I & M Mark 82 Installation & Maintenance Instructions for

I & M Mark 82 Installation & Maintenance Instructions for
I & M Mark 82
Installation & Maintenance Instructions for
Mark 82 Temperature Regulators
3170 Wasson Road • Cincinnati, OH 45209 USA
Phone 513-533-5600 • Fax 513-871-0105
[email protected] • www.jordanvalve.com
Warning: Jordan Valve Temperature Regulators must only be used, installed and repaired in accordance with these
Installation & Maintenance Instructions. Observe all applicable public and company codes and regulations. In the event
of leakage or other malfunction, call a qualified service person; continued operation may cause system failure or a
general hazard. Before servicing any valve, disconnect, shut off, or bypass all pressurized fluid. Before disassembling a
valve, be sure to release all spring tension.
Please read these instructions carefully!
regulator.
The flow arrow on the regulator body must be pointed in the direction of the flow. The regulator may be
installed vertically or horizontally without affecting its
operation.
7.
For best control, 3’ 0” straight sections of pipe should
be installed on either side of the regulator.
8.
Upstream and downstream piping near the regulator
should be insulated to minimize condensation in hot
vapor lines.
9.
For injection heating applications, the regulator
should be installed above the maximum water level
in the tank, or a check valve should be installed to
prevent water from backing up into the regulator.
10. For best regulation, the temperature regulator
should be installed as closely as possible to the unit
in which the temperature is being controlled.
11. On steam control applications, install a steam trap
of sufficient capacity to drain the coil or condenser.
Be sure to have a good fall to the trap, and no back
pressure. Best control is obtained when the coil or
condenser is kept dry.
6.
Your Jordan Valve product will provide you with long-term,
trouble-free service if it is correctly installed. Spending a
few minutes of your time reading these instructions now
may save hours of trouble and downtime later.
Installation
Main Steam Line
3
5
7
4
1
1
4
6
R
1
2
2
By-Pass Line
1
Steam
Trap
Condensate
Return Line
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.
7.
Shut-Off Valve
Pipe Union
Strainer & Drain Valve
Pressure Gauge
Jordan Regulator
Relief Valve
Thermal Bulb
To protect the temperature regulator from grit, scale,
thread chips, and other foreign matter, all pipe lines
and piping components should be blown out and
thoroughly cleaned before the temperature regulator is installed.
Shutoff valves, pressure gauges, and bypass piping
should be installed as indicated in the diagram to
provide easier adjustment, operation and testing.
In preparing threaded pipe connections, care should
be taken to prevent pipe sealing compound from
getting into the pipe lines. Pipe sealing compound
should be used sparingly, leaving the two lead
threads clean.
A line strainer should be installed on the inlet side
of the temperature regulator to protect it from grit,
scale and other foreign matter. A 0.033 perforated
screen is usually suitable. Line strainers are available from Jordan Valve.
Install the regulator in the highest horizontal line of
piping to provide drainage for inlet and outlet piping, to prevent water hammer, and to obtain faster
Bulb Installation
The Thermal System is a hermetically sealed unit
consisting of a sensing bulb, capillary tubing, protective armor, and actuator assembly. This unit
contains the thermostatic charge that operates
the temperature regulator. Please do not tamper
with it. In case the charge is lost, the thermal
system must be replaced as a complete unit. It is
not repairable in the field and must be returned
to the factory for repairs.
1.
2.
Correct Installation – For effective temperature control, correct installation of the sensing bulb is essential. For best results, the bulb should be installed
at a point of true representative temperature and
where there is good circulation. A thermometer or
other temperature sensing device (if used) should
be placed as close as possible to the sensing bulb
of the regulator.
Handle the capillary and armor carefully so they are
not crushed, kinked or twisted. A bend of 4½” ra-
3.
4.
5.
6.
7.
8.
9.
dius or larger is recommended.
Horizontal Mounting – When the bulb is to be
mounted horizontally, it must be turned so that the
word TOP (stamped on the adaptor) faces upward.
Vertical Mounting – No special precaution is required when the bulb is mounted vertically pointing
down.
Inverted Mounting – A special capillary is required
if the tip of the bulb will be higher than the capillary end. The temperature regulator equipped with
a standard capillary will not function properly in an
inverted position.
Insertion – For accurate control, the entire length of
the bulb should be inserted. Avoid locating a bulb
in the direct path of steam or water. Never lay a bulb
on the bottom of the tank. Approximately 8” is sufficient distance from the source of heat or coolant
to the sensing bulb.
Pipeline Mounting – When installing a sensing bulb
in piping, be sure that the pipeline is at least twice
the diameter of the sensing bulb so that free flow is
obtained around the bulb.
Finned Bulbs – Finned bulbs should be installed at
right angles to the air movement. Good circulation
is required to sense the average temperatures.
When the bulb is installed at a point higher than the
regulator itself, the range may be somewhat lowered. Conversely, the range may be raised if the
bulb is installed below the regulator.
If You Experience Undercooling or Overcooling:
Be sure the coolant is circulating properly and that
all steps have been taken as indicated for underheating or overheating in the steps above.
If You Experience Thermal System Failure:
Thermal system failure is usually indicated by failure of the
regulator to respond to temperature changes, and when
all other trouble shooting steps have failed to correct the
problem. The adjusting spring will hold a direct acting
valve OPEN or reverse acting valve CLOSED.
The thermal system can be tested by placing the sensing bulb in a container which can be quickly heated with
steam or hot water, or cooled with cold water or crushed
ice. Observe the valve stem while alternately heating and
cooling the bulb. If the stem does not move, it is likely that
the thermal system has lost its fill. The thermal system is
hermetically sealed and cannot be repaired in the field. It
must be replaced by a complete, new thermal system or
the old unit must be repaired at the factory.
Start Up
1.
2.
3.
Trouble Shooting
4.
If You Experience Erratic Control:
An oversized valve causes cycling or hunting. An
undersized valve causes temperature to drop under
peak loads. Recalculate required size from Jordan
Catalog TCV.
Inlet pressure may be low.
Steam traps downstream my need reconditioning.
Foreign matter may be lodged in valve seats.
Valve stroke may be out of adjustment.
5.
6.
Close the inlet and outlet shut-off valves.
Slowly open the by-pass, and begin heating or cooling action.
Fully open the inlet shut-off valve. Then slowly open
the outlet shut-off valve.
Close the by-pass valves when the approximate
temperature is reached.
Allow approximately 30 minutes to reach stable operation before attempting to adjust the temperature
setting (and after each new setting).
To change the control temperature, rotate the adjusting wheel downward to decrease and upward to
increase the temperature setting.
Note: These instructions apply to both the direct acting
and the reverse acting regulators. The reverse acting regulator is identical to the direct acting regulator except for
the design and operation of the pilot valve.
If You Experience Underheating:
Be sure the by-pass seats are fully open.
Be sue the inlet pressure is adequate.
Clean line strainer screens.
Clean steam traps and be sure they are working
properly. If the return line from the trap is cool, the
steam coil may be clogged.
7.
8.
If You Experience Overheating:
Overheating is often caused by foreign matter holding the valve seats in the open position. Inspect and
clean seats or replace them.
Check stroke adjustment.
Check for damage or failure of the thermal system.
In the direct acting regulator, an increase of temperature at the sensing bulb will close the pilot valve
seats which causes the main valve seats to close.
In the reverse acting regulator, an increase of temperature at the sensing bulb will open the pilot valve
seats and main valve seats.
Therefore the reverse acting pilot valve assembly is an
inverted version of the direct acting pilot valve. However,
because of design differences, the upper bonnet of the
regulator must be replaced to change the valve action.
-2-
Valve Seats
A.
Disassembly
The valve seats of all Jordan regulators are
lapped to a light band flatness. Maintaining such
tolerances is of great importance for your assurance of excellent control and tight shut-off. Do
not use metallic objects in removing the seats.
Care in handling is important. Improper handling
will result in leakage or improper control upon
installation.
1.
2.
3.
4.
5.
6.
7.
Close shut-off valve on each side of the regulator.
Remove the control valve from the line.
Note the scribe line on the side of the valve body
and cap. Secure the outlet body hex (6) in a vise.
Remove inlet pilot tube (25). Remove the cap screws
(28) and lift the cap (7) straight up. Please note that
there is an index pin secured in the valve cap that
fits into the index pin hole in the valve plate (2). This
index ping is on the same side as the scribe line on
the valve cap and body, and it positions the valve
plate in the valve body.
Before removing, check the valve disc (1) for a
stamped arrow. This arrow points to the scribed
line and the index pin hole in the valve plate. Since
the disc can be rotated 180° in some sizes without
affecting stroke adjustment, there may be no arrow
on the valve disc. Remove the valve disc and place
on bench with the lapped surface up.
A light tapping on the valve body is normally sufficient to loosen the pressure rings (8). Invert the
valve body while holding the pressure ring and plate
in place; then slowly let them drop out of the body
into your hand.
Clean all the parts of the body and cap with solvent.
The valve disc and plate then may be cleaned. Place
a piece of 4/0 polishing paper or jeweler’s cloth on a
smooth, flat surface such as a surface plate and polish the lapped seating surfaces using a figure eight
motion. If the parts are scarred, do not attempt to
re-lap them, but return them to the factory for repair
or replacement. If the seats are not scarred deeply,
they can be repaired many times at nominal cost.
The vertical milled sections of the valve cap serve as
a guide for the disc while stroking. A 0.005 feeler
gauge should be used to check the clearance between the valve disc and the disc guides. To do so,
place the valve disc in the cap with the lapped surfaces facing upward and check this clearance. If the
clearance is less than 0.005, clean the disc guides
with a smooth file.
B.
Reassembly
1.
Replace the valve plate. In replacing, make certain
that the index pin hole is on the same side as the
scribe line on the valve body. Align the disc pin so
that it is centered in the body bore and protrudes
upward through the slot in the plate.
2.
In replacing the valve disc, the stamped arrow
should be pointing to the scribe line on the valve
body. Place the valve disc on the valve plate, engaging the disc pin.
3.
If necessary, heat (or cool) the sensing bulb to open
the pilot valve.
4.
To check the stroke adjustment, blow air into the
inlet pilot connection. The main valve will stroke to
the open position, and the orifices should be open
and in perfect alignment. If they are not, an adjustment is required.
5.
To obtain the proper adjustment, remove the valve
plate and disc from the valve body and loosen the
stem locknut (18). Adjustment is obtained by rotating the disc pin (4) on the valve stem.
6.
When this preliminary adjustment is obtained, lock
the valve stem locknut while holding the disc pin
with an open end wrench.
7.
Now rotate the disc pin so that the valve plate and
disc can be positioned in the valve body.
8.
Insert the valve plate and disc in the body bore, using the same precautions as outlined above.
9.
The seats will be in the closed position. To check
the adjustment again, blow air into the inlet pilot
connection to open the valve. Check the alignment
of the orifices.
10. If orifices do not line up properly, further adjustment
will be required.
11. Place the plate and disc into the body bore followed
by the pressure ring (8).
12. Note that the pressure ring (8) has one lapped surface. In replacing the pressure ring, make certain
that the lapped surface faces the valve plate.
13. In replacing the valve cap (7), note that the scribe
line on the valve cap and the valve body must be in
alignment. Use care to make certain the disc guides
and the index pin are properly aligned with the valve
disc and the index pin hole in the valve plate. Normally, a slight rotation of the valve cap is sufficient to
obtain proper alignment.
14. Replace the cap screws and tighten uniformly, being
careful not to torque excessively.
15. Replace inlet pilot tube (25).
Thermal System
1.
2.
-3-
The thermal system is a hermetically sealed unit
consisting of a sensing bulb, capillary tubing, protective armor, and actuator assembly. This unit contains the thermostatic charge that operates the TCV.
Please do not tamper with it. In case the charge is
lost, the thermal system must be replaced as a complete unit. It is not repairable in the field and must
be replaced or returned to the factory for repairs.
The thermal system is easily removed in the field
3.
4.
5.
by releasing the spring compression (by rotating the
adjusting wheel downwards) and removing the four
fillister head actuator screws (39).
Lift out the upper spring guide (41) and pilot stem
(33). If necessary to replace pilot stem, remove the
upper locknut (40) and unscrew the upper spring
guide. Count the number of turns required to remove the upper spring guide. Replace the upper
spring guide on the new pilot stem, using the same
number of turns that were used to remove it. Lock it
in position, using the upper locknut (40).
After removing the upper spring guide assembly, the
adjusting spring (31) may be removed. Replace if
necessary and replace the upper spring guide assembly.
Place the thermal system onto the cage (11) and
reinsert the four actuator screws. The valve stroke
adjustment will not be affected if these steps are
carefully followed.
Replacement of Stem Packing
1.
2.
3.
4.
5.
6.
7.
8.
Turn adjusting wheel (35) until all spring compression is removed.
Completely unthread the ring nut (23).
Lift off entire top assembly, being careful to avoid
the trapped steam which will now escape. Examine
the pilot stem (33) for dirt.
Remove packing nut (13) and packing gland (14).
Remove pilot seat (12) and examine the Teflon ring
for foreign matter which might prevent the pilot stem
from seating properly.
In the direct acting regulator, the lower end of the pilot stem is the seating surface. In the reverse acting
regulator, the lower pilot stem is separate from the
pilot stem and is removed after the pilot seat.
Replace packing (15) and o-ring (16).
Reassembly in reverse order.
Thermometer
Replacement of Main Valve Diaphragm
1.
Remove the inlet pilot tube (25) and outlet pilot tube
(26). Follow the procedure outlined under Valve
Seats and remove the valve disc and plate.
2.
Unscrew the bottom cap (20) and remove the lower
spring (22) and lower spring guide (21).
3.
Remove the bonnet screws (29) and lift the bonnet
assembly from the main valve body (6).
4.
The diaphragm (30) can now be removed and replaced if necessary.
5.
Remove the diaphragm plate (32).
6.
To remove the disc pin (4), unscrew the stem locknut (18) and the disc pin from the valve stem (5).
The stem can now be removed upward through the
body flange.
7.
The disc pin is removed through the valve body
base.
8.
Reassemble in reverse order. Insert the stem
through the body flange and disc pin into the body
bore.
9.
Thread the stem into the locknut and then into the
disc pin approximately ¼”.
10. Place the main diaphragm plate (32) on the valve
stem.
11. Replace the main diaphragm, making sure that it is
installed properly in the recess of the valve body.
12. Place the valve bonnet assembly on the valve body
and tighten cap screws uniformly to approximately
120 inch/pounds torque.
13. Insert the return spring guide (21) and the return
spring (22) in the bottom cap (20) making certain
that the spring guide engages the disc pin properly.
14. A stroke adjustment will be required. Please not the
procedure outlined under Valve Seats, Reassembly.
15. Replace the inlet pilot tube and outlet pilot tubes.
-4-
If the regulator is equipped with a dial thermometer, it can
be re-calibrated by holding the pointer hub with a screwdriver and moving the pointer to the correct temperature.
Torque
Torque Requirements for Body Bolts
Valve Size
Torque (in./lbs.)
1/4” & 3/8”
70
1/2” & 3/4”
110
1” & 1-1/4”
120
1-1/2”
140
2”
140
Ordering Spare Parts
Use only genuine Jordan Valve parts to keep your valve
in good working order. So we can supply the parts, which
were designed for your valve, we must know exactly which
product you are using. The only guarantee to getting the
correct replacement parts is to provide your Jordan Representative with the valve serial number. This number is
located on the valve identification tag. If the serial number
is not available, the parts needed for your valve might be
determined using the following information: Model number, Valve Body size, Plug Material and Seat Size, Spring
Range or Set Point, Trim Material, Part Name - Number
and Quantity (see parts list chart).
Note: Without a valve serial number, any parts ordered
incorrectly are subject to a minimum 25% restock charge
when returned.
Illustration and Parts List
45
40-48
46
42
31
38
37
34
12
23
16
12.1
51
47
44
43
39
41
11
33
35
13
14
15
17
12.2
10
29
26
25
7
30
32
5
18
4
1
8
28
2
6
21
22
20
Item
Description
Item
Description
Item
Description
1
Disc
16
O-Ring
34
Nut
2
Plate
17
Pipe Plug
35
Adjusting Wheel
4
Disc Pin
18
Nut
37
Washer
5
Stem
20
Bottom Cap
38
Adjusting Screw
6
Body
21
Spring Guide
39
Screw
7
Cap
22
Lower Spring
40
Nut
8
Pressure Ring
23
Ring Nut
41
Spring Guide
10
Bonnet
25
Inlet Pilot Tube
42
Screw
11
Cage
26
Outlet Pilot Tube
43
Diaphragm Case
12
Pilot Seat
28
Body Cap Screw
44
Diaphragm Dome
12.1*
Pilot Stem
29
Bonnet Cap Screw
45
Diaphragm Plate
12.2*
Pilot Stem Spring
30
Diaphragm
46
Diaphragm
13
Packing Nut
31
Adjusting Spring
47
Gasket
14
Packing Gland
32
Diaphragm Plate
48
Lock Washer
15
Packing
33
Stem
†
Recommended Spare Parts
*
Parts required for reverse acting regulators only.
Bulletin IM-MK82-1010
3170 Wasson Road • Cincinnati, OH 45209 USA
Phone 513-533-5600 • Fax 513-871-0105
[email protected] • www.jordanvalve.com
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