)
5. Check tightness of screws connections body bonnet
Fig. 1 Series 2000 valve assembly 6. Check tightness of actuator post nuts.
7. Check tightness of stem connector.

Overhauling procedure
Valve overhaul requires disassembling the valve body.
WARNING. Depressurize the line to atmospheric pressure and
drain all fluids before working on the valve.
Make a thorough inspection of the plug, seat ring and stem to
determine whether these parts should be re-used, reworked or
replaced.

Note
For an easy inspection of the valve trim, the bonnet may be
removed from the valve body with the actuator still mounted
and attached to the valve stem.
To minimize the possibility of leakage, always replace the valve
body gaskets whenever the valve is disassembled.
 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

Actuator removal
1. Disconnect actuator and valve stem by removing stem clamp bolts and clamp.
Note
On reverse actuators the preadjusted spring force is effective. Therefore apply enough
air pressure to the actuator to stroke the stem to middle position (50% stroke) before
disconnecting actuator and valve stem.
2. Reduce the loading pressure in the actuator to atmosphere.
3. Disconnect the pneumatic connection to the actuator.
4. Remove the two hexagon nuts from the actuator.
5. Lift actuator off valve.

Mounting actuator on valve

1. Push the valve stem down by hand to fully close the valve.
2. Replace the complete actuator, locating the actuator rods in
the holes on the bonnet bridge piece and fit the hexagon nuts to
the rods without completely tightening the nuts.
3. Connect the adjustable air supply to the actuator.
4. On direct acting actuator (Figure 8) apply sufficient air
pressure to the actuator to fully stroke the actuator to nominal
stroke plus 5%.
5. On reverse acting actuator (Figure 9) apply suffcient pressure
to the actuator to start point (eg. 0,5 bar).
6. Attach the stem connector as this point making sure that the
stroke indicating pointer faces the lowest making on the stroke
indicator plate with the plug in the fully closed position. Tighten
the stem clamp cap screws fully.
7. Completely tighten the actuator rod nuts securing the actuator
firmly to the valve.
8. Fine adjustment may be made (with the plug off the seat) by
slightly slackening the plug stem towards or away from actuator
stem (Figure 10) using spanners fitted to the flats provided on
both stems for this purpose.
9. Readjust the travel indicator plate as necessary

Valve service Fig. 2: Series 2000, actuator assembly

Replacing plug
1. Disconnect actuator and valve stem by removing stem clamp bolts and clamp.
Note
On reverse actuators the preadjusted spring force is effective. Therefore apply enough air pressure to the
actuator to stroke the stem to middle position (50% stroke) before disconnecting actuator and valve
stem.
2. Reduce the loading pressure in the actuator to atmosphere.
3. Disconnect the pneumatic connection to the actuator.
4. Remove nuts securing bonnet to valve body.
5. Lift off the bonnet along with the actuator, valve plug and stem.
6. Loosen the packing box gland nuts until they are just finger tight.
7. Remove the plug and stem assembly from bonnet. A replacement plug and stem assembly may now be
fitted if required. When withdrawing or replacing the valve stem use a gentle turning motion to avoid damage
to the packing material.

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

Replacing seat ring

1. Remove the actuator, bonnet and plug from the valve body
(see “replacing plug procedure” 1 to 5).
2. Remove seat ring and fit replacement using a suitable seat ring tool
(Figure 3).
The application of a high performance lubricant is recommended.
When refitting the seat ring, MoS2 additives are also advantageous if
compatible with the process fluid.

Replacing sealing of soft seat plug

(DN 125 and DN 150)
1. Disassemble the valve as shown “replacing plug procedure” 1 to 7
2. Loosen the srews and remove clamp ring (Figure 6).
3. Replace sealing ring. Figure 3: seat ring tool
4. Screw clamp ring with plug. The sealing ring must be pressed until
the metallic stop of the clamp ring.
5. Assemble the valve in reverse order.

Lapping plug and seat ring

1. The sealing surfaces can be improved by using a good quality
carborundum paste with 280 grit size.
2. Apply lapping compound to seating surfaces of plug and seat
ring.
3. Lap plug into seat ring (Figure 4) to obtain good seating
surfaces on both. Do not remove too much metal. Stop lapping
after seating surfaces of 1/32 inch (0,8 mm) wide has been
obtained in seating of plug. Check the correct seating of the plug.
4. Remove all traces of lapping compound from sections of the
plug and seat ring completely. Figure 4: Lapping plug into seat ring

Packing replacement
1. Disconnect actuator and valve (see “replacing plug” 1 to 2).
2. Remove packing gland packing nuts, flange and follower. Pull
out packing with a hook, being careful to avoid scratching the
packing box wall.
3. Clean packing box and all metal parts.
4. Install new packing (Figure 5) and associated parts in correct
sequence and replace the packing flange and nuts. With PTFE
spring loaded packing, tighten gland nuts until limited by travel
stop, fitted to the packing. In case of PTFE or graphite packing,
tighten just enough to prevent leakage.

Figure 6: Soft seat plug

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

Replacing of bellows seal

NOT: The plug stem must NOT be rotated or damage to the bellows assembly will result!
1. Follow the “replacing plug procedure” steps 1 to 5 to remove the complete bellows seal bonnet (Figure 7) and
bonnet packing assembly from the valve body.
2. Loosen the packing gland nuts in the case of adjustable bonnet packing. Separate the packing bonnet from the
bellows seal housing by removing the hexagon nuts and then remove the packing bonnet using a turning motion to
avoid damage to the packing due to the threads of the valve stem.
3. Pull the valve plug stem out of the guide bushing until the pin securing the plug to the stem is revealed. Remove the
pin and unscrew the plug from the stem.
4. Bellows seal / valve stem assembly may now be withdrawn from the bellows seal housing. Examine for any
indication of leakage or damage and replace with new assembly if necessary using new flat gaskets throughout.
5. Reassemble in reverse order. Drill new hole through plug and valve stem at right angle to old hole in stem. Size of
new hole to be appropriate to allow force fitting of new pin. Prior to refitting actuator test for efficiency of bellows seal
by applying 5 bar air pressure to the valve body and checking for any leakage at the test connection provided below
the packing chamber.

Reversing valve action

1. Remove the stem clamp and disconnect the air supply (see “replacing plug
procedure” 1 to 3).
2. Remove the short bolts around the diaphragm chamber. Gradually loosen
each of the long bolts, factory fitted with warning labels, slackening each
bolts, factory fitted with warning labels, slackening each bolt alternatively by
one or two turns to progressively relieve the compression of the actuator
springs inside the chamber. PTFE-V-ring packing self adjusting
WARNING: Long bolts must always be removed last to ensure that the
spring compression is fully released before the diaphragm upper casing is
removed! Risk of injury!
3. Remove the diaphragm upper casing.
4. Remove the actuator stem nut, using a spanner on the flats provided on the
lower end of the stem to prevent rotation. The clamp plates, diaphragm,
spring plate, spacer and springs may now be removed.
5. Assemble the internal parts in accordance with Figure 8 (directing) or
figure 9 (reverse acting). Follow above disassembly procedure 1 to 4 in
reverse sequence. Ensure that the actuator springs are evenly distributed Adjustable packing
inside the casing and vertically located by the spring buttons of the diaphragm
plate. Figure 5: Packing

Reversing valve action of Tandem actuator Series 2000

1. Remove actuator from valve. Disassemble at first the upper actuator chamber and then the lower actuator chamber.
(see „reversing valve action procedur“ 1 to 4).
2. Remove both chambers in the middle.
3. Remove complete actuator stem. Remove pin securing the connection of the stems. Unscrew the stems.
4. Remove all parts (Spring plate, counterpart, springs, spacer, diaphragm)
5. Reassemble all internal parts acc. Figure 11 (direct or reverse acting) following 1 to 4 in reverse order.
Note: It is absolutely necessary that the springs are uniformly distributed in the chamber. They have to be in right
angle to the spring plate!

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

Actuator service
Replacing the actuator diaphragm
1. Remove the stem clamp and disconnect the air supply
(see “replacing plug procedure” 1 to 3).
2. Remove the short bolts around the diaphragm chamber. Gradually loosen
each of the long bolts, factory fitted with warning labels, slackening each bolt
alternatively by one or two turns to progressively relieve the compression of
the actuator springs inside the chamber.
WARNING: Long bolts must always be removed last to ensure that the spring
compression is fully released before the diaphragm upper casing is removed!
Risk of injury!
3. Remove the diaphragm upper casing.
4. Remove the actuator stem nut, using a spanner on the flats provided on the
lower end of the stem to prevent rotation. The clamp plates, diaphragm, spring
plate, spacer and spring may be removed.
5. Use a new actuator diaphragm and assemble the internal parts in accordance
with Figure 8 (direct action) or Figure 9 (reverse action). Follow above dis- Fig. 7: Bellows seal bonnet
assemble procedure 1 to 4 in reverse order. Ensure that the actuator springs are
evenly distributed inside the casting and vertically located by the spring buttons of the diaphragm plate.

Fig. 8: actuator direct acting Fig.9: actuator reverse acting Fig. 10: Stem clamp, connection
between actuator and valve stem

Replacing of stem seal

1. Disassemble actuator as described in “replacing of actuator diaphragm procedure” 1 to 4.
2. Remove actuator from the valve by removing the hexagon nuts from the two actuator rods.
3. Withdraw the actuator stem through the bottom of the diaphragm lower case.
4. Renew the stem seal and replace the actuator stem from below through the bottom of the lower case after applying
silicone based grease to the two chambers in the stem seal.
5. Reassemble the actuator as described in “reversing valve action procedure”, point 5.

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

direct acting reverse acting

Fig. 11: actuator assembling Series 2000T, tandem

Spring compression adjustement

The valve stroke is adjusted simply by altering the distance between the end of the plug stem and actuator stem within
the split stem clamp (Figure 10).
1. Remove the stem clamp by following “actuator removal procedure” 1 to 3.
2. Adjust the valve stroke by following “mounting actuator on valve procedure” point 1, 3 to 6, 8 and 9.

Connection air supply

On valves wihout positioner, the control air signal line is connected directly to the appropriate actuator air chamber.
On a direct acting actuator (air –to-close), the control air line is connected to the upper, and on a reverse acting
actuator (air-to-open) to the lower actuator chamber. On actuator with positioner the interconnecting piping between
positioner and actuator is factory installed.
A suitable air suooly must be piped to the supply port of the positioner. If an airset is factory fitted the piping between
airset and positioner supply port is factory installed and the air supply must be piped to the airset.
Air connections are 1/ inch NPT. Use of non-matching fittings may result in damaged threads and leaks.
Caution!
Do not tamper with pressure regulator adjustment. Reduced outlet pressure may be insufficient for valve
operation, while increased pressure may damage the valve.
Pressure limits for the various valve-and-actuator combinations are listed in Specification Sheet.

Checking operation
The valve is adjusted and tested at the factory before shipment and should require no further
adjustment in the field. After installation, use a regulated air supply to stroke the valve through several
cycles to ensure that it operates smoothly.

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

GENERAL SAFETY INFORMATION Qualified personnel

Using of Valves and Actuator, manufactured by A. Qualified personnel are people who, on account of
Hock MSR- u. Electronic Service GmbH (shortened their training, experience and instruction and their
“HOCK”) in accordance regulations. knowledge of relevant standards, specifications,
accident prevention regulations and operating
Terms concerning safety conditions, have been authorized by those responsible
The safety terms DANGER, WARNING, CAUTION and for the safety of the plant to perform the necessary
NOTE are used instructions to highlight particular work and who can recognize and avoid possible
danger and/or to provide additional information on dangers.
aspects that may not be readily apparent.
DANGER: indicates that death, severe personal injury Spare parts
and/or substantial property damage will occur if Use only HOCK original parts. HOCK cannot accept
properprecautions are not taken. responsibility for any damages that occur from using
WARNING: indicates that death, severe personal spare parts or fastening materials from other
injury and/or substantial property damage can occur if manufactures. If HOCK products (especially sealing
proper precautions are not taken. materials) have been on store for longer periods
CAUTION: indicates that minor personal injury and/or check these for corrosion or deterioration before
property damage can occur if proper precautions are using these products.
not taken.
NOTE: indicates and provides additional technical Unpacking
information, which may not be very obvious even to Each delivery includes a packing slip. When
qualified personnel. Compliance with other, not unpacking, check all delivered valves and accessories
particularly emphasised notes, with regard to using this packing slip. Larger valves can be lifted
transport, assembly, operation and maintenance and using slings in the yoke or if present, using the lifting
with regard to technical documentation (e.g. in the lugs or eyebolt connections provided for the purpose.
operation instruction, product documentation or on If slings are used, attach them so that the other tubing
the product itself) is essential, in order to avoid faults, or attaching parts are not damaged.
which in themselves might directly or indirectly cause WARNING
severe personal injury or propertydamage. If slings are used, be aware that the centre of
gravity
Using of the valve be above the lifting point. In this case,
The following instructions are designed to assist in secure or support the valve rotating, to prevent
unpacking, installing and performing maintenance. damage or personal injury.
Product users and maintenance personnel should Report transport damage to the carrier immediately.
thoroughly review this bulletin prior to installing, In case of discrepancies, please contact A. Hock
operating or performing any maintenance. MSR-u. Electronic Service GmbH.
DANGER, risk of injury! In most cases HOCK-valves
and actuators are designed for specific applications
(e.g. with regard to medium, pressure,
temperature). For this reason they should not be
used in other applications without first consulting
the manufacturer.
Protective clothing
HOCK-valves and actuators are often used
inroblematic applications (e.g. extremely high
pressures, dangerous, toxic or corrosive mediums).
In particular valves with bellows seals point to such
applications. When performing service, inspection or
repair operations always ensure, that the valve and
actuator are depressurised and that the valve has
been cleaned and is free from harmful substances.
In such cases pay particular attention to personal
protecting (protective clothing, gloves, glasses etc.).

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 A. Hock MSR- und Electronic Service GmbH Valve Division
Wörth am Main

Installation QUICK CHECK

DANGER Before operating, check the valve as follows:
Before installation check the order-no. and/or the Open and close the valve, and observe the moment of
tag-no. to that the valve/actuator is correct for the the actuator stem. The movement must be smooth.
intended application. Check maximum stroke trough change of signal (ie
Do not insulate extensions that are provided for hot or pneumatic/electrical signal).
cold services. Check all air connections for leaks.
Pipelines must be correctly aligned to ensure that the Check packing nut(s) for proper tightness. Packing
valve is not fitted under tension. Fire protecting for nut(s) should be slightly over finger-tight; however,
HOCK products must be provide by the end user. tighten only as necessary to prevent stem leakage
NOTE (see appropriate IOM for details).
According to the Pressure Equipment Directive the NOTE
HOCK Valves must not be installed as an accessory An excessively tightened packing can cause
with safety function. excessive packing wear and can hinder of the plug
stem.
Check fail-safe position. To do this, close supply
Commisioning pressure and/or electrical signal and observe whether
Clean tubing prior to installing. the valve open or closes defined.
If possible, install the valve in an upright position If temperature cycling occurs, re-tighten all bolt
(actuator on top), to ease maintenance. An upright connections and packing as necessary and check for
installation position is important with low-temperature leaks.
applications, in order to keep the distance between
the packing material and the medium as large as
possible. The packing material then retains the General maintenance
ambient temperature as much as possible. To avoid possible injury to personnel or damage to
NOTE products, safety requirements and local health and
Observe the diminished pressure curve when safety rules must be strictly adhered to. Modifying
overstepping the specified border temperature. this product, substituting non-factory parts, or using
NOTE maintenance procedures other than outlined in this
Do not insulate extensions bonnets that are instruction could drastically affect performance and
provided for hot or cold services. be hazardous to personnel and equipment, and will
Make sure that sufficient overhead clearance above void existing warranties.
the actuator is maintained, to follow for disassembly DANGER, risk of injury. Between actuator and valve
of plug from the valve body. See installation, there are moving parts. To avoid injury all handy,
Operating and Maintenance manual (IOM) for detailed hair and clothing away from all moving parts when
information. operating valve.
After installing, check direction of flow again. The Welding to repair or the connect the valve may only
direction of flow is shown by the arrow on the valve. be performed by trained and qualified welding
If the valve is to be welded into the line, make sure personnel. Apart from the operating instructions and
that the valve is shielded from excessive heat. the obligatory accident prevention directives valid in
Welding must be performed by qualified welders. the country of use, all recognised regulations for
Connecting supply pressure and signal lines safety and good engineering practices must be
Control valves are supplied with a positioner. The end followed.
connections for supply pressure and signal are clearly WARNING
marked. Actuator and positioner are suitable for max. BEFORE valves are returned to HOCK for repair or
supply pressure as detailed on the product and within maintenance take care that the product is free of
the applicable IOM’s. If the supply pressure exceeds medium and clean.
the pressure specified, a pressure reducing station is
required. If instrument air is not available, install an oil
separator/air filter in the air inlet line. All connections
must be leak free.

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 Storage NOTE
HOCK products are manufactured from various An excessively tightened gland nut can cause
materials. Products not manufactured resistant excessive packing wear and can hinder the free
materials are pro-vided with an appropriate protection. movement of the plug stem.
This means that HOCK products are well protected If possible, open and close valve and check for
from corrosion. Nevertheless HOCK products must maximum stroke and smooth movement of the plug
always be adequately stored in clean, dry stem. Irregular movement of the plug stem may
environment. Plastic caps fitted to the flange faces to indicate internal defects.
prevent the ingress for foreign materials. NOTE
These caps should not be removed until the valve With graphite packing, irregular movement of the
actually mounted into the system. plug stem is possible.
DANGER, risk of injury. Keep hands, hair, clothing,
etc. away from all moving parts. Failure to do so
Valve and actuator variations can lead to serious injury.
These instructions cannot claim to cover all details of Check all accessories for firm seating.
all possible product variations, nor in particular can If possible, close supply pressure and check the fail-
they provide information for every possible example of safe position.
installation, operation or maintenance. This means Check stems boot wear.
that the instructions normally include only the Check actuator for leaks. To do this, spray housing,
directions to be followed by qualified personnel where air connections and plug stem guide with leak spray
the product is being used for it’s defined purpose. If and check for any bubble formation.
there are any uncertainties in this respect particularly Clean plug stem.
in the event of missing product-related information, Check air filter, if present, and if necessary replace
clarification must be obtained at HOCK. insert.
NOTE
Periodic maintenance For further information please contact A. HOCK
Check valves for correct functioning at regular MSR u. ELECTRONIC SERVICE GMBH. IOM’s are
intervals (depending on the application and criticality) available in English, German, French and various
as follows. This check can be made when installed other languages.
and in many cases without interrupting production.
Examine gaskets for leaks and if necessary retighten
fasteners.
Check bellow gaskets and test connection - if present
- for external leaks.
Check valve for damage caused by corrosive resides
or corrosive vapours.
Clean valves and if necessary repaint.
Check glands for leakage. Adjust as necessary. See
Installation, Operating and Maintenance manual (IOM)
for detailed information.

A. Hock MSR- u. Electronic Service GmbH Distributor:

Dr.-Konrad-Wiegand-Strasse 13
D-63939 Wörth am Main

Valve Division
Tel.: +49 (0) 9372 94 756 -12 Fax -22
[email protected] www.viragovalves.eu
www.ahock.com

EN-Valve_Series_2000_SERV
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