Jordan Valve Mark 80 Temperature Regulator Installation & Maintenance Instructions

I & M Mark 80
Installation & Maintenance Instructions for
Mark 80 Temperature Regulator
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!
5.
Your Jordan Valve product will provide you with long,
trouble-free service if it is correctly installed and maintained. Spending a few minutes now reading these instructions can save hours of trouble and downtime later.
When making repairs, use only genuine Jordan Valve
parts, available for immediate shipment from the factory.
Ideal Installation
Main Steam
3
7.
8.
5
Line
4
1
1
7
4
R
1
2
6
1
Condensate
Return Line
1.
2.
3.
4.
9.
2
By-Pass Line
Steam
Trap
6.
1. Shut off Valve
2. Pipe Union
3. Strainer and Drain Valve
4. Pressure Gauge
5. Jordan Regulator
6. Relief Valve
7. Thermal Bulb
To protect the valve from grit, scale, thread chips
and other foreign matter, ALL pipelines and piping
components should be blown out and thoroughly
cleaned before the installation process begins.
Shutoff valves, pressure gauges and by-pass piping
should be installed as indicated in the Ideal Installation Schematic to provide easier adjustment, operation, and testing.
A line strainer should be installed on the inlet side
of the valve to protect it from grit, scale and other
foreign matter. A 0.033 perforated screen is usually
suitable for this purpose. Line strainers are available from Jordan Valve.
For best control, 3’ 0” straight sections of pipe
should be installed on either side of the valve.
10.
11.
12.
13.
In preparing threaded pipe connections, care
should be exercised to prevent pipe-sealing compound from getting into the pipelines. Pipe-sealing
compound should be used sparingly, leaving the
two end threads clean. Jordan uses, and recommends, thread sealer Teflon ribbon.
The flow arrow on the valve body must be pointed
in the direction of flow. Ideally, the valve should be
installed in the highest horizontal line of piping to
provide drainage for inlet and outlet piping, to prevent water hammer, and to obtain faster response.
If possible, install a relief valve downstream from
the valve. Set at 15 psi above the control point of
the valve.
In hot vapor lines, upstream and downstream piping near the valve should be insulated to minimize
condensation.
In gas service, if the control pressure (downstream)
is 25% of the inlet pressure or less, expand the
outlet piping at least one pipe size. A standard
tapered expander connected to the outlet of the
valve is recommended.
Where surges are severe, a piping accumulator is
recommended.
On steam control applications, install a steam trap
with sufficient capacity to drain the coil or condenser. Be sure to have a good fall to the trap, and no
backpressure. Best control is maintained if the coil
or condenser is kept dry.
For injection heating applications, the regulator
should be installed above the maximum water level
in the tank, or a check valve should be used to prevent water from backing up into the regulator.
For best regulation, the temperature regulator
should be installed as closely as possible to the
unit in which the temperature is being controlled.
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 evaluation.
PROTECT VALVES WITH LINE STRAINERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
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 or for damage or failure of the thermal system.
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 4-1/2”
radius 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 adapter) 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 the bulb on the bottom of a tank. Approximately 8” is sufficient distance from the source of
heat or coolant to the sensing bulb.
PIPELINE MOUNTING — When installing the sensing bulb in piping, be sure that the pipeline is at
least twice the diameter of the sensing bulb so that
the 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 temperature.
When the bulb is installed at a point higher than the
regulator itself, the range will probably be somewhat lowered. Conversely, the range will be raised
if the bulb is installed below the regulator.
If You Experience Undercooling or Overcooling:
 Be sure that coolant is circulating properly and that
all steps have been taken as indicated for underheating or overheating in items 2 and 3 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 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
must be repaired at the factory.
Start Up
1.
2.
3.
4.
5.
Trouble Shooting
6.
If You Experience Erratic Control:
 An oversized valve causes cycling or hunting. An
under sized valve causes temperature to drop under peak loads. Recalculate required size.
 Inlet pressure may be low.
 Steam traps downstream may need reconditioning.
 Foreign matter may be lodged in valve seats.
 Valve stroke may be out of adjustment.
7.
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.
Body and cap bolts should be retightened per
torque procedures after valve reaches operating
temperature.
Valve Maintenance
Caution: Make certain that there is no pressure in the
valve before loosening any fittings or joints. The following steps are recommended:
1. Close inlet shutoff valve.
2. Allow pressure to bleed off through downstream
piping. Do not attempt to reverse the valve by
bleeding pressure from the upstream side of the
valve.
3. When the pressure gauges indicate that all
pressure has been removed from the system,
If You Experience Underheating:
 Be sure that shut-off valves are fully open.
 Be sure that inlet pressure is adequate.
 Clean line strainer screens.
 Clean steam traps and be sure that they are working properly. If the return line from the trap is cool,
the steam coil may be clogged.
-2-
close the outlet shutoff valve, and the valve may be
serviced.
Note: refer to the drawing at the end of this document for description and proper orientation of parts.
2.
Valve Seats
3.
A. DISASSEMBLY
The valve seats in all Jordan regulators are lapped
to a light band flatness. Maintaining such tolerances is of paramount importance for your assurance of excellent control and tight shut-off. Do
not use metallic objects in removing the seats.
Care in handling is imperative.
1.
2.
3.
4.
5.
Close the shutoff valve on each side of the valve,
and remove valve from line.
Note scribed “<” on the side of the valve body (1)
and cap (2). Secure the body outlet flat in a vise.
Remove the cap screws and two nuts, and lift the
cap straight up.
Before removing, check the disc (5) for a stamped
arrow. This arrow points to the “<” on the body.
Remove the disc guide and the disc. Place the
valve disc on the bench with lapped surface facing
up. Protect the lapped surfaced on both sides of
the disc guide.
Stem, Disc Pin & Packing Replacement
1.
2.
3.
4.
IMPROPER HANDLING OF SEATS WILL RESULT IN
LEAKAGE OR POOR CONTROL.
5.
It is imperative that the disc pin not be rotated when
disassembling, cleaning, or reassembling, since this
affects the stroke adjustment.
6.
4.
5.
6.
that it is centered in the body bore and protrudes
though the center slot in the valve plate (unless
you are changing the valve action - See Section on
Changing Valve Action.)
Place the disc on the plate, engaging the index pin.
If there is an arrow on the disc, it should point toward the index pin hole on the plate.
Place the disc guide onto the plate, engaging the
disc pin. Rotate the assembly slightly until the slot
openings in the disc are parallel to the opening in
the plate, and perpendicular to the stem. Stroking
the valve will aid in this alignment.
Align the “>” on the cap with the “<” on the body,
and place the cap over the two studs in the body.
Install the nuts and cap screws. Tighten uniformly.
See back page for torque requirements and tightening procedures.
Lightly tap on the body to remove the plate (4).
Invert the body, let valve plate drop out into your
hand, and place it on the bench with lapped surface facing up.
Clean all the parts, body, and cap with solvent.
Place a piece of 4/0 polishing cloth or jewelers
cloth on a smooth, flat surface such as a surface
plate, and polish the disc, plate, and disc guide
lapped seating surfaces using a “figure 8” motion.
If the parts are scarred, do not attempt to re-lap
them, but return them to the factory for repair and
replacement. If the seats are not scarred deeply,
they can be repaired at nominal cost.
The vertical sections of the disc guide serve as
guides for the disc while stroking. A 0.005” feeler
gauge should be used to check for clearance between this surface and the side of the disc. If the
clearance is less, clean the guide surfaces in the
disc guide with a fine file.
7.
8.
9.
10.
11.
12.
13.
14.
B. REASSEMBLY
1. Place the plate in the body, lapped surface facing
the cap. The index pin hole should be on the same
side as the “<” on the body. Align the disc pin so
15.
16.
-3-
Remove disc and plate following the procedure
outlined under Valve Seats.
Loosen stem connector nut and bolt and remove
connector.
Back out the four allen head yoke screws (1/2” - 2”
sizes) which will allow the body to be separated
from the yoke.
Remove the packing flange nuts and the packing
flange.
Loosen the stem locknut and rotate the disc pin
counterclockwise, pulling the valve stem upward
while doing so.
When pulling the stem completely out of the body
you will remove most of the packing assembly also.
The remaining parts of the packing assembly can
“fished” out with a small screw driver.
Clean the packing bore in the body with solvent
and blow dry.
The disc-pin may be removed through the body
bore.
Clean the stem and disc-pin with solvent if they are
to be reused.
Reassemble the disc-pin, stem and locknut in the
valve body as they originally were.
Replace the packing spring and packing retainer in
the packing bore.
Reassemble the new packing on the stem with the
open part of the “V” downward (^). There will be a
flat on the top and bottom. Place the packing follower on top of the packing.
Gently push the packing into the packing bore and
place the packing flange on the stem and over the
packing studs.
Put on the flange nuts and tighten them partially. At
this point it is recommended that you gently move
the stem up and down three or four times to align
the assembly.
Tighten the flange nuts until the packing follower
bottoms out on the top of the body.
Replace actuator in reverse order. Reassemble the
valve by inserting seats as outlined in Valve Assembly Section for the size valve you are working with.
Then follow the instruction for seat alignment.
Thermal System
1.
2.
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 returned to the factory for repairs.
The thermal system is easily removed in the field
releasing the spring compression (by rotating the
adjusting wheel downwards) and removing the four
filister head actuator screws (7Y). Do not remove
the adaptor plate (4A) as this will allow excessive
stroking of the specially formed diaphragm, thereby
causing malfunction. To reassemble, merely place
the new thermal system onto the yoke (1Y) and
reinsert the four actuator screws. The valve stroke
adjustment will not be affected if the steps are followed carefully.
Valve Stroke Adjustment
If the temperature regulator requires a stroke adjustment
after maintenance on one of the above points, follow
these procedures.
A.
1.
Direct Acting
Make sure that the actuator stem is stroked fully
upwards by the spring.
2. Loosen the locknut (8V) and the stem connector
bolt (12Y) but do not remove the connector assembly (10Y).
3. Install the plate and disc in the valve body following the procedures outlined under VALVE SEATS.
Orifices of the disc and plate must perfectly align
in the full open position. Loosen the stem locknut
(8V) and adjust the position of the disc on the plate
by rotating the valve stem (9V) (clockwise to raise
and counter clockwise to lower) until the seats are
in the fully opened position.
Note: The stem will rotate in the stem connector if the
connector bolt is loosened slightly. Proper positioning of
the valve stem and actuator stem must be maintained
during adjustment of the seats.
B.
1.
Reverse Acting
Make sure that the actuator stem is stroked fully
downwards. Loosen the spring completely and pull
down on the stem or heat the bulb so that the actuator moves the stem downward. Then, follow the
procedures 2 and 3 under Direct Acting above.
After perfect alignment is obtained, tighten the stem
connector bolt and nut (11Y, 12Y) and the locknut (8V)
Ordering Spare Parts
Use only genuine Jordan Valve parts to keep your valve
in good working order. So that 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, Seat Material and
Cv Rating, Spring Range and Set Point, Trim Material, Part
Name - Number and Quantity.
NOTE: Any parts ordered without a valve serial number
that are found to be incorrect are subject to up to a minimum 25% restock charge when returned.
Torque Requirements
Body Material
Valve Size
Cast Iron
Ductile Iron
Bronze
Cast Steel
Stainless Steel
1/2” & 3/4”
140 in.-lbs.
200 in.-lbs.
1” & 1-1/4”
140 in.-lbs.
200 in.-lbs.
1-1/2” & 2”
140 in.-lbs.
200 in.-lbs.
5
2
4
3
1
6
6 bolts
(or multiples)
7
2
6
3
4
5
1
8
8 bolts
(or multiples)
Illustration and Parts List
1
2
3A2
3A1
4
5
13Y
6
4A
14Y
5A
8
7Y
2S
9
5Y
10
6Y
3Y
14Y
Special Note
3
1A
2A
4Y
To reverse the action of a temperature
regulator, rotate the disc and plate
180°. A slight stroke adjustment may
be necessary.
Direct Acting
Reverse Acting
up and down
down and open
INDEX PIN
INDEX PIN
11Y
9V
9Y
15V
12Y
16V
10Y
13V
1Y
14V
12V
2Y
20V
11V
3V
10V
8V
4V
7V
5V
1V
17V
2V
Item
Description
Item
Description
Item
Description
1V
Body
17V
Body Cap Screw
14Y
Lockwasher
2V
Cap
20V
Body Stud and Nut
1A
Actuator Assembly
3V
Plate
1AC
Name Plate (not shown)
2A
Stroke Stop
4V
Disc
2S
Spring
3A1
Diaphragm Plate
5V
Disc Guide
1Y
Yoke
3A2
Diaphragm Plate Lug
6V
Index Pin (not shown)
2Y
Yoke Screw
4A
Adaptor Mounting Plate
7V
Disc Pin
3Y
Adjusting Post
5A
Mounting Plate Screw
8V
Stem Locknut
4Y
Jam Nut
1
Capillary
9V
Valve Stem
5Y
Adjusting Screw
2
Armor
10V
Packing Spring
6Y
Spring Washer
3
Retaining Ring
11V
Packing Retainer
7Y
Actuator Screw
4
Short Adaptor
12V
Packing
9Y
Actuator Stem
5
Retaining Ring
13V
Packing Follower
10Y
Stem Connector
6
Bulb Nut
14V
Packing Flange
11Y
Stem Connector Nut
8
Tank Fitting
15V
Packing Flange Stud
12Y
Stem Connector Bolt
9
Bulb Assembly
16V
Packing Flange Nut
13Y
Stroke Stop Nut
10
Well Assembly
Bulletin IM-MK80-0909
3170 Wasson Road • Cincinnati, OH 45209 USA
Phone 513-533-5600 • Fax 513-871-0105
[email protected] • www.jordanvalve.com
Thermal System
TYPE B BULB - PLAIN
Type B — A plain bulb which does not have a tank fitting.
It is made for suspension in open tanks. The capillary
and armor should be properly supported so that the possibility of crimping is eliminated. Type B bulbs are used
for coated bulbs. Plastisol coating is suitable for 160°F
maximum. Use Teflon for higher temperature.
Tank Fitting
1” NPT
TYPE A BULB - STANDARD
Type A — The standard JORDAN thermal bulb that can
be used for applications requiring threading of the bulb
into a tank, piping, etc. It may also be threaded into a
thermowell. Fitting is 1” NPT. Refer to factory for special
lengths.
Inverted
Mounting
1” NPT
Tank Fitting
TYPE C BULB - FINNED
Type C — A finned bulb made for sensing atmospheres.
Its fins increase the effective exposed surface, giving the
necessary sensitivity. It is used effectively in air ducts, drying kilns, etc. Good circulation is necessary, and the bulb
is generally installed with the use of a split flange downstream of the blower or fan. Available in copper with aluminum fins only. An 8” diameter flange is optional.
Tank
Fitting
Tank
Fitting
Dead Section
TYPE D BULB - RIGID EXTENSION
Type D — A rigid extension type thermal bulb. The extension is generally a dead section. The length of the live section is the same as the Type A, and the length of the dead
section would depend upon our requirements. Used on
large tanks where poor circulation causes false temperature readings at the walls. The tank fitting can be threaded
directly into the tank, and a well is not required.
TYPE E BULB - EXTENSION
Type E — An extended type thermal bulb that is pressure
tight. If mounted horizontally, a well is needed for support.
The length of the live section is the same as the standard
bulb.
Thermal System
OPERATION OF THERMAL SYSTEM
The LIQUID-VAPOR thermal system used on all Jordan temperature regulators is capable of delivering far more operating power than the simple liquid expansion system used on
many competitive valves.
A pre-measured amount of volatile liquid fill is drawn into
the thermal system, filling the upper diaphragm chamber,
the capillary tube, and most of the bulb. As the controlled
temperature increases, the volatile liquid fill in the sensing
bulb begins to vaporize and creates pressure in the sealed
system. This pressure, exerted on the diaphragm, drives the
valve stem which closes direct acting valve seats or opens
reverse acting valve seats.
Other Jordan Regulators have cast iron diaphragm housing
plates with a diaphragm bolted between them.
CAPILLARY & ARMOR
The capillary, connecting the sensing bulb to the diaphragm
housing is copper as standard, or stainless steel as an alternate. Standard length is 8’ 0” but other lengths, even up to
100’ 0”, are available on special order.
A flexible stainless steel armor is used to protect the copper
capillary tube on standard thermal systems. Other materials
such as Plastisol, Polypropylene, and Teflon are available on
special order.
FILL
Capillary
Armor
The type of volatile liquid used in Jordan thermal systems
depends upon the desired temperature range. Jordan engineers have carefully selected liquid fills that can be used for
controlling temperature from -20°F to 450°F.
INVERTED MOUNTING
SENSING BULB
The sensing bulb contains the volatile liquid fill. Standard
sensing bulbs are copper and stainless steel. Other materials are available on special order. Special protective
coatings such as Plastisol, or Teflon are also available on
special order. The type B bulb is always used when a special protective coating is required. Special bulbs may, in
some cases, be made to fit existing equipment; however,
the dimensions change sharply and must be confirmed by
Jordan’s Engineering Department.
The word
TOP is
stamped
here
Capillary
Vapor
If the sensing bulb is to be mounted in an inverted position
(Fig. 3) the capillary is shortened so that its tip will remain
immersed in the liquid fill.
Figure 3
Vapor
Diaphragm
The capillary tube extends to the end of the sensing bulb
and is bent so that it will always be in the volatile liquid fill.
(Fig’s 2 & 4) The word TOP is stamped on the bulb fitting so
the installer can mount it properly.
Vapor
Liquid
Fill
Liquid
Tank Fitting
Figure 4
Figure 2
Liquid
DIAPHRAGM & DIAPHRAGM HOUSING
Many Jordan temperature regulators feature the SWA actuator. The diaphragm housing is composed on two formed
stainless steel plates. A stainless steel diaphragm is placed
between the two plates and the three parts are heliarc
welded to assure a vapor-tight assembly.
TANK FITTING
Tank fittings are furnished with thermal system types A, D,
E and F unless a thermowell is purchased with the valve.
The external threads on the fitting are 1” NPT; the internal
threads, matching the bulb nut threads, are 1-1/4” - 18
UNEF-2B. Also available are tank fittings having 3/4” NPT
external threads.