Patterson-Kelley P-K Compact Operating And Maintenance Instructions Manual

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PATTERSON KELLEY

COMPACT SEMI-INSTANTANEOUS HOT WATER HEATER

Installation of Loose Shipped Controls

1)

• Spence T61 Temperature Controller and “J” or “K” Series Pneumatic Control Valve

Please install as shown on drawing 1. Pipe 1/4" copper tubing to the 1/8" port on left side of body. From the right 1/8" port, pipe 1/4" tubing to the 1/4" steam valve shut-off solenoid valve . (The solenoid valve can be piped in anywhere on the control air line to the Spence “J” series control valve). From the solenoid valve continue 1/4" copper tubing on to the Spence “J” or “K” series control valve. The tubing

MUST

be supplied to the bottom 1/4" port on the valve actuator. Continue to follow the installation instructions supplied in this manual for the T61 temperature controller and “J” or “K” series pneumatic control valve .

The T61 temperature controller should be set at desired hot water temperature.

2)

• Solenoid Valves

The hot water dump solenoid valve does come pre-wired. The steam valve shutoff solenoid valve is not, and is to be wired to the port in the control panel marked steam valve pilot (SVP)

3) Vacuum Breaker

• Please install the vacuum breaker in the vertical position as shown in drawing 1.

It can be teed in after the control valve or there is a connection right on the steam line into the heat exchanger tubes. That connection can also be used for the vacuum breaker (Please install the vacuum breaker in the vertical position)

4) Steam Trap

• Please follow installation instructions provided in this manual.

Spence "J" or "K" Series

Pneumatic Control

Valve

Spence "T61"

Temp. Controller

Steam Valve Shut-Off

Solenoid

Vacuum

Breaker

DRAWING 1

Hot Water Dump

Solenoid

SD 8011A

Technical Data

PENCE

NGINEERING

OMPANY,

NC.

150 COLDENHAM ROAD, WALDEN, NY 12586-2035

F F

KOMBAT K1 & K4

Control Valve

Sizes

/

" through 4"

ANSI CLASS 125/250

The Kombat Series K Control Valve is designed for economical control of steam, water, gas and process applications in typical institutional, commercial and industrial processes. The Kombat

Series K is available with either a direct or reverse acting actuator that meets most application requirements.

K1 1 ⁄

" - 2"

ANSI B16.15

K4 2 1 ⁄

" - 4"

ANSI B16.1

MAXIMUM RATED FLOW COEFFICIENTS* (Cv)

1 /

5.2

3 /

VALVE SIZE

1 1 /

20 25 30

2 1 /

146

Size

1 ⁄

3 ⁄

(15)-(20)

(25)

1 1 ⁄

-1 1 ⁄

(32)-(40)

(50)

2 1 ⁄

(65)

(80)

(100)

DIMENSIONS inches (mm) AND WEIGHTS pounds (kg)

5 1 ⁄

11 ⁄

(140) (43)

7 3 ⁄

2 7 ⁄

(183) (74)

36 in 2

1 3 ⁄

9 7 ⁄

(30) (251)

E F Weight

60 in 2

—

36 in 2 60 in 2

9 1 ⁄

—

(235) —

36 in 2 60 in 2

21 —

(9.5) —

2 5 ⁄

9 7 ⁄

11 3 ⁄

9 1 ⁄

11 1 ⁄

25 1 ⁄

(58) (251) (298) (235) (286) (11.6) (17)

2 7 ⁄

9 7 ⁄

11 3 ⁄

9 1 ⁄

11 1 ⁄

31 1 ⁄

(74) (251) (298) (235) (286) (14.3) (20)

8 7 ⁄

3 1 ⁄

(226) (79)

8 7 ⁄

9 3 ⁄

⁄

(226) (79)

2 7 ⁄

9 7 ⁄

11 3 ⁄

9 1 ⁄

11 1 ⁄

33 1 ⁄

(74) (251) (298) (235) (286) (15.2) (21)

4 5 ⁄

(238) (133) (118)

—

11 7 ⁄

(302)

— 11 1 ⁄

— (286)

—

(33)

10 6 1 ⁄

5 3 ⁄

(254) (155) (136)

11 7 ⁄

7 1 ⁄

7 3 ⁄

(302) (181) (187)

—

11 7 ⁄

(302)

11 7 ⁄

(302)

— 11 1 ⁄

— (286)

— 11 1 ⁄

— (286)

—

(39)

145

(66)

PRESSURE/TEMPERATURE CHART

450

400

350

300

250

200

150

100

0 50 100 150 200 250 300 350

TEMPERATURE (

400 450

ANSI/ASME B16.15 CLASS 250

ANSI/ASME B16.1 CLASS 125

SATURATED STEAM

Cv TABLE

PERCENT OF TRAVEL

Valve Size Travel Orifice

1/2

3/4

1-1/4

1-1/2

2-1/2

1/4

5/16

1/4

5/16

3/4

5 10 20 30 40 50

60 70 80 90 100

1.0

0.1

0.3

0.2

0.5

0.3

0.36

0.41

0.46

0.51

0.56

0.6

0.65

0.7

0.9

1.1

1.3

1.5

1.7

1.9

2 2.1

0.3

0.6

1.2

1.7

0.15

0.25

0.65

1.5

2.2

2.7

2.6

3.3

2.9

3.7

3.1

3.9

3.2

4.1

3.25

4.2

3.3

4.3

0.7

0.8

1.2

1.3

1.7

2.0

2.4

4.0

2.7

3.3

3.8

6.5

3.2

4.2

5.5

9.3

3.8

4.9

7.4

12.6

4.3

5.5

9.0

15.3

4.7

6.0

10.0

17.0

4.9

6.4

10.6

18.1

5.1

6.8

10.9

19.1

5.2

7.0

11.0

20.0

2.0

4.5

7.2

9.9

12.4

15.2

18.2

20.9

23.4

25.0

7.4

10.6

15.1

18.8

22.8

26.1

28.3

30.0

104

116

62.5

127

65.7

134

140

146

OPERATING PRINCIPLE

The Kombat K1 & K4 Valves are flow to open, globe style, pneumatic diaphragm control valves. The pneumatic actuator can be arranged to operate with either air to close or air to open control. A controller sensing the controlled variable provides a signal to the actuator of the control valve to obtain the desired control.

RECOMMENDED INSTALLATION

SPENCE SAFETY

RELIEF VALVE

SPENCE

UNIFLEX

UNION

SPENCE

UNIFLEX

UNION

SPENCE

STEAM

TRAP

SPENCE DRIP

PAN ELBOW

SPENCE

STEAM TRAP

SPENCE Y

STRAINER

SPENCE K1 & K4

CONTROL VALVE

SPENCE

STEAM TRAP

FIGURE 1 - Typical Steam Installation

CAUTION!

INSTALLATION

The piping system must be adequately designed and supported to prevent extraordinary loads to the pressure equipment.

Locate the valve in a straight run of horizontal pipe as shown in

Figure 1. The valve should be mounted with the actuator in the upright position. Allow room for removal of the actuator. Prevent pipeline hammering in compressible fluid service by providing proper drainage before and after the valve. Avoid damaging effects of scale and dirt in pipelines by using a strainer. A 3valve by-pass to facilitate inspection and maintenance without interrupting service is recommended. To eliminate excessive noise with steam and other compressible fluids, enlarge the delivery pipe size to effect a reasonable flow velocity at the reduced pressure. A concentric transition is recommended. If possible, avoid sharp turns close to the valve bullheaded tee connections to a low pressure main. Install initial and delivery pressure gauges to indicate performance. If the rating of the delivery system or connected equipment is less than the initial pressure, provide a safety relief valve.

START-UP

Flush piping system thoroughly to clear it of welding beads, scale, sand, etc. Install valve with the arrow on the side of the valve body pointing in the direction of fluid flow. Install controller and accessories in accordance with instructions furnished by the manufacturer of these items. Connect necessary air lines and/or electrical connections to diaphragm chamber and valve mounted accessories. Use 1/4” O.D. tubing for all air lines. If length of the air line exceeds 25 ft, use 3/8” O.D. tubing.

Insulation, if desired, may be applied to the valve body only. Do not insulate bonnet. Caution: Hazardous fluids may be handled by this valve. Only qualified personnel, who are familiar with your installation, should be permitted to install, readjust, inspect or maintain the valve.

TROUBLESHOOTING

For troubleshooting of the controlling device and accessories, see instruction furnished by manufacturer of these items. To troubleshoot valve and actuator, check for the following: change in operating conditions; pneumatic signal failure; diaphragm failure; foreign matter lodged between seat ring and plug; actuator vent plug may be: plugged, missing, replaced with a solid plug; packing leakage.

Size

(inches)

Orifice

1/2 A, C, E

3/4

1-1/4

1-1/2

2-1/2

K1 & K4 ACTUATOR SHUTOFF TABLE

(Refer to Temperature Limits)

Act.

Bench

Reverse Shutoff*

Size Range 3-15 psi 0-20 psi † 0-30 psi ‡

Bench

Direct Shutoff*

Range 3-15 psi 0-20 psi † 0-30 psi ‡

6-15 0-400

— —

6-15 0-300

6-15 0-100 —

9-15 101-225 —

12-15 226-300 —

12-15 0-400 —

—

9-15 0-150 —

12-15 151-250 —

13-15 251-400 —

— — —

9-15 0-150 —

12-15 151-200 —

13-15 201-250 —

12-15 0-300 —

13-15 301-400 —

12-15 0-150 —

13-15 151-200 —

12-15 0-225 —

13-15 226-275 —

12-15 0-50 —

13-15 51-75

12-15 0-125

—

13-15 126-175 — —

10-15 0-75 0-100 0-100

—

3-8

12-15 76-125 101-125 101-125 3-8

22-30 — 125 125 3-8

10-15 0-40 0-60

12-15 41-60 0-80

22-30 —

12-15 0-20

22-30 —

81-110 81-110

0-32

33-50

0-60

0-80

0-32

33-50

3-8

—

3-7

—

3-7

—

3-9

—

3-7

3-9

—

3-7

3-12 0-400

3-12 0-300

—

3-9 301-400 —

3-9 0-400 —

3-9

—

3-7

0-250

—

0-400

—

0-100

—

0-400

0-150

—

0-300

—

0-200

—

0-100

—

—-

—

— — —

0-70 0-110 0-200

0-40

0-10

0-60

0-15

0-100

0-25

—

* Shutoff pressures are in conformance with ANSI/FCI 70-2 Class IV

CAUTION: K1 designed for 3-15 psi. Do not exceed 20 psi.

Reverse Acting - Fail Closed/Air to Open (FC/ATO)

Direct Acting - Fail Open/Air to Close (FO/ATC)

† Based on 20 psi air supply with positioner.

‡ Based on 30 psi air supply.

PRODUCT IDENTIFICATION

KOMBAT SERIES K VALVE ORDERING CODE

MODEL NUMBER ORIFICE SIZE CONNECTIONS TRIM PACKING — ACTUATOR

(Must be 2 Digits) (Must be 2 Digits)

SPRING

(Must be 2 Digits)

— POSITIONER POSIT. SET

(Must be 2 Digits) (Must be 2 Digits) example: K 1

K1 - Bronze, Pneumatic

K4 - Cast Iron, Pneumatic

K5 - Bronze, Electric, FC

K6 - Bronze, Electric, FO

E 8 1 1 — 3 6

C - 1 ⁄

2 - 125 Flg 1 - Metal 1 - V-ring K1 & K4 only

D - 3 ⁄

E - 1

8 - Unions 01 - None

36 – 36 in 2

F - 1 1 ⁄

G - 1 1 ⁄

60 – 60 in 2

H - 2"

J - 2 1 ⁄

K - 3

M - 4

K5 & K6 only

90 - 0-10vDC

91 - 4-20mA

92 - 0-135 ohm

R B —

K1, K5, K6 only

DA - 3-12 Dir 36

DB - 3-9 Dir 36

K4 only

DH - 3 - 8 Dir 60

RH - 10-15 Rev 60

RA - 6-15 Rev 36 RQ - 12-15 Rev 60

RB - 9-15 Rev 36 RT - 22-30 Rev 60

RC - 12-15 Rev 36

RD - 13-15 Rev 36

DF - 3-10 Dir 60

DG - 3-7 Dir 60

RG - 12-15 Rev 60

RH - 13-15 Rev 60

01 - None (K5, K6 only)

M P

A - None

MI - Moore I/P

MP - Moore P

4P - PMV P4 P

5I - PMV P5 I/P

5P - PMV P5 P

ACCESSORIES

(Must be 2 Digits)

0 2 0 1

For use with K4 Valves Only

01 - None 01 - None

02 - 3-15/4-20 mA 02 - Limit Switch, Mechanical

03 - 3-9/4-12 mA 03 - Limit Switch, Proximity Sw.

04 - 9-15/12-20 mA 04 - Feedback Potentiometer 1K

05 - Feedback 4-20mA Posit. Tra

MAINTENANCE

Warning: Injury or death can occur due to failure to completely isolate valve from all sources of pressure before beginning disassembly. Do not proceed until valve has been completely isolated from process stream and vented to atmosphere.

REMOVAL OF ACTUATOR FROM VALVE BODY

ASSEMBLY

Close inlet and outlet stop valves. Be sure valve body is not under pressure. Remove all accessories from control valve.

Refer to Figure 2.

Reverse Acting Pneumatic Actuator

Loosen stem nuts (24) and move to approximately 1/3 down valve stem. Re-tighten being careful not to move valve stem.

Energize actuator with air to lift the plug off the seat. Disengage lock nut (26) from bonnet (25). De-energize actuator. The actuator and yoke should move away from bonnet. Lift actuator and yoke assembly along with plug (39) off the seat. With an adjustable wrench, unthread valve stem from actuator stem (Fig.

6, #16) until valve stem is disengaged from actuator stem .

Remove stem nuts, indicator, packing nut and lock nut.

Direct Acting Pneumatic Actuator

Energize actuator with air slightly (in case of back seating).

Loosen stem nuts (24) and re-tighten approximately 1/8” away from actuator stem (Fig. 6, #16). Disengage lock nut (26) from bonnet (25). With an adjustable wrench, unscrew valve stem from actuator stem. When valve stem reaches seat, lift actuator

(to prevent galling seat and plug). Remove stem nuts, indicator and lock nut.

DISASSEMBLY OF VALVE BODY

Remove stem nuts (24), indicator (32) and lock nut (26). Lift yoke off bonnet (25). To complete body disassembly, unscrew bonnet for K1 and cap (42) for K4. For K4 remove bonnet nuts (34) and lift off blind flange (35), bonnet, stem and plug assembly (37).

Remove gasket (36). A new gasket should be installed each time valve body is disassembled. Turn stem and plug assembly out of bonnet through packing. Replace packing if necessary. All parts should be inspected for wear and cleaned thoroughly before re-assembling valve body.

DISASSEMBLY OF ACTUATOR

Remove actuator from valve. Remove regular casing bolts (4) and casing nuts (5). Gradually loosen nuts on remaining long casing bolts (14) to allow pre-compression of actuator springs.

Remove upper casing (2). Pull actuator stem (16), along with diaphragm (15), springs (3) and piston (13), out through bushing

(7). Place a wrench on the machined flats of actuator stem, and remove stem nut (10) or travel stop (22), seal washer (12) and stem washer (11). Remove o-ring (8) from bushing and replace if necessary. Lubricate o-ring after installing.

RE-ASSEMBLY OF ACTUATOR

Refer to Figure 6 for correct orientation of casings, diaphragm

(15), piston (13), stem (16) and springs (3) for direct or reverse action. Be sure piston spring recesses line up between casing ribs as shown in Figure 8C. Lubricate bushing O-ring (8) and insert actuator stem through bushing. Re-attach upper casing

(2) with long bolts (14) & nuts (5), tightening alternately. Install remaining casing nuts and bolts. Apply air to diaphragm case and check for leakage, full travel and dead band less than .2 psi.

LAPPING PLUG INTO SEAT

Seats and plugs should never require more than the lightest touch up with very fine (400 grit) grinding compound. Heavy lapping will produce galling, a wider seating surface and a groove in the plug, all of which tend to cause leakage. Reface a damaged surface before attempting to grind it in. Lap sparingly.

Replace stem and plug (39) in bonnet (25) through packing.

Apply lapping compound to plug. Place bonnet and bonnet flange (35 for K4 only) on body. After lapping, disassemble and clean all parts thoroughly.

PACKING REPLACEMENT

Check stem for gouges if packing leaks. Replacement packing cartridges can be installed.

RE-ASSEMBLY OF VALVE BODY (K1)

Tighten bonnet (25) to body. Replace yoke (9), lock nut (26), stem nuts (24) and travel indicator (32) over stem (34).

RE-ASSEMBLY OF VALVE BODY (K4)

Install a new gasket (36). Attach bonnet (26) and bonnet flange

(35) to body with bonnet studs and nuts (33, 34). Be sure to tighten bolts alternately and evenly to ensure proper seating of the plug. Replace yoke (9), lock nut (27), stem nuts (31) and travel indicator (23) over stem (30).

REPLACING ACTUATOR ON VALVE BODY -

PNEUMATIC

Put actuator assembly over valve stem. Place lock nut (Fig. 2,

#26), and stem nuts (24) with travel indicator (32) on valve stem.

Rest actuator stem (16) on valve stem. Tighten stem nuts approximately 2/3 down valve stem. Lift actuator assembly and engage valve stem with actuator stem (be careful not to gall plug & seat).

Reverse Acting

When sufficient engagement is met, the actuator can be energized with air to place the yoke on the bonnet (25) and lift the plug off the seat. Tighten lock nut and packing nut.

Direct Acting

Engage valve stem with actuator stem so no contact is made between plug and seat when bottom of yoke is rested on bonnet. Tighten lock nut.

ACTUATOR ADJUSTMENT - PNEUMATIC

Close inlet and outlet stop valves. Be sure valve body is not under pressure. Place a wrench on the machined flats of

actuator stem (16). Counter two stem nuts (24) approximately halfway down the threads of the stem (34).

Reverse Acting

Apply sufficient air pressure to diaphragm case to start moving valve through its rated travel. This is shown by travel indicator

(32). Engage lower stem nut (24) and turn body stem (34) into actuator stem (16) until pre-compression of actuator springs (3) is relieved (plug should not be seating on seat ring when air pressure is removed from actuator case). Apply prescribed setting pressure to actuator. This is determined by specific operating conditions. Turn body stem out of actuator stem until plug seats on seat ring (28). To prevent galling, do not turn body stem after plug has contacted seat ring. Turn stem nuts up plug

& stem assembly and tighten to lock them in position. Reduce air signal to 0 psi and calibrate indicator scale (20). Check that full travel is achieved with a 15 psi signal (for 22-30 spring range, use 30 psi signal).

Direct Acting

Engage lower stem nut (24) and turn body stem (34) into actuator stem (16) until plug & stem assembly stops at upper limit of travel and/or a slight downward movement of actuator stem is detected. Turn stem nuts up body stem and tighten them to lock in position. Calibrate indicator scale (20). Check that full travel is achieved at a 3 psi signal.

It is solely the responsibility of the system designer and the user to select products and materials suitable for their specific application requirements and to ensure proper installation, operation and maintenance of these products. Assistance shall be afforded with the selection of the materials based on the technical information supplied to Spence Engineering Company, Inc.; however, the system designer and user retain final responsibility. The designer should consider applicable Codes, material compatibility, product ratings and application details in the selection and application. Improper selection, application or use of the products described herein can cause personal injury or property damage. If the designer or user intends to use the product for an application or use other than originally specified, he must reconfirm that the selection is suitable for the new operating conditions.

ITEM

NO.

23A*

23B**

28A

35*

36**

28B

PART NAME

STEM BOLT - SHORT

STEM BOLT - LONG

STEM NUT

BONNET ASSY

LOCK NUT

WAVE WASHER

SEAT RING, 1/2A K1

SEAT RING, 1/2B K1

SEAT RING, 1/2C K1

SEAT RING, 1/2E K1

SEAT RING, T K1

SEAT RING, 1/2A K5

SEAT RING, 1/2B K5

SEAT RING, 1/2C K5

SEAT RING, 1/2E K5

SEAT RING, T K5

TAILPIECE

ST STL

GALV IRON

BODY BRONZE

CAP BRASS

TRAVEL INDICATOR

V RING PACKING SET

STEM

YOKE BUSHING

ALUM

TFE/SS/VITON

ST STL

BRASS

SPACER

NUT

GUIDE

PLUG, 1/2A

PLUG, 1/2B

PLUG, 1/2C

PLUG, 1/2D

PLUG, 1/2E

PLUG, T

UNION NUT

BRASS

ST STL

GALV IRON

ST STL

MATERIAL

BRASS

ST STL

* Not included in body assembly; order K-KIT separately.

**Not included in body assembly: order separately.

K1 VALVE BODY ASSEMBLY PART NUMBERS

562A113-01

SMP462

292B110-01

—

05-12962-00

204A104-01

552A117-01

04-17278-00

04-17280-00

05-17342-00

—

554A155

SMP467

3/4

04-17277-00

04-17281-00

05-17342-00

557B109-01

05-17330-00

—

SM217

—

562A112-01

SX227

292B110-01

—

05-12962-00

204A104-01

552A117-01

04-17278-00

04-17280-00

05-17342-00

—

554A154

554A158

554A153

554A156

554A159

554A157

SMP487

1/2

04-17277-00

04-17281-00

05-17342-00

557B109-01

05-17330-00

—

SN217

SUU217

SN217

SX217

562A110-01

562A114-02

SMP463

SAM1167B

557B101-01

05-12962-00

204A104-01

552A115-01

04-17278-00

04-17280-00

—

556A111-01

—

554A146-02

SMP468

VALVE SIZE

04-17277-00

1-1/4

04-17277-00

04-17281-00

05-17342-00

04-17281-00

05-17342-00

557B107-02

05-17330-00

122A155-01

—

557B107-02

05-17330-00

122A155-02

—

562A114-02

—

562A114-03

—

562A114-03

SBB227

SAN1167B

SB312E

05-12962-00

204A104-01

552A115-02

04-17278-00

04-17280-00

—

556A111-02

—

554A146-03

SMP470

562A114-05

SMP593

564B116-01

SB312E

05-12962-00

204A104-01

552A115-02

04-17278-00

04-17280-00

—

556A111-02

—

554A146-05

SMP592

04-17277-00

04-17281-00

05-17342-00

557B110-02

05-17330-00

122A155-02

—

562A114-05

—

562A114-04

SMP465

SAN1167B

SB312E

05-12962-00

204A104-01

552A115-02

04-17278-00

04-17280-00

—

556A111-02

—

554A146-04

SMP470

1-1/2

04-17277-00

04-17281-00

05-17342-00

557B110-02

05-17330-00

122A155-02

—

562A114-04

—

FIGURE 2 -

VALVE BODY ASSEMBLY - K1 1" - 2"

FIGURE 4 -

VALVE BODY ASSEMBLY - K1 - 1/2" - 3/4"

When ordering parts, it is essential that the valve type, size, service and serial number be stated.

Select part by item number, but order by part number.

Specify complete part number when ordering.

ITEM

NO.

K4 VALVE BODY ASSEMBLY PART NUMBERS

PART NAME

Pointer

Stem bolt

Packing box

Bonnet

Nut

Yoke bushing

Stem bearing

Valve stem

Nut

Disc

Tap stud

Nut

Blind flange

Gasket

Disc stem

Nut

Seat Ring

Cap

Pipe plug

MATERIAL

Aluminum

Brass

Ductile iron

Stl/zinc pltd

Brass

303 ss

316 ss

420 ss

Steel

Cast iron

Graphite

304 ss

C1018

420 ss

Cast iron

12L14

2-1/2

5-12962-0

4-17277-0

204A104-01

558B113-02

5-17330-0

4-17278-0

SU260

552A117-02

5-17342-0

4-08242-0

4-10119-0

5-02860-0

4-17334-0

5-02367-1

4-17333-0

5-02973-0

4-11539-0

4-01325-0

4-03769-0

VALVE SIZE

5-12962-0

4-17277-0

204A104-01

558B113-02

5-17330-0

4-17278-0

SU260

552A117-02

5-17342-0

4-01918-0

4-05443-0

5-02856-0

4-17337-0

5-02369-1

4-17340-0

5-02973-0

4-11484-0

4-00655-0

4-17339-0

4-03769-0

5-12962-0

4-17277-0

204A104-01

558B113-02

5-17330-0

4-17278-0

SU260

552A117-02

5-17342-0

4-01931-0

4-10119-0

5-02860-0

4-17334-0

5-02371-1

4-17344-0

5-02974-0

4-11565-0

4-00659-0

4-17346-0

4-03769-0

K1 and K4 are designed and manufactured in accordance with Article 3, Section 3 of the

Pressure Equipment Directive.

FIGURE 5 -

VALVE BODY ASSEMBLY - K4

K1 & K4 ACTUATOR PART NUMBERS

ITEM # PART NAME

1 Vent plug

Upper casing

Springs

Casing bolt standard

Casing nut

Lower casing

Bushing

*8 O Ring

9 Yoke

*10 Stem nut

*11 Stem washer

*12 Seal washer

13 Piston

*14 Casing bolt long

*15 Diaphragm - 36 sq. in.

Diaphragm - 60 sq. in.

16 Actuator stem

17 Machine screw

18 Casing gasket

19 Machine screw

*20 Indicator scale

*21 Specification plate

**22 Stop 12-15 psi

Stop 10-15 & 22-30 psi

303 ss

Steel

Buna-n

Steel

Aluminum

Brass

*These parts furnished in Actuator Repair Kit.

** Used in K4 only

MATERIAL

H.D.poly

Stl/powder coat

Steel

304 ss

316ss

Stl/powder coat

Bronze

Buna-n

CI/powder coat

Steel

316 ss

Steel

316 ss

304 ss

Nitrile

PART #

—

QTY

— 1

See Below See Below

—

10/14

12/16

5-04017-0

—

5-13374-0

5-12963-0

5-13203-0

—

5-04889-0

0-12968-0

1/3

@-12986-0

—

5-13190-0

5-13199-0

5-17360-0

5-17362-0

REVERSE

REVERSE ACTING

DIRECT

Other

DIRECT ACTING

05-04841-00

Special arrangement for 22-30 range

Optional spacer

#04-17280-00 for #36

Rev. Act. 9-15 psi &

#60 Rev. Act 12-15 psi

FIGURE 6 - ACTUATOR ASSEMBLY - K1 & K4

K1 & K4 ACTUATOR SPRING KITS

Part # Reverse Shutof

(Air-to-Open) Bench Range

K1 K4 ††

Direct Shutoff †

(Air-to-Close) Bench Range

K1 K4

Spring Kit Includes:

Spring

Part # Notes Code Range Code Range Code Range Code Range QTY Color Part#

36KIT100 (1) 36RA 6 - 15 36DA 3 - 12 6 YELLOW 05-12991-00

36KIT102 (3) 36RB 9 - 15

36KIT104 (2) (4) 36RC 12 - 15

36KIT108 (2) (4) 36RE 13- 15

36KIT110 (1) -

60KIT100 (1) (4) 60RG 12 - 15

36DB 3 - 9

60DG 3 - 7

6 YELLOW 05-12992-00

6 RED 05-13090-01

6 GREEN 05-13085-00

6 METAL 05-05121-00

6 BROWN 05-13093-01

05-04889-00

(2) Bolts

60KIT102 (1) (4) 60RH 13 - 15 60RH 10 - 15

60KIT104 (5)

60KIT110 (1) -

60RQ 12 - 15

60RT 22 - 30 -

3 - 8

4 BROWN 05-13093-01

6 BLACK 05-13097-00

6 BROWN 05-13093-00

05-04889-00

(2) Bolts

See detail in Fig. 6

† For Direct Shutoff - Invert Springs, Piston and Diaphragm from Reverse Shutoff Actuator.

†† To convert a K1 actuator to a K4 actuator you must add travel stop (05-17362-00) into the actuator and vice versa.

(1) For K1 & K4 ONLY - Mounts using KKIT-1

(2) For K1 ONLY - Mounts using KKIT-2

(3) For K1 ONLY - Mounts using KKIT-3

(4) Includes J-Valve travel scale

ACTUATOR REPAIR KIT PART NUMBERS

LOWER CASING

BOLT HOLE

(5) For K4 ONLY - Mounts using KKIT-1 & spacer 04-17280-00

36 SQ. IN.

51447

60 SQ. IN.

51448

PISTON

SPRING

RECESSES

STEM

FLATS

K1 & K4 ACTUATOR CONNECTOR KITS

PART # SIZE ORIFICE SEAT FOR USE WITH

STYLE K1 K4

KKIT-1 1/2 - 4 All

KKIT-2 1/2 - 2 All

All

KKIT-3 1/2 - 2 All All X

Stem Bolt

KKIT Includes:

Bushing

04-17277-00 04-17278-00

Spacer

04-17281-00 07-17278-00 -

04-17281-00 04-17278-00 04-17280-00

FIGURE 8 - PISTON

DIAPHRAGM ASSEMBLY

SD 4522C

Technical Data

PENCE

NGINEERING

OMPANY,

NC.

150 COLDENHAM ROAD, WALDEN, NY 12586-2035

3 5 / 8 "

5 5 / 8 "

1 / 8 " NPT 1 / 2 " NPT

12"

TYPE T61, T62 & T63 PILOT

Air Master TYPE T61, T62 & T63

PNEUMATIC TEMPERATURE

CONTROLLER

The T61 Series Temperature Regulator is ideal for wide ranging, fast changing loads on instantaneous heaters and other difficult process applications. The cascade principle, normally used only on instrument type regulators, is the basis for this inexpensive design. The T61, when used with a properly selected A Series

Pilot or Control Valve, continuously adjusts a pressure regulator to the required heater pressure. This action, coupled with the fast response of a bimetallic thermostat, gives exceptional results.

Added convenience and economy results from the wide (200°F) adjustable range and the low air consumption (.35 cfm). These controllers have adjustable proportional band as well as overtemperature protection.

SPECIFICATIONS

Max. Air Supply Pressure ………………32 psi

Max. Signal Pressure ……………………2 psi below Supply

Mounting …………………………………1/2" NPT

Air Connections …………………………1/8" NPT

Air Consumption, Maximum ……………0.70 SCFM

Air Consumption, Normal ………………0.35 SCFM

Proportional Band (Adjustable) …………1/4 to 2 psi per 1°F

Weight ……………………………………2 3/4 lb.

TEMPERATURE RANGES

T61 & T62

T63

50° to 250°F

150° to 300°F

OPERATING PRINCIPLE

When used with Regulator

The regulator is operated by it’s initial steam pressure. It is normally closed, being held so by initial pressure on the disc and by an internal main spring. The pressure pilot is actuated by means of an air signal applied to it’s diaphragm. This signal is received from the temperature pilot as a result of the temperature bulb sensing a drop in temperature from the control setting.

When steam is turned on, it flows through the pressure pilot (Fig.

2) to the No 8B tee. Bleedport No. 4A restricts the flow, builds pressure under the diaphragm and opens the main valve.

Restriction No. 5A steadies the operation of the regulator.

Steam flowing to the heater develops a rising delivery pressure which feeds back through the control pipe to the pressure pilot diaphragm. As this pressure approached a balance with the air pressure signal supplied by the temperature pilot , the pressure pilot throttles. This, in turn, allows the main valve to assume a position to maintain the set temperature.

As the temperature at the outlet of the heater increases, it causes the T61 Pilot to reduce the loading air pressure and this, in turn, will cause the pressure regulator to modulate the steam flow to the heater.

When used with Pneumatic Control Valve

The T61 Series Pilot will send a proportional air signal from 0 psi to a maximum of 30 psi (not greater than 2 psi less than the supplied pressure) within a ???? degree span. The Pilot will increase signal as the temperature falls, which will either open or close the control valve, depending upon actuator configuration.

INSTALLATION

PLANNING

Locate the regulator in a horizontal pipe. Prevent water hammer and erratic operation by providing a trap ahead of the regulator.

Avoid damaging effects of scale and dirt in pipelines by using a strainer to protect the regulator. Provide a three valve bypass to facilitate inspection of the regulator without interrupting service.

MAIN VALVE

Flush the main piping system thoroughly to clear it of welding beads, scale, sand, etc. Mount main valve with diaphragm chamber down and arrow on body pointing in the direction of flow. Screwed end valve should be mounted in unions.

PILOT

Mount the pilot with the bulb projecting entirely into the liquid or air being controlled. If the body is not in a horizontal position with air gages on top, the set screw (5) on bottom of body nearest the bulb may be loosened and body rotated to horizontal position.

Retighten the set screw.

Connect a reliable source of clean compressed air (not to exceed

32 psi) to the inlet of the pilot. The supply air should be set at 2 psi above the maximum desired air signal. If air is available at a higher pressure, install a pressure reducing valve. CAUTION: Be sure to blow out all lines before making final connections.

Connect pilot outlet to 1/4" tap on top of pressure pilot.

START-UP AND SETTING

With supply air shut off, set temperature adjusting knob at the lowest temperature setting. Turn on supply air. The supply air should be set at 2 psi above the maximum desired air signal. If air is available at a higher pressure, install a pressure reducing valve. No more than 1 to 2 pounds should show on the control air gage (supplied with the T61 Pilot).

increased, the temperature pilot is being called on to function at a setting finer than the installation will permit. At this point, factors such as thermostat location, trapping and valve size should be reexamined.

If the regulator swings immediately on startup and does not settle out and decreasing the sensitivity by turning the sensitivity screw

(7) counterclockwise cannot be tolerated, the installation as a Gradually turn up temperature adjusting knob until rising loading air pressure causes regulator to open. Continue raising temperature setting in this fashion until desired control temperature is reached.

whole should be restudied.

RECOMMENDED INSTALLATION

The T61 Pilot is factory set so that 5 degrees variation above and below the controlled temperature will cause the loading air pressure to vary approx-

Initial

Pressure

Angle Valve imately 8 pounds. The factory setting will usually produce satisfactory control.

If closer control is desired, the sensitivity of the T61 Pilot can be increased by turning the sensitivity screw (7) clockwise.

This will cause the control temperatures to move to a position below the set point.

This effect must then be corrected by readjusting the temperature adjusting knob (4).

Make these adjustments slowly, turning the sensitivity screw no more than 1/8 turn and allow two or three minutes after each adjustment for the system to settle out. Practical range of adjustment of the sensitivity screw is 1/2 turn from the factory setting.

After final setting is reached, it may be necessary to release the set screw in the temperature adjusting knob and reposition it so that the indicator is aligned with the temperature being controlled. At this point, the set screw is retightened.

Steam

Trap

Gate

Valve

Type EAT61

Temperature

Regulator

Strainer

Quick Vent

Air Valve &

Vacuum Breaker

Gate

Valve

Gate

Valve

Control

Pipe

Instantaneous Heater

F and T

Steam

Trap

Condensate

FIGURE 1

Strainer

Safety Valve

Hot Water

Service

Type T61

Temperature

Pilot

Check

Valve

From

Circulating Pump

Check

Valve

Pressure

Relief

Valve

Cold

Water

Supply

Drain

If a hunt develops (a steadily swinging temperature) when the sensitivity is

TROUBLE SHOOTING

FAILURE TO OPEN

1. Check supply gage to be sure it shows 2 psi higher than the required signal pressure.

2. Turn adjusting knob to top of temperature range. Pressure should go to within 2 or 3 pounds of supply pressure. If not, check for dirt in sensitivity screw and ball seating surface.

FAILURE TO CLOSE OR OVERRIDING

DELIVERY PRESSURE

1. Adjusting knob may have been tampered with.

2. If air pressure will not bleed down when adjusting knob is turned to bottom of range, it is likely that vent is plugged.

Sensitivity screw (7) improperly adjusted (open too wide).

ERRATIC CONTROL

1. Hunting

2. Gradual wandering over too wide a spread.

3. Fast over and under rides are the result of fast load changes, usually accentuated by the thermostat being located at a point where it cannot immediately sense a change in conditions.

INSTALLATION FAULTS

1. Poor circulation through heater. Constant circulation should be employed.

2. Traps on the return may be discharging erratically or may be improperly installed.

3. Sticky check valve.

4. High lift to condensate hot well. Gravity drainage from heater should be arranged or return pump installed.

DISMANTLING

1. Remove sensitivity screw (7) and clean.

2. Unlock knob set screw. Loosen and move adjusting knob (4) out to clear stop on dial plate and lock to shaft. Unscrew spool (3) from body by rotating adjusting knob counterclockwise.

Control

Pipe

Pilot

Type A85

Serial

No. Plate

Restriction

Bend

No. 8B Tee

1/4" Union

FIGURE 2

Bleedport Bend

No. 4A Bleedport

Serial No. Plate

Do not insulate below this line

Main Valve

Type E or E2

No. 5A Restriction

Elbow—Type E

No. 5B Open

Elbow—Type E2

TYPE T62

FIGURE 3

TYPE T61, T63

3. Care should be taken not to damage O-rings (6). Examine for nicks and other defects.

4. Examine spool (3) and ball (2) for defects.

5. Clean spool and ball with air pressure.

6. Reassemble.

TESTING & CALIBRATING

Reverse or Direct Acting

Plug the pilot control air port and apply supply pressure 2 psi above the control range to the supply air port.

Open the sensitivity screw (7) one turn while establishing a steady system temperature.

Reverse Acting (T61 & T63) Pilots Only

(Control pressure decreases with increasing temperature)

Turn the spool (3) clockwise to the point where the invar rod, ball and seat are in contact. The control gauge should show pressure near the top of the control range.

Turn the spool counter-clockwise until the control pressure is at the middle of the range.

Continue to turn the spool counter-clockwise until the low end of the range is reached. Adjust the sensitivity screw as required so this occurs within a 5° change on the dial. The control pressure should vary from the minimum to the maximum (15 or 30 psi) with a 10° change of the dial setting.

When used with an A-pilot the minimum is 3 psi, when used with a control valve the minimum is the lower end of the bench range.

SERIAL NUMBER PLATE

AND FLOW ARROW

SUPPLY

AIR

1/8"NPT

CONTROL AIR

TO PILOT

1/8"NPT

VENT (DO

NOT PLUG)

TYPE T61 PILOT

REVERSE ACTING

PILOT

BODY

T61, T63 and T64 Pilots are designed and manufactured in accordance with Aritcle 3,

Section 3 of the Pressure

Equipment Directive 97/23/EC.

ITEM

NO.

PART NAME

Bulb Assy. 50-250 (T61,T62 except SS)

MATERIAL

Bronze

Bulb Assy. 150-350 (T63 & T61,T62 SS only) St. Steel

*Ball

*Spool Reverse Acting - T61 & T63

St. Steel

Brass

Adjusting Knob

Body Set Screw

*Spool Sealing Rings

*Sensitivity Screw

Plastic

Steel

Viton

Steel

St. Steel 8

*Valve Spring

Pressure Gauge

10 1/8 Nipple

11 1/8 Tee

12 Spool Direct Acting Assy. - T62

Repair Kit - T61, T63, T64 (Reverse Acting)

Brass

*These parts furnished in Repair Kit

PART NO.

07-40190-03

07-40191-03

05-07709-00

04-07741-00

05-07927-00

05-11134-00

05-04004-00

05-07930-0

05-05175-00

05-17460-00

05-17459-00

05-17458-00

07-43770-00

08-11507-01

T61–Reverse Acting

T62–Direct Acting

T63–High Temperature Reverse Acting

Reverse Acting–Air control signal decreases as process temperature increases.

Direct Acting–Air control signal increases as process temperature increases.

When ordering parts, it is essential that the pilot type, service and serial number be stated.

Select part by item number, but order by part number. Specify complete part number when ordering.

P.O. Box 248 Buffalo, NY 14225-0248 Tel: 1-888-300-9155 Fax: 1-888-300-9160 www.coltonind.com [email protected]

Installation, Operating & Maintenance Instructions

CFT Series Float & Thermostatic Steam Traps

Introduction

The COLTON CFT Series float & thermostatic steam trap is designed to automatically drain the condensate from steam equipment and steam mains.

CFT series steam traps should be installed in an accessible position and location easy for servicing.

The maximum differential pressure (

ª

P) stamped on the product name plate must be greater than the maximum differential pressure across the trap.

Be sure to install trap straight (with the name plate facing forward in a horizontal position), plumb, and in a level position to ensure proper operation.

Warning:

Steam systems can be dangerous and safety precautions must be observed. Before working on steam equipment, make sure that the pressure has been released and the equipment has cooled.

Installation:

Before installing your steam trap, blow all dirt and scale from the equipment and piping. Install the trap below and close to the equipment being drained - avoiding long lengths of horizontal piping leading to the steam trap.

Pitch all horizontal inlet lines toward the steam trap to help eliminate potential water hammer problems

Pipe plugs, included separately, must be placed in the two unused connections on all 3/4", 1" and 1-1/4" CFT-015 and

CFT-030 traps. See “Piping Combinations Detail”

A dirt pocket and strainer (with blowdown) should always be provided ahead of trap

Union fittings and shut-off valves should be installed on both inlet and outlet of trap for ease of servicing and trap testing

All models (even those with an integral screen) should have a line strainer installed ahead of them and union fittings and shut-off valves should be installed on both sides of the trap for ease of testing and maintenance. A test and exhaust valve installed on the trap outlet can be used to relieve line pressure prior to servicing and to allow you to visually check the trap for steam leaks during future inspections.

Maintenance:

Accumulated dirt and sludge can be removed by “Blowing Down” through the drain in the bottom of the trap. The trap mechanism should be inspected periodically and all dirt removed from working parts. Worn parts must be replaced.

Installation & Maintenance Instructions

2-WAY INTERNAL PILOTED-OPERATED SOLENOID VALVES

NORMALLY CLOSED OPERATION Ċ GENERAL SERVICE

3/8 I , 1/2 I OR 3/4 I NPT

NOTICE: See separate solenoid installation and maintenance instructions for information on: Wiring, Solenoid Temperature,

Cause of Improper Operation, Coil or Solenoid Replacement.

DESCRIPTION

Series 8210 valves are 2-way normally closed internal pilot-operated solenoid valves designed for general service. Valves are made of rugged forged brass. Series 8210 valves are provided with a general purpose solenoid enclosure.

Series EF8210 and 8211 are the same as Series 8210 except they are provided with an explosionproof or explosionproof/watertight solenoid enclosure.

OPERATION

Normally Closed: Valve is closed when solenoid is de-energized; open when energized.

IMPORTANT: Minimum operating pressure differential required is 5 psi.

Manual Operator (optional feature)

Manual operator allows manual operation when desired or during an electrical power outage. To engage manual operator (open the valve), push in knurled cap and rotate stem clockwise 180 _ . Valve will now be in the same position as when the solenoid is energized. To disengage manual operator (close the valve), turn stem counterclockwise 180 _ .

Push in and rotate

180°clockwise to operate

CAUTION: For valve to operate electrically, manual operator stem must be fully rotated counterclockwise.

Relocation of Manual Operator

Manual operator may be relocated at 90 _ increments by rotating the valve bonnet as follows:

WARNING: To prevent the possibility of death, serious injury or property damage, turn off electrical power, depressurize valve, and vent fluid to a safe area before relocating manual operator.

1. See separate solenoid installation and maintenance instruction's and follow instructions to loosen solenoid to allow rotation of enclosure.

2. Be sure manual operator stem is fully rotated counterclockwise.

3. Remove bonnet screws from valve body.

4. Lift valve bonnet slightly and rotate to desired position. Do not rotate the diaphragm assembly with the valve bonnet.

5. Replace bonnet screws and torque in a crisscross manner to

95 ± 10 in-lbs [10,7 ± 1,1 Nm].

6. Position and tighten solenoid in place, see separate instructions.

WARNING: To prevent the possibility of death, serious injury or property damage, check valve for proper operation before returning to service.

7. Test operate valve electrically and manually. Be sure valve can be test operated without effecting other equipment.

8. Restore line pressure and electrical power supply to valve.

[ 7.1]

.28 dia.

2 mounting holes

Figure 1. Mounting bracket dimensions

Piping

Connect piping to valve according to markings on valve body. Apply pipe compound sparingly to male pipe threads only. If applied to valve threads, the compound may enter the valve and cause operational difficulty. Avoid pipe strain by properly supporting and aligning piping. When tightening the pipe, do not use valve or solenoid as a lever. Locate wrenches applied to valve body or piping as close as possible to connection point.

Printed in U.S.A.

SERIES

8210

8211

Form No.V5848R2

INSTALLATION

Check nameplate for correct catalog number, pressure, voltage, frequency, and service. Never apply incompatible fluids or exceed pressure rating of the valve. Installation and valve maintenance to be performed by qualified personnel.

Future Service Considerations

Provision should be made for performing seat leakage, external leakage, and operational tests on the valve with a nonhazardous, noncombustible fluid after disassembly and reassembly.

Temperature Limitations

For maximum valve ambient and fluid temperatures, refer to chart below. Check catalog number and watt rating on nameplate.

Watt

Rating

AC or

6.1

Catalog

Number

Prefix

None or DF

None, KF,

SF, or SC

HT, KH, ST or SU

Solenoid

Class

Max.

Amb.

Temp. _ F

122

140

125

140

Max.

Fluid

Temp. _ F

180

11.2

11.6

None or HT F or H

None, HT,

KF, KH, SC,

SF or ST

F or H

104

150

Positioning

This valve is designed to perform properly when mounted in any position. However, for optimum life and performance, the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulating in the solenoid base sub-assembly area.

Mounting

For mounting bracket (optional feature) dimensions, refer to Figure 1.

[42]

1.66

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50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

CAUTION: To protect the solenoid valve, install a strainer or filter suitable for the service involved in the inlet side as close to the valve as possible. Clean periodically depending on service conditions. See ASCO Series 8600, 8601 and 8602 for strainers.

MAINTENANCE

WARNING: To prevent the possibility of death, serious injury or property damage, turn off electrical power, depressurize valve, and vent fluid to a safe area before servicing the valve.

NOTE: It is not necessary to remove the valve from the pipeline for repairs.

Cleaning

All solenoid valves should be cleaned periodically. The time between cleanings will vary depending on the medium and service conditions.

In general, if the voltage to the coil is correct, sluggish valve operation, excessive noise or leakage will indicate that cleaning is required. In the extreme case, faulty valve operation will occur and the valve may fail to open or close. Clean strainer or filter when cleaning the valve.

Preventive Maintenance

S Keep the medium flowing through the valve as free from dirt and foreign material as possible.

S While in service, the valve should be operated at least once a month to insure proper opening and closing.

S Depending on the medium and service conditions, periodic inspection of internal valve parts for damage or excessive wear is recommended. Thoroughly clean all parts. If parts are worn or damaged, install a complete ASCO Rebuild Kit.

Causes of Improper Operation

S Incorrect Pressure: Check valve pressure. Pressure to valve must be within range specified on nameplate.

S Excessive Leakage: Disassemble valve and clean all parts. If parts are worn or damaged, install a complete ASCO Rebuild Kit.

Valve Disassembly

1. Disassemble valve in an orderly fashion using exploded views for identification and placement of parts. Refer to Figure 2 for

AC construction; Figure 3 for DC construction.

2. Remove solenoid enclosure. See separate instructions.

S For AC construction (standard or with manual operator), proceed as follows:

3. For standard construction, remove bonnet screws, solenoid base sub-assembly, core spring, core assembly, diaphragm spring, diaphragm assembly and body gasket from valve body.

4. For manual operator constructions, unscrew solenoid base sub-assembly first then follow step 3 for removal of parts.

5. For normal maintenance (cleaning) it is not necessary to disassemble the manual operator unless an ASCO Rebuild Kit is being installed. To disassemble, remove stem pin, manual operator stem, stem spring and stem gaskets (2).

S For DC construction (standard or with manual operator), proceed as follows:

6. Unscrew solenoid base sub-assembly first then follow step 3 and 5 for removal of parts.

Note: Diaphragm spring is omitted for DC construction.

7. All Parts are now accessible for cleaning or replacement

Kit.

. If parts are worn or damaged, install a complete ASCO Rebuild

Valve Reassembly

1. Lubricate body gasket and solenoid base gasket with DOW

CORNING r 200 Fluid lubricant or an equivalent high-grade silicone fluid.

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2. Lubricate manual operator stem gaskets (2) with DOW

CORNING r 111 Compound lubricant or an equivalent high-grade silicone grease.

3. Replace body gasket and diaphragm assembly. Locate bleed hole in diaphragm assembly approximately 45 _ from valve outlet.

S For AC construction (standard or with manual operator), proceed as follows:

4. Position diaphragm spring on diaphragm assembly. Be sure large end of diaphragm spring seats in cup of diaphragm assembly. For manual operator constructions, small end of diaphragm spring seats in cup of diaphragm assembly.

5. Install wide end of core spring in core assembly first, closed end protrudes from top of core assembly.

6. For standard construction, position core assembly with core spring and solenoid base sub-assembly (integral with bonnet) over diaphragm spring and diaphragm assembly.

7. Install bonnet screws and hand thread screws as far as possible, then torque bonnet screws in a crisscross manner to 95 ± 10 in-lbs [10,7 ± 1,1 Nm].

8. For valve constructions with a manual operator, first install valve bonnet and bonnet screws as described in step 7.

9. Install solenoid base gasket, core assembly with core spring and solenoid base sub-assembly.

10. Torque solenoid base sub-assembly to 175 ± 25 in-lbs

[19,8 ± 2,8 Nm].

11. For valves with a manual operator proceed as follows:

A. Install two manual operator stem gaskets on stem.

Refer to Step 2 for lubrication instructions.

B. Install stem spring and stem assembly with gaskets into valve bonnet.

C. Push stem assembly into valve bonnet; align stem pin hole and install stem pin.

D. Operate manual operator to be sure there is no misalignment or binding. Then rotate manual operator stem counterclockwise as far as possible.

S For DC construction (standard or with manual operator), proceed as follows:

12. For standard or manual operator constructions, replace valve bonnet and follow steps 7, 9 and 10. For manual operator constructions, install core spring in core assembly following step 5.

13. Install solenoid. See separate instructions.

WARNING: To prevent the possibility of death, serious injury or property damage, check valve for proper operation before returning to service. Also perform internal seat and external leakage tests with a nonhazardous, noncombustible fluid.

14. Restore line pressure and electrical power supply to valve.

15. After maintenance is completed, operate the valve a few times to be sure of proper operation. A metallic click signifies the solenoid is operating.

ORDERING INFORMATION

FOR ASCO REBUILD KITS

Parts marked with an asterisk (*) in the exploded view are supplied in

Rebuild Kits. When Ordering Rebuild Kits for ASCO valves, order the Rebuild Kit number stamped on the valve nameplate. If the number of the kit is not visible, order by indicating the number of kits required, and the Catalog Number and Serial Number of the valve(s) for which they are intended.

Form No V5848R2

Part Name

Solenoid base sub-assembly

Bonnet screws

Indicates Parts Supplied

In ASCO Rebuild Kits

Torque Chart

Torque Value Inch-Pounds

175 ± 25

95 ± 10 bonnet screw (4) mounting bracket two positions

(optional) bonnet screw (4)

Torque Value Newton-Meters

19,8 ± 2,8

10,7 ± 1,1 solenoid base sub-assembly core spring

(see note 2) core assembly solenoid base gasket stem spring core spring

(see note 2) core assembly diaphragm spring

(large end of spring to seat in cup of diaphragm assembly) diaphragm assembly bleed hole

(see note1) body gasket valve body stem pin bleed hole

(see note1) stem diaphragm spring

(small end of spring to seat in cup of diaphragm assembly) diaphragm assembly

AC Construction

Standard

AC Construction with Manual Operator

Note:

1. Locate bleed hole in diaphragm assembly approximately 45 _ from valve outlet.

2. Wide end of core spring in core first, closed end protrudes from top of core.

Figure 2. Series 8210 - AC construction without solenoid.

Form No.V5848R2

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50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Part Name

Solenoid base sub-assembly

Bonnet screws

Torque Chart

Torque Value Inch-Pounds

175 ± 25

95 ± 10 core assembly core spring solenoid base gasket

Indicates Parts Supplied

In ASCO Rebuild Kits solenoid base sub-assembly bonnet screw (4) mounting bracket two positions

(optional) valve bonnet diaphragm assembly bleed hole

(see note) bonnet screw (4) stem pin bleed hole

(see note) body gasket

Torque Value Newton-Meters

19,8 ± 2,8

10,7 ± 1,1 core spring

( wide end in core first, closed end protrudes from top of core) core assembly solenoid base gasket stem spring stem diaphragm assembly valve body

DC Construction

Standard

DC Construction with Manual Operator

Note:

Locate bleed hole in diaphragm assembly approximately 45° from valve outlet.

Figure 3. Series 8210 - DC construction without solenoid.

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