Uban Imi0009e

I N S T R U C T I O N S
For installing and servicing self-operating p r e s s u r e

regulators UBA and UBAN
IMI0009E.doc
CARRARO S.R.L. 20090 SEGRATE (MI)- via E.Fermi
E-MAIL: [email protected] Rev.4 13/07/02
VALVOLE E STRUMENTAZIONE TEL.(02) 269912.1 - FAX.(02) 2692.2452 Page 1 of 19
MAIN INDEX
Page
1. General information .......................................................................................................3
2. Guarantee ......................................................................................................................3
3. Validity of instructions .....................................................................................................3
4. Safety indications............................................................................................................4
5. Safety warnings .............................................................................................................5
6. Safety precautions .........................................................................................................6

7. Handling and storage......................................................................................................7
8. Installation and assembly instructions UBAN - UBAN/V - UBAN/V1 – UBA - UBA/V
8.1. Cross-section drawing............................................................................................8

8.2. Installation...............................................................................................................9
8.3. Start-up and calibration ..........................................................................................10
8.4. Maintenance...........................................................................................................11
8.5. Versions..................................................................................................................12
9. Installation and assembly instructions UBAN/D1–UBAN/V/D1 – UBAN/D2–UBAN/D2
9.1. Cross-section drawing UBAN/D1 UBAN/V/D1 ......................................................13

9.2. Cross-section drawing UBAN/D2 UBAN/V/D2 ......................................................14
9.3. Installation...............................................................................................................15
9.4. Installation diagrams ..............................................................................................15
9.5. Start-up and calibration ..........................................................................................16
10. Repairs ..................................................................................................................19
IMI0009E.doc
1. GENERAL INFORMATION:
1.1 – RIGHT TO MAKE MODIFICATIONS AND "COPYRIGHT"
The regulations, standards, etc. mentioned in these operating instructions are based on the knowledge that
was available when they were drawn up and are not subject to modification. Users are responsible for
applying the latest versions of these.
The supplier reserves the right to make modifications and technical improvements to data and information
whenever it sees fit. Under no circumstances may users require modifications or improvements to be made
to valves that have already been delivered.
2. GUARANTEE
The scope and duration of the guarantee are indicated in the manufacturer's "General Conditions of Sale".
The applicable conditions are those that were in force at the moment of delivery.
Amongst other things, the guarantee does not cover damage to valves deriving from the following:
° Ignorance or non-observance of these operating instructions!
° Insufficiently trained fitters, operators or maintenance men.
° Normal wear and tear
° Incorrect or negligent use of the valves.
The manufacturer declines all liability for the following which are not covered by the guarantee:
° Non-observance of accident prevention regulations and/or safety legislation.
° Incorrect assembly, start-up or use
° Improper or incorrect use, inappropriate use or different working conditions from those agreed
° Users are solely liable for physical injury and/or damage to property if the above is not observed.
3. VALIDITY OF INSTRUCTIONS
These instructions refer to self-operated single-seat pressure regulators featuring spring-loaded

membrane servomotors:
8) UBAN – UBAN/V – UBAN/V1 (Figs.1-2)

UBA – UBA/V
9) UBAN/D1 – UBAN/V/D1 (Figs. 9 – 10)

UBAN/V/D1 – UBAN/V/D2
IMI0009E.doc
4. PRODUCT SAFETY INDICATIONS AND TAG SYSTEM
If and where appropriate, safety indications have been put inside tags on the sides of the pages of this
manual.
These rectangular tags are placed vertically (as shown in the following examples) and contain four different
messages communicating:
- The level of risk
- The nature of the risk
- The effects of the risk on people or products
- Instructions, if necessary, on how to avoid the risk
The box at the top contains a warning word (DANGER – WARNING – CAUTION - ATTENTION) which
indicates the level of risk.
The box in the middle contains a drawing indicating the nature of the risk and its possible effects on people
and property. In some cases, the drawing may suggest what preventive measures can be taken, such as
wearing safety clothing.
The box at the bottom may contain a message with instructions on how to avoid the risk. In the event of risks
for people, the message may also contain a more precise definition of the risk and its effects on people.
1) DANGER – Immediate risk which will certainly cause serious injury or

death.
2) WARNING – Risk or hazardous behaviour which may cause serious injury
or death.
3) CAUTION – Risk or hazardous behaviour which may cause minor injury.
IMI0009E.doc
5. SAFETY WARNINGS
Thorough maintenance operations and overhauls are important for the safe and reliable operation of all
valves.
The service procedures recommended by CARRARO and described in this manual are effective methods for
carrying out maintenance operations. Please note that this service manual contains various warning and
caution notices which should be read carefully in order to minimise the risk of injury to people or the
possibility of using incorrect work methods which may damage the valves or make them unsafe. It is
important to realise, however, that these warnings cannot be exhaustive.
CARRARO is unable to know, assess and inform customers or users of all the conceivable methods of
performing maintenance operations and all the risks deriving from the use of such methods.
Consequently, CARRARO has not even attempted to start such a task. Therefore, whoever uses a service
method or piece of equipment which is not recommended by CARRARO must make sure that neither his
own or other people's safety, nor valve safety and performance are jeopardised by the chosen method.
In case of doubt about the method used, please contact CARRARO.
Testing, installing or dismounting the valves or accessories may cause you to come into contact with fluids at
very high pressures or temperatures and/or corrosive or erosive.
Therefore, take all safety precautions while testing, installing or dismounting the product; these include,
wearing ear plugs, goggles and safety clothing, such as gloves, both in or near the work area.
Given the large number of conditions and circumstances that may arise while working on the products and
the consequent risks deriving from the way this is done, CARRARO is not able to prevent all risks of injury to
people and damage to property and can only help by asking you to take the utmost care and giving you the
following safety suggestions.
Users of CARRARO products are responsible for training the staff that will use the product.
It is most important for these people to acquire a thorough knowledge of the instructions relative to the
product, especially the ones contained in this manual.
IMI0009E.doc
6. SAFETY PRECAUTIONS
Always observe the current plant safety regulations together with the
following indications:
° Wear safety clothing. Hot water can scald you and overheated steam is
invisible.
° When dismounting a valve, wear safety clothing to prevent being

sprayed by any process fluid that may have accumulated inside.
Make sure the valve is isolated from any pressure source in the system
before starting to dismount it.
° Inspect/service the valves at least once a year.
° Please consult CARRARO before working on valve parts.
IMI0009E.doc
7. TRANSPORT, STORAGE AND HANDLING
Transport
Depending on their size, valves can be transported loose, packed in cardboard boxes or in wooden crates.
All the valve ends are fitted with covers to prevent dirt from entering. Packs can be placed on pallets if
required. Follow all and any indications written on the packaging.
ATTENTION!
Operators moving loads must take all necessary precautions to prevent accidents.
Storage
Valves must be kept in a dry place to protect them from atmospheric conditions. They may only be removed
from their crates or packing immediately prior to installation.
The end protections and covers must be kept on until the last moment. Valves, whether packed or not, must
not be subject to violent knocks.
Valves, whether packed or not, must always be kept upright, that is, never lying on one side, in order to
prevent distortion and damage to internal parts.
Handling
When unpacking the valves and removing the end protectors immediately prior to installation, take great care
to make sure that foreign bodies do not enter the valve inlet and outlet holes while it is being connected.
ATTENTION!
When handling the valve, make sure the work area is kept clear in order to prevent injury
to people and damage to property.
IMI0009E.doc
8) UBAN – UBAN/V - UBAN/V1 – UBA – UBA/V
8.1 Cross-section drawing
IMI0009E.doc
Figs.1-2-3-4-5 show the cross-sections of UBAN and UBAN/V valves together with part names and versions.
8.2 INSTALLATION
8.2.1 UBAN and UBAN/V valves must be installed with the servomotor (2) facing upwards and the
membrane perfectly horizontal, as shown in Fig.6.
In pressure reducers regulating very low downline pressures (normally lower than 100 mm water column; the
rating plate is mounted upside down and is therefore indicative), they must be mounted with the servomotor
facing downwards and perfectly horizontal, as shown in Fig. 7; the weight of the mobile equipment is greater
than the force of the pressure regulated on the membrane and must therefore be supported by the spring.
8.2.2 Before mounting the valve on the piping, make sure the insides of the pipes are scrupulously clean,
especially the upline section; blow down the piping if possible to eliminate any remaining dirt: small
drops of solder may seriously damage the valve.
Fig.6 Fig.7
1) Adjustment screw (springholder)

2) Servomotor
3) Pressure gauge
4) Valve body
5) Drain hole
8.2.3 ATTENTION: The spring cover is not normally airtight and has a hole (5) in Figs. 6 and 7 which
prevents it from pressurising if the membrane breaks. If the spring cover is airtight (Fig. 4), made from
carbon steel and stainless steel, the hole (5) in Figs. 6 and 7 is always threaded 1/4" NPT and must be
connected to a pipe conveying the discharge to a suitable place (safely and constantly at atmospheric
pressure).
This hole can be closed with a plug or a pressure gauge signalling the breakage of a membrane, as long as
the downline installation is protected by a safety valve.
8.2.4 If there is the slightest possibility of the pressure downline from the reduction valve exceeding the
maximum admissible pressure for the downline installation, a safety valve must be installed, without an on-
off valve in between, in order to discharge the entire flow travelling downline in the above situation.
IMI0009E.doc
Fig.8
Pressure reducer assembly : 1) Reduction valve – 2) safety valve –3) pressure gauge
8.2.5 Please bear in mind that the regulated pressure sensing line nipple is located inside the valve, for
which reason the pressure drops in the piping connecting the reducer to the point of use of the regulated
fluid must be deducted from the regulated pressure value, creating pressure variations at the point of use
according to variations in flow; this must be considered when calculating the size of the connection piping.
8.2.6 When it is essential to avoid pressure variations at the point of use, the valves are fitted with an
external sensing line nipple, as shown in Part. B. The 1/8" female threaded connector must be connected to
a nipple as near as possible to the point of use.
8.2.7 If you are not sure that the regulated fluid is clean, install a filter before the regulator.
External sensing line nipple (only on request)
8.3 START-UP AND CALIBRATION.
8.3.1 Make sure that any downline on/off lines (Fig.6) are closed. Slowly open the upline valve keeping
your eye on the pressure gauge and be ready to close it again if downline pressure becomes excessive
without the pressure regulator cutting in. In this case, depressurise the circuit downline and turn the
adjustment screw (15) in Fig. 1 anti-clockwise to reduce pressure (calibration). When the downline system is
working at full power, turn the adjustment screw (15) to calibrate.
8.3.2 If the situation is different from the above, adapt the above operations to the existing situation.
IMI0009E.doc
8.4 MAINTENANCE.
8.4.1 If the regulated fluid is clean and the plant is fitted with a filter, maintenance operations will be
infrequent occurrences.
The user himself must establish a suitable interval between one inspection of the seats and the next, also
depending on the effective need for the valve to close airtight in some cases. When performing this
inspection, remove the valve on the piping and dismount all the components as shown below. Firstly, make
sure the recommended spare parts are available (Figs.1-2-3-4-5, parts list).
8.4.2 Dismounting the components (see Figs.1-2-3-4-5).
8.4.2.1 Dismounting the servomotor.

Release the spring by unscrewing the adjustment screw after loosening the lock nut, leaving it in position or
noting down its position in order to restore calibration after reassembly. If the cap is airtight (Fig.4), first
remove the cap (30) with relative gasket.
Remove the spring housing (13) by loosening the nuts (20).
Do not touch the housings of the 220 and 360 servomotors. Remove the spring. Unscrew the nut (17).
Remove the membrane with the relative washers.
8.4.2.2 Dismounting the body.

Unscrew the nuts (27c) and remove the cover (1). Unscrew the nuts (27a) Fig.1 (flanged valve) or the screws
(29) Fig.2 (threaded valves). Remove the high pressure body (4) keeping the shutter in a suitable position;
remove the shutter.
8.4.2.3 Parts inspection.

All the components are now ready to be inspected. Replace any worn ones. Clean all the parts.
In particular, check the state of the disk of the shutter, both elastic and metal, and the seat of the orifice.
If the seat is worn, true it by rubbing it with a metal disk and abrasive paste. If necessary, remount it on the
body.
If no expert operators are available, send the whole valve back to our factory for revision.
Another important component to control is the membrane; replace it if the surface is in poor condition. The
same applies to Teflon protections.
Replace all the gaskets after cleaning the surfaces they lie on.
8.4.2.4 Reassembly.
Carry out the dismounting operations in reverse order.
Push the stem of the shutter into the guide and put the high pressure body into position, tightening the nuts
or screws, after replacing the gaskets (2a). Mount the membrane. Replace the small retention ring (10) after
thoroughly cleaning its seat. Mount the membrane, taking care to mount the Teflon membrane (for UBAN/V)
underneath, towards the valve body, lying on the disk (21). Remount the membrane disk and spring guide
disk, tighten the nut (17), positioning the membrane so that when the membrane-bracket assembly is fully
rotated to the right and left, each hole rotates by the same angle as the matching hole on the servomotor
flange. This means that the bracket is at right-angles to the high pressure body. Match the holes of the
membrane with the holes in the servomotor flange and remount the spring, springholder and housing.
Remount the cover (1). Return the screw (15) to the position marked by the nut (14) or the position you
noted down (see 8.4.2.1). Exact calibration must then be checked when the valve starts working again.
IMI0009E.doc
8.4.3 Replacing the membrane.
The membrane may be broken or require replacement without having to make other controls. If the valve is
easy to access and isolate, it can be replaced while leaving the valve on the piping. In this case, make sure
that the valve is depressurised and can in no way be pressurised during the operation. Dismount the
servomotor by carrying out all the operations indicated in point 8.4.2.2
Replace and mount the membrane and reassemble the servomotor as shown in point 8.4.20.1. Check
calibration once more when the valve starts working again.
8.5 UBAN and UBAN/V versions with balancing device (Fig.5).

The UBAN and UBAN/V versions with balancing device are fitted with a balancing spring mounted on the
cover (1) (Fig.1). The same applies to what was said about the other valves: remember the existence of this
spring only during operations involving dismounting and remounting the cover (1) (see paragraph 8.4.2.2 -
8.4.2.4).
ATTENTION!
When welding piping, do not attach the earth connector to the valve
as this may damage important sliding parts.
8.5.1 UBA and UBA/V valves with cast iron body.

The UBA and UBA/V versions are identical to UBAN and UBAN/V in the versions with threaded ends (Fig.2),
except for the following:
- the low pressure body is made from cast iron.
The body is closed by means of a threaded disk screwed onto the body, instead of being fixed with screws
and nuts. The inlet and outlet ends are always threaded. There are therefore no substantial differences from
the functional point of view and as regards installation, start-up and calibration, and maintenance.
It should only be remembered that the cover is threaded and screwed to the body. The instructions for valves
UBAN and UBAN/V in the previous chapters also apply to these versions. Remove the cover (1) with a 46
mm hex wrench.
N.B.: After each maintenance operation, replenish your stock of spare parts by reordering used items.
IMI0009E.doc
9) UBAN/D
9.1 Cross-section drawing UBAN/D1 - UBAN/V/D1 Fig. 9
IMI0009E.doc
9.2 Cross-section drawing UBAN/D2 - UBAN/V/D2 Fig. 10
IMI0009E.doc
The UBAN/D valves comprise two groups of regulators:
Group 1 :
All the group 1 regulators have just one membrane; one of the controlled pressures acts under the
membrane through an internal sensing line nipple while the other acts over the membrane through a sensing
line nipple on the spring housing. The shutter is kept open by the spring. The following types belong to this
group :
UBAN/D1 - UBAN/V/D1 (see Fig. 9);
Group 2 :
All the group 2 regulators have two membranes separated by a chamber communicating with the outside;
the controlled pressures act under the lower membrane (through an internal sensing line nipple) and over the
upper membrane (through a sensing line nipple on the spring housing).
The shutter is kept open by the spring. The following types belong to this group :
UBAN/D2 - UBAN/V/D2 (see Fig. 10);
9.3 INSTALLATION
9.3.1 All UBAN/D regulators must be installed with the servomotor facing upwards and the membrane
horizontal.
9.4 INSTALLATION DIAGRAMS

In most cases the flow crosses the valve as shown by the arrow in Figs. 9-10. The installation diagrams are
therefore as follows:
Group 1 valves : Fig. 11
Group 2 valves : Fig. 12
9.4.1 Install an on/off valve upline, downline and on the sensing and discharge line nipple piping, in order
to service the valve (if necessary) while the plant is pressurised. Install one filter or pressure gauge downline
from the regulator and another one on the sensing line nipple, as shown in the diagrams, in order to calibrate
the differential pressure and keep it constantly under control.
9.4.2 Before mounting the valve on the piping, make sure the insides of the pipes are scrupulously clean,
especially the upline section; blow down the piping if possible to eliminate any remaining dirt: small drops of
solder may seriously damage the valve.
9.4.3 In group 2 valves, the chamber between the two membranes must be connected to piping taking the
discharge to a suitable place, safely and constantly at atmospheric pressure. This hole can be closed with a
plug or pressure gauge with an electrical contact for the remote signalling that the membrane has broken, as
long as the downline plant is protected as shown in the following point.
9.4.4 If there is the slightest possibility of the pressure downline from the valve exceeding the maximum
admissible pressure for the downline installation, a safety valve must be installed, without an on-off valve in
between, in order to discharge the entire flow travelling downline in the above situation.
9.4.5 Please bear in mind that the regulated pressure sensing line nipple is inside the valve, for which
reason the pressure drops in the piping connecting the regulator to the point of use of the regulated fluid
must be deducted from the regulated pressure value, creating pressure variations at the point of use
according to the variation in flow; this must be considered when calculating the size of the connection piping.
When it is essential to avoid pressure variations at the point of use, the regulator is fitted with an external
sensing line nipple, replacing the internal one and fitted to the lower flange of the servomotor. This nipple
must be connected as near as possible to the point of use where the installation of a pressure gauge is
recommended.
IMI0009E.doc
9.5 START-UP AND CALIBRATION
9.5.1 This operation is similar for both groups. The sensing line nipple valve and the upline and downline
on/off valves must be closed. Slightly open the downline valve and then the upline valve together with the
sensing line nipple, making sure that the pressure difference read on the pressure gauges is correct. If
necessary, to decrease it, turn the adjustment screw (18) anticlockwise to increase differential pressure and
vice-versa.
When the required value is reached, fully open all the valves. When the downline system is working at full
power, calibrate by adjusting the screw (18).
9.5.2 If the plant configuration is different from the above, adapt the above operations to the existing
situation.
9.6 MAINTENANCE
9.6.1 If the regulated fluid is clean and the plant is fitted with a filter, maintenance operations will be
infrequent occurrences. The user himself must establish the interval between one inspection of the seats and
the next, also depending on the effective need for the valve to close airtight. When performing this
inspection, remove the valve on the piping and dismount all the components as shown below.
Firstly, make sure the recommended spare parts are available (Figs. 9-10, parts list).
9.6.2 Dismounting the components.

Dismounting and remounting operations for all types of UBAN/D regulators as long as the membranes are
considered. These are:
- 1 simple elastomer membrane for UBAN/D1
- 1 triple membrane (one elastomer plus one Teflon on either side) for UBAN/V/D1
- 2 elastomer membranes (one per side) for UBAN/D2
- 2 double membranes (one elastomer plus one in Teflon on each pressure side) for UBAN/V/D2. Make sure
the spares match the above and take great care when mounting the membrane assembly.
9.6.3 Dismounting the servomotor.

Release the spring by turning the adjustment screw clockwise and count and note down the number of turns
in order to restore calibration after reassembly. Remove the spring housing (9) by loosening the nuts (21).
Do not touch the housings of the 220 and 360 servomotors. Remove the spring. Unscrew the nut (11).
Remove:
- the membrane with the relative washers for valves UBAN/D1 and UBAN/V/D1
- the assembly comprising the two membranes, washers, servomotor ring and intermediate plate for valves
UBAN/D2 and UBAN/V/D2.
9.6.4 Dismounting the body.

Unscrew the nuts (27) and remove the cover (1).
Remove the nuts (27a) of the inlet flange (flanged valves), or the screws (32) of the valves with threaded
ends; remove the high pressure body (24) keeping the shutter in a suitable position. Remove the shutter.
IMI0009E.doc
9.6.5 Parts inspection.

All the components are now ready to be inspected. Replace any worn ones. Clean all the parts.
In particular, check the state of the disk of the shutter, both elastic and metal, and the seat of the orifice. If
the seat is worn, true it by rubbing it with a metal disk and abrasive paste. If necessary, remount it on the
body; if no expert operators are available, send the whole valve to our factory for revision.
Another important component to control is the membrane assembly. Check the surfaces and replace any
damaged Teflon membranes. Replace all the gaskets after cleaning the surfaces they lie on. Replace the O-
rings (8).
9.6.6 Reassembly.
Carry out the dismounting operations in reverse order.
Push the stem of the shutter into the guide and put the high pressure body into position with the plug (31).
For valves with flanged ends, put the flange into position; tighten the nuts or screws uniformly. Mount the
membrane/s (see 9.6.3.) taking care to properly arrange the Teflon protections. Make sure the seats of the
O-rings are perfectly clean before mounting them. Assemble:
- for D1 valves: bracket, membrane disks, membrane and spring guide disks (with relative gaskets ), nut.
- for D2 valves: bracket, membrane disk, lower membrane, intermediate disk and servomotor ring, upper
membrane, spring guide (with relative gaskets), nut.
Before remounting the nut and tightening, position the membrane/s so that when the membrane-bracket
assembly is fully rotated to the right and left, each hole rotates by the same angle as the matching hole on
the servomotor flange. This means that the bracket is at right-angles to the high pressure body.
Tighten the nut (and the lock nut for D2). Match the holes of the membrane/s with the holes in the
servomotor flange and remount the spring, springholder and housing.
Put back the cover (1). Turn the adjustment screw the number of turns noted down during dismounting.
Exact calibration must then be checked when the valve starts working again.
9.6.7 Replacing the membrane.

The membrane may be broken or require replacement without having to make other controls. If the valve is
easy to access and isolate, it can be replaced while leaving the valve on the piping. In this case, make sure
that the valve is depressurised and can in no way be pressurised during the operation. Dismount the
servomotor by carrying out the operations indicated in point 9.6.3. Replace and mount the membrane/s and
reassemble the servomotor as shown in points 9.6.3 - 9.6.2 – 9.6.6
IMI0009E.doc
Fig. 11 Example of installation layout – Group 1 valves: “UBAN/D1 and UBAN/V/D1
Fig. 12 Example of installation layout – Group 2 valves: “UBAN/D2 and UBAN/V/D2
IMI0009E.doc
10. REPAIRS
10.1 If it is not possible to eliminate the problems, send faulty valves to the supplier/manufacturer,
together with a description of the problem.
10.2 In order to receive spare parts or information, always quote the series number shown on the rating
plate attached to the valve or punched on the outer surface of the flanges.
10.3 Rating plate (example)
ATTENTION!
The maker declines all liability for modifications to the product or

operations that are not contemplated in this manual.
IMI0009E.doc

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I N S T R U C T I O N S

For installing and servicing self-operating p r e s s u r e

6. Safety precautions .........................................................................................................6

8.1. Cross-section drawing............................................................................................8

9.1. Cross-section drawing UBAN/D1 UBAN/V/D1 ......................................................13

1.1 – RIGHT TO MAKE MODIFICATIONS AND "COPYRIGHT"

These instructions refer to self-operated single-seat pressure regulators featuring spring-loaded

8) UBAN – UBAN/V – UBAN/V1 (Figs.1-2)

9) UBAN/D1 – UBAN/V/D1 (Figs. 9 – 10)

1) DANGER – Immediate risk which will certainly cause serious injury or

° When dismounting a valve, wear safety clothing to prevent being

° Inspect/service the valves at least once a year.

° Please consult CARRARO before working on valve parts.

8.1 Cross-section drawing

1) Adjustment screw (springholder)

External sensing line nipple (only on request)

8.3 START-UP AND CALIBRATION.

8.4.2 Dismounting the components (see Figs.1-2-3-4-5).

8.4.2.1 Dismounting the servomotor.

8.4.2.2 Dismounting the body.

8.4.2.3 Parts inspection.

8.5 UBAN and UBAN/V versions with balancing device (Fig.5).

8.5.1 UBA and UBA/V valves with cast iron body.

9.4 INSTALLATION DIAGRAMS

9.6.2 Dismounting the components.

9.6.3 Dismounting the servomotor.

9.6.4 Dismounting the body.

9.6.5 Parts inspection.

9.6.7 Replacing the membrane.

Fig. 12 Example of installation layout – Group 2 valves: “UBAN/D2 and UBAN/V/D2

10.3 Rating plate (example)

The maker declines all liability for modifications to the product or

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