5200 Convair Drive Carson City, NV 89704 775.883.2500 Fax 775.883.6388 www.universalanalyzers.

com

1190 SERIES
VORTEX SAMPLE COOLER

See us on the WEB at http://www.universalanalyzers.com e-mail address: sales@universalanalyzers.com MAN1190 Rev C

1701 S. Sutro Terrace Carson City, NV 89704 775.883.2500 Fax 775.883.6388 www.universalanalyzers.com

LIMITED WARRANTY
ALL PRODUCTS MANUFACTURED BY UNIVERSAL ANALYZERS INC. ARE WARRANTED TO BE FREE OF MANUFACTURING DEFECTS FOR A PERIOD OF ONE YEAR FROM THE DATE OF RECEIPT AT THE CUSTOMERS RECEIVING AREA AND FOR AN ADDITIONAL PERIOD OF UP TO 90 DAYS IF THE PRODUCT IS PLACED IN SERVICE AFTER BEING IN STORAGE. THIS WARRANTY COVERS MATERIALS AND LABOR TO RESTORE ANY PRODUCTS TO ORIGINAL FACTORY SPECIFICATIONS IF A DEFECT IS FOUND WITHIN THE WARRANTY PERIOD. THE DEFECTIVE PRODUCT SHOULD BE SENT, FREIGHT PREPAID, TO THE FACTORY IN CARSON CITY, NEVADA. REPAIRS WILL BE PERFORMED AT THE FACTORY AND RETURNED, PREPAID, BY THE SAME SHIPPING METHOD USED TO SEND THE PRODUCT TO THE FACTORY. THIS WARRANTY DOES NOT APPLY WHERE THE EQUIPMENT HAS SUSTAINED DAMAGE DUE TO NEGLECT, MODIFICATION, CORROSION, OR OTHER REASON BEYOND THE SCOPE OF THE NORMAL DEFINITION OF MANUFACTURING DEFECT. FURTHER, THIS WARRANTY IS LIMITED TO REPLACING THE DEFECTIVE COMPONENTS AND RETURNING THE EQUIPMENT MANUFACTURED BY UNIVERSAL ANALYZERS INC. TO THE CUSTOMER IN WORKING CONDITION. ANY OTHER CLAIMS ARE OUTSIDE THE SCOPE OF THIS WARRANTY. NO WARRANTIES ARE MADE AS TO THE SUITABILITY OF THE USE OF THE EQUIPMENT IN ANY PARTICULAR APPLICATION OR LOCATION. THE SUITABILITY OF THE USE OF THE EQUIPMENT IS THE RESPONSIBILITY OF THE CUSTOMER AND THE INSTALLING CONTRACTOR.

Universal Analyzers Inc.

1701 SOUTH SUTRO TERRACE TELEPHONE: (775) 883-2500

CARSON CITY, NV 89706 FAX: (775) 883-6388

UNIVERSAL ANALYZERS MODEL 1190 SAMPLE COOLER

NON-ELECTRIC, COMPRESSED AIR OPERATION FOR NON-SPARK ATMOSPHERES SPECIFICATIONS GAS SAMPLE FLOW RATE: (TWO Impingers): (ONE Impinger ): 0 TO 16 L/M (at STP) 0 TO 8 L/M (at STP) 700 DEGREES F. (351 C.) 280 DEGREES F. (138 C.) 178 DEGREES F. ( 81 C.) 50 % * 34 DEGREES F. ( 1 C.) 105 DEGREES F. ( 41 C.) 400 BTUS PER HOUR (380 kJ/Hr.) (at 100 to 150 psig air pressure) 200 BTUS PER HOUR (190 kJ/Hr.) 4 L/M at 50 % WATER BY VOLUME 10 L/M at 20 % or less WATER 41 DEGREES F. ( 5 C.) 3/8 TUBING FITTING 1/4 TUBING FITTING 3/8 TUBING FITTING

MAXIMUM INLET TEMPERATURE: STAINLESS STEEL HEAT EXCHANGER: KYNAR/GLASS HEAT EXCHANGER: MAXIMUM INLET GAS DEWPOINT: MAXIMUM INLET WATER CONCENTRATION: MIMIMUM AMBIENT TEMPERATURE: MAXIMUM AMBIENT TEMPERATURE: MAXIMUM COOLING POWER: COOLING POWER USING 80 psig AIR: MAXIMUM WATER REMOVAL CAPABILITY: OUTLET SAMPLE DEW POINT: GAS SAMPLE INLET FITTING: GAS SAMPLE OUTLET FITTING: BOTTOM WATER DRAIN FITTING

COMPRESSED AIR REQUIREMENT:

ELECTRICAL CLASSIFICATION: DIMENSIONS: WEIGHT: SOLUBLE GAS REMOVAL RATES:

15 CFM @ 100 PSIG

NOT APPLICABLE, AIRPOWERED 16 HIGH x 14 WIDE x 8 DEEP 20 LBS ( 9 KG) NO 0% LOSS NO2 <10% LOSS SO2 < 2% LOSS CO 0% LOSS CO2 < 2% LOSS

* at reduced flow rate.

1190 Text Rev -

APPLICATION In order to sample combustion product stack gas or exhaust from Internal Combustion (IC) engines, a method to remove moisture from the sample without removing gas components of interest is a must. The Universal Analyzers Peltier Effect Sample Cooler is an ideal way to decrease the dew point of combustion gasses to a repeatable, stable, constant low dew point. The Universal Analyzer Gas Sample Coolers prevent water condensation in sample prefilters, sample pumps, and gas analyzers. For gas analyzers where water vapor is an interferrent, a stable, repeatable dew point becomes a part of the gas analyzer's performance specification. The Universal Analyzers sample cooler provides this constant water concentration resulting in an accurate analysis of the components of interest. The gas sample to be analyzed is brought to the sample cooler, first through a sample probe which usually contains a heated filter, and then through a heated sample line which keeps the sample above it's dew point. The Universal Analyzers Sample Cooler then condenses water from the sample which lowers the dew point to 5 degrees C. (41 degrees F.). Particulate matter which escaped being filtered by the heated stack filter and which passes through the sample cooler can be removed by a visible sample prefilter, available from Universal Analyzers, located downstream from the sample cooler. A gas sample pump may be required as part of the sampling system if the sample is not under pressure. If the sample pump is placed ahead of the sample cooler, it should be provided with a heated head to avoid the condensation of water vapor due to the pump being below the dew point temperature of the sample. More commonly, the sample pump will be placed after the sample cooler in order to draw the sample through the cooler so that it has been dehydrated before the sample passes through the pump. The sample pump should either be located in an area which is not classified as hazardous or should be suitable for the hazardous area. Sample pumps with Explosion Proof or air driven motors are available. A means to control the flow of the sample through the system should be available and visible to the operator. This could be accomplished through the use of pressure regulators with gauges, flowmeters, and/or flow control needle valves. Condensate removal from the heat exchanger(s) within the Sample Cooler can be accomplished through one of the following alternative methods: 1. A continuously running peristaltic tubing pump. (The motor should be suitable for the hazardous area classification.) 2. Installing the heat exchanger as a bypass condenser, pulling excess sample through with an educator. 3. Use a liquid drainer. This requires the sample to be at a positive pressure. 4. A barometric leg can be designed to be seal the drain and provide an escape conduit for the condensate.

DESCRIPTION The Model 1140 cools the sample through the use of a Vortex Tube. Clean dry compressed air, preferably Instrument Air, supplied by the plant passes through a generator within the vortex tube which separates the high velocity molecules from the low velocity molecules to provide cold air within the sample cooler to remove the heat from the sample. Three square feet of heat transfer surface, inside the cooler transmits the heat from the gas sample, heating the cold air. The key to the success of the Universal Analyzers Sample Cooler being able to condense the water from a wet gas sample with a minimal loss of the water soluble gas fraction, is due to the design of the heat exchanger. The separation occurs in a classical impinger which has a highly polished cylindrical surface cooled to the desired dew point temperature. The gas sample is brought to the bottom of the cylinder through an insulated tube and allowed to rise through a narrow annular area to insure the entire sample is influenced by the cold surface. The condensate falls down the cold polished surface in the form of a sheet (as opposed to droplets or the bubbling of the gas sample through the condensate) which minimizes the surface area in contact with the gas sample. The internal, three square ft. heat sink is constructed from anodized pure aluminum fins which carry and transfer heat to the air which is directed at the heat sink by the vortex tube. The pure aluminum material is a far better conductor of heat that the aluminum alloys which are normally used for extruded heat sinks. The result is an assembly which has superior heat exhausting capabilities. A thermal valve is supplied as a control valve to limit the air supply when the heat transfer block containing the sample heat exchangers approached freezing. The thermal valve is operated with a thermal bulb located within the heat transfer block and connected with a capillary tube. The control valve is a non-electric valve which is actuated by the fluid within the thermal bulb. Since it is non-electric, it can be used in Division 1 or 2 hazardous areas.

INSTALLATION INSTRUCTIONS Mount the Model 1140 Gas Sample Chiller on a vertical surface away from the weather. If it is needed to be located in the weather, an enclosure should be provided. Pipe a source of clean, dry compressed air to the control valve on the side of the chiller. The pressure during operation should be between 80 and 150 psig at the control valve for most efficient operation. The optimum pressure is between 100 and 125 psig. At 80 psig, the cooling capacity of the vortex tube is reduced about 30% below that available at 100 psig. The supply air line should be sized to avoid significant pressure drop due to the flow of air during operation (~4 SCFM). Sample tubing should be brought to the each heat exchanger inlet. A 3/8" tubing fitting is provided at the top of the heat exchanger as the sample inlet. The dry sample outlet is a "1/4" tubing fitting coming out of the top at an angle.

The gas sample should flow through an additional filter (with a clear bowl for checking the condition of the filter) as a safety measure before entering the analyzer(s). A 3/8" NPT female connection is provided as the condensate drain connection at the bottom of the heat exchanger. Equipment to remove the condensate must be installed. Several methods are discussed above. START UP PROCEDURE Open the valve from the air supply to the sample cooler. The temperature will start to drop immediately. A thermocouple can be inserted in the port on the right hand side of the chiller to follow the temperature drop of the chiller. Start the sample gas flow. Water should be observed to be removed from the bottom of the heat exchanger when steady state conditions are established. Turn on the analyzer(s) and calibrate as required. TROUBLE SHOOTING The presence of water in liquid form after the sample cooler is an indication of a fault in the system. Reasons for the presence of condensate in the system after the sample cooler could be one or more of the following: 1. Overloading of the cooling capacity of the cooler due to too much water vapor or too great a sample flow rate. 2. A fault in the condensate removal equipment. The heat exchanger has become full of condensate. 3. An air leak in the condensate removal tubing. 4. The pressure of the compressed air driving the vortex tube has dropped below 60 psig at the inlet of the thermal valve. 5. Water or solid materials in the compressed air supply has blocked or reduced the efficiency of the generator.

Calibration Procedure: 1. Connect an airline to the Vortex unit. The compressed air pressure should be a minimum of 90 psig. The compressed air temperature should be about 20oC. 2. Insert a thermocouple into the top left vent hole of the Heat Sink approximately 6 inches. 3. Insert a second thermocouple into the hole on the rights side of the Heat Transfer Block. 4. Completely open the Temperature Control Valve by turning the adjustment screw on top of the valve clockwise. 5. Close the Vortex airflow adjustment screw located on the bottom of the Vortex (the hot air discharge tube). Then open the screw approximately 1-1/4 turns (*See Below). 6. Turn on the air line. 7. Move the thermocouple in the Heat Sink up and down until the location of the lowest observed temperature is found. This should be in the center of the cold discharge tube on the Vortex. 8. Adjust the Vortex airflow screw until the cold air temperature is 4.0oC (25oF). 9. Allow the Heat Transfer Block to reach 4.5oC. Note: as the Heat Transfer Block temperature drops the cold air temperature will also drop. The final temperature of the cold air should be 9.5oC. 10. Adjust the Temperature Control Valve until the valve closes when the Heat Sink is 4.0oC. Then open the valve 1/2 turn. * 4 CFM = Approx. 3/4 Turn * 10 CFM = Approx. 1-1/2 Turns Dimensional drawings, installation drawings, and schematics are included as part of this manual. If additional information is required, assistance can be obtained by calling (775) 8832500 or (800) 993-9309 or FAX request to (775) 883-6388.

2
8 11/16" 7 1/8"

7 1/2"

MOUNTING HOLES FOR 1/4" HARDWARE (SUPPLIED BY OTHERS) 4 TYP

TOTAL COOLING # OF MODEL COMPRESSED AIR CAPACITY @ 100 NO. IMPINGERS REQUIRED "X" PSIG (690 KPa) 3 2CFM (0.06 M/MIN) 55 B.T.U. / HR 1 1120 3 1140 4CFM (0.06 M/MIN) 110 B.T.U. / HR 1 3 1160 10CFM (0.06 M/MIN) 260 B.T.U. / HR 2 3 15CFM (0.06 M/MIN) 400 B.T.U. / HR 1190 2

1/4"

SAMPLE INLET 3/8" TUBE

IMPINGER 10" (SEE TABLE FOR # OF IMPINGERS) SAMPLE OUTLET 1/4" TUBE TYP

8"

16 1/4"

B
CONDENSATE VORTEX OUTLET TUBE 3/8" NPT LEFT SIDE

VORTEX TEMPERATURE ADJUST SCREW

B
FRONT
B 10/06/99 REDRAW FOR VORTEX HTSINK DETAILS DESCRIPTION REV DATE REVISIONS EAM RD DWN APVD

VORTEX ADJUST SCREW (HOT AIR EXHAUST)

COMPRESSED AIR INLET 1/2"NPT MIN 80 PSIG @ "X" SCFM (SEE TABLE)

1100 SERIES VORTEX COOLED SAMPLE COOLER OUTLINE & MOUNTING DIMENSIONS
PART NO. NOT ISSUED FOR 1100 SERIES COOLERS

UNIVERSAL ANALYZERS I NC.

1701 South Sutro Terrace Carson City, Nevada 89706 USA

DRAWN BY APVD BY

H. MITCHELL T. BARBEN II SCALE 1:2

DRAWING NO

P0042
SIZE

DATE 05/07/93

SHEET 1 OF 1

A 8
LEFT SIDE

D 8

FRONT VIEW

6
3/8" NPT

1" PVC BALL VALVE (SHOWN NORMALLY OPEN)

TO CLOSE

19" CLEAR PVC CONDENSATE RESERVOIR

TO OPEN

3
1" PVC BALL VALVE (SHOWN NORMALLY CLOSED) NUT WRENCH FLATS PVC ADAPTERS SUPPLIED FOR 1" NPT OR 1" SLIP FIT 1" PVC PIPE (SUPPLIED BY OTHERS)

A REV

02/02/00 DATE

UPDATE VORTEX COOLER OUTLINE DESCRIPTION REVISIONS

EAM

RD

DWN APVD

NUT

CONDENSATE REMOVAL POT OUTLINE

PART NO. FOR

4955-0011

UNIVERSAL ANALYZERS INC.

CONDENSATE DRAIN
1701 South Sutro Terrace Carson City, Nevada 89706 USA

DRAWN BY APVD BY

DRAWING NO HARVEY MITCHELL P0116 T. BARBEN II DATE SCALE SIZE 10/3/94 1:1 C

SHEET 1 OF 1

8
B A

7
B

5
VITON O-RING P/N 4904-0013

4
INSULATED INNER TUBE ASSY

2
OUTER TUBE ASSY

.305 I.D.

D
"L" (SEE TABLE) CONDENSATE DRAIN 3/8"NPT

SAMPLE GAS OUTLET C 1/4" TUBE

A TOP VIEW SAMPLE GAS INLET 3/8" TUBE

PLUG 1/16" NPT

ANNULAR SPACE .060" WIDE (GAS TO BE DRIED RISES IN THIS SPACE) SECTION A-A
UNIVERSAL ANALYZERS SERIES 400/500 400/500 400/500 400/500 400/500 800/1000/1100/3000 800/1000/1100/3000 800/1000/1100/3000 800/1000/1100/3000 800/1000/1100/3000
A REV 02/09/99 DATE REVISE P/N TABLE FOR TEFLON COATED DESCRIPTION REVISIONS EAM RD

HEAT APPROX LENGTH EXCHANGER OUTER TUBE MATERIAL P/N "L" 5" 5200-S050 316 S.S. 5" 5200-T050 TITANIUM 5" 5200-A050 ALLOY 20 5" 5200-C050 HASTELLOY C-276 5" 5200-S05T TEFLON COATED 316 S.S. 10" 5200-S010 316 S.S. 10" 5200-T010 TITANIUM 10" 5200-A010 ALLOY 20 10" 5200-C010 HASTELLOY C-276 10" 5200-S01T TEFLON COATED 316 S.S.

DWN APVD

1). SEE SHEET 2 FOR ASSEMBLY INSTRUCTIONS.

HEAT EXCHANGER METALLIC NON-TEMPERATURE SENSING OUTLINE

PART NO. SEE TABLE FOR SEE TABLE

UNIVERSAL ANALYZERS INC.

1701 South SutroTerrace Carson City, Nevada 897 06 USA

DRAWN BY APVD BY

SECTION B-B

EV MUSSELMAN H. MITCHELL DATE SCALE 12/11/95 NONE

DRAWING NO

P0147
SIZE

SHEET 1 OF 2

D
INNER TUBE MATERIAL IDENTIFIER S

VITON O-RING #2-021 SEE NOTES

D
OUTER TUBE ASSEMBLY METALLIC

"L"

C
HEAT EXCHANGER SEPERABLE INNER APPROX P/N TUBE ASSY "L" P/N LENGTH 5" 5200-S050 5201-0015 5" 5200-T050 " 5" 5200-A050 " 5" 5200-C050 " 5" 5200-S05T 5201-0041 10" 5200-S010 5201-0016 10" 5200-T010 " 10" 5200-A010 " 10" 5200-C010 " 10" 5200-S01T 5201-0042

INNER TUBE ASSEMBLY

OUTER TUBE MATERIAL IDENTIFIER

SPARE PARTS LIST OUTER VITON O-RING PLUG TUBE ASSY #2-021 P/N 1/16"NPT P/N P/N 5201-0012 4904-0013 4951-0058 5201-0024 " " 5201-0022 " " 5201-0020 " " 5201-0043 " " 5201-0013 4904-0013 4951-0058 5201-0025 " " 5201-0023 " " 5201-0021 " " 5201-0044 " "

NOTES: 1). O-RING IS FACTORY INSTALLED IN METALLIC OUTER TUBE. 2). LIGHTLY LUBRICATE O-RING WITH SILICONE GREASE BEFORE ASSEMBLY. B

A REV

02/09/99 DATE

REVISE TABLE TO INCLUDE TEFLON PARTS EAM DESCRIPTION REVISIONS

RD

DWN APVD

HEAT EXCHANGER ASSEMBLY NON-TEMPERATURE SENSING METALLIC

PART NO. SEE TABLE FOR INSTRUMENT

UNIVERSAL ANALYZERS INC.

1701 South SutroTerrace Carson City, Nevada 8970 6 USA

DRAWN BY APVD BY

EV MUSSELMAN H. MITCHELL DATE SCALE 12/11/95 NONE

DRAWING NO

P0147
SIZE

SHEET 2 OF 2

D
PLUG 1/16" NPT CHILLED SURFACE

ANNULAR SPACE .060" WIDE (GAS TO BE DRIED RISES IN THIS SPACE) INSULATED SECTION

TOP VIEW

0.300" INSIDE DIAMETER "L" (SEE TABLE) SIDE VIEW

CONDENSATE DRAIN 3/8"NPT

DRY GAS OUTLET 1/4" TUBE

B
1). SEE SHEET 2 FOR ASSEMBLY INSTRUCTIONS. SAMPLE GAS INLET 3/8" TUBE

LENGTH "L"

5"

10"

15"

UNIVERSAL QTY OF GLASS KYNAR HEAT ANALYZERS EXCHANGERS PER EXCHANGER SAMPLE COOLER SAMPLE COOLER ASSEMBLY P/N MODELS 1 520 2 530 5200-K050 2 540 4 570 1 1040 2 1050 5200-K010 2 1060 2 1080 4 1090 FGA2 5200-K015 1

C REV

01/19/04 DATE

Revision Per Sheet 2 DESCRIPTION REVISIONS

RPH

TB

DWN APVD

HEAT EXCHANGER GLASS / KYNAR NON-TEMPERATURE SENSING OUTLINE

PART NO. SEE TABLE FOR INSTRUMENT

UNIVERSAL ANALYZERS INC.

1701 South Sutro Terrace Carson City, Nevada 89706 USA

DRAWN BY APVD BY

DRAWING NO EV MUSSELMAN P0149 H. MITCHELL DATE SCALE SIZE C 12/11/95 1:1

SHEET 1 OF 2

PLUG 1/6"NPT

EXPLODED GLASS KYNAR HEAT EXCHANGER

#2-120 VITON O-RING (SEE NOTE 2) KYNAR HEAD (SEE NOTE 1)

GLASS TUBE KYNAR INSULATED SECTION ASSEMBLY

#2-018 VITON O-RING (SEE NOTE 2) KYNAR DRAIN FITTING (SEE NOTE 1) KYNAR DRAIN FITTING 15" VERSION

C
GLASS KYNAR HEAT EXCHANGER ASSEMBLY LENGTH "L" P/N 5" 5200-K050 10" 5200-K010 15" 5200-K015 KYNAR INSULATED SECTION ASSY P/N 5110-2003 5110-2004 5110-2006 SPARE PARTS LIST KYNAR GLASS DRAIN TUBE FITTING P/N P/N 5201-0002 5110-2002 5201-0001 " 5201-0066 5201-0078 #2-120 VITON O-RING P/N 4904-0004 " " #2-018 VITON O-RING P/N 4904-0003 " "

KYNAR HEAD
P/N 5201-0017 " "

1/16" NPT PLUG

P/N 4951-0066 " "

7/8" WRENCH FLATS

COMPLETE GLASS KYNAR HEAT EXCHANGER ASSEMBLY

C 01/19/04 DATE Added Kynar Drain P/N for 15" Length DESCRIPTION REVISIONS RPH TB

NOTES: 1). O-RINGS ARE FACTORY INSTALLED IN KYNAR HEAD AND KYNAR DRAIN FITTINGS

REV

DWN APVD

2). LIGHTLY LUBRICATE O-RINGS WITH SILICONE GREASE BEFORE ASSEMBLY.

PART NO. SEE TABLE

HEAT EXCHANGER GLASS / KYNAR NON-TEMPERATURE SENSING SPARE PART INSTALLATION

FOR INSTRUMENT

UNIVERSAL ANALYZERS INC.

1701 South Sutro Terrace Carson City, Nevada 89706 USA

DRAWN BY APVD BY

DRAWING NO EV MUSSELMAN P0149 H. MITCHELL DATE SCALE SIZE C 12/11/95 1:1

SHEET 2 OF 2

Universal Analyzers Inc.

1701 SOUTH SUTRO TERRACE TELEPHONE: (775) 883-2500

CARSON CITY, NV 89706 FAX: (775) 883-6388

SPARE PARTS RECOMMENDATIONS FOR MODEL 1160 & 1190 For Metallic Heat Exchanger Chillers: 1 ea. 5200-S010 316SS Separable Heat Exchanger/Impinger, 10 inch 1 ea. 5200-C010 Hastelloy C276 Separable Heat Exchanger/Impinger 1 ea. 5201-0013 316SS Replacement condensation sleeve, 10 inch 1 ea. 5201-0021 Hastelloy C276 Replacement condensation sleeve, 10 in. 5 ea. 4904-0013 Viton o-ring for sealing metallic heat exchangers, 2-013 For Glass/Kynar Heat Exchanger Chillers: 2 ea. 5200-K010 Glass/Kynar Heat Exchanger/Impingers, 10 inch 4 ea. 4904-0003 O-ring, 2-018, Viton, Glass Heat Exchanger, bottom 4 ea. 4904-0004 O-ring, 2-120, Viton, Glass Heat Exchanger, top For all Model 1160 & 1190 Sample Chillers: 1 ea. 8010-0001 Heat Sink Paste, 0.1 ounce container 1 ea. 4955-0009 Temperature Control Valve with thermal bulb 1 ea. 4960-0004 Vortex Tube, 10 SCFM 1 ea. 4960-0003 Vortex Tube, 15 SCFM 1 ea. 4960-0008 10 SCFM replacement Vortex Tube Generator kit 1 ea. 4960-0009 15 SCFM replacement Vortex Tube Generator kit

1190 Spare Parts Rev A

UNIVERSAL ANALYZERS INC. MOISTURE CONVERSION TABLE

DEW POINT, DEGREES C. -100 -50 -20 -10 -5 -4 -3 -2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 % WATER BY VOLUME % WATER BY WEIGHT AT SATURATION AT SATURATION 0.00000139 0.00000081 0.00388 0.00241 0.102 0.0633 0.256 0.1596 0.396 0.229 0.432 0.268 0.469 0.291 0.510 0.317 0.555 0.345 0.602 0.364 0.649 0.404 0.696 0.433 0.750 0.466 0.803 0.499 0.861 0.535 0.922 0.573 0.988 0.614 1.06 0.658 1.13 0.702 1.21 0.753 1.29 0.802 1.38 0.860 1.48 0.920 1.58 0.980 1.68 1.044 2.31 1.433 3.13 2.004 4.19 2.64 5.55 3.54 7.28 4.67 9.46 6.12 12.2 8.0 15.5 10.3 19.7 13.3 24.4 16.8 30.7 21.7 38.0 27.8 46.7 35.6 57.2 45.7 69.2 58.4 WATER VAPOR PRESSURE, mm. Hg 0.0000099 0.0295 0.776 1.950 3.014 3.280 3.569 3.880 4.223 4.579 4.937 5.294 5.70 6.10 6.54 7.01 7.51 8.05 8.58 9.15 9.8 10.5 11.2 12.0 12.8 17.5 23.8

LIT3001

Corporation
VORTEX TUBE INSTALLATION & MAINTENANCE

COMPRESSED AIR LINE SIZES Compressed air lines should be sized to hold pressure drops to a minimum. Do not use restrictive fittings such as quick connects. They can starve the Vortex Tube by causing excessive line pressure drop. The following chart gives suggested line sizes for pipe and hose.
Line Sizes For Runs Up To: Model 3202 thru 3208 Model 3402 thru 3408 Model 3210 thru 3240 Model 3410 thru 3440 Model 3250 thru 3299 Model 3450 thru 3499 10 FT (3m) Pipe 1/8" Hose 1/4" 10-50 FT (3 - 15.2m) Pipe 1/4" Hose 3/8" 50-100 FT (15.2 - 30.5m) Pipe 1/4" Hose 3/8"

To prevent problems associated with oil, use Model 9005 Oil Removal Filter for Vortex Tubes up to 30 SCFM (850 SLPM) or Model 9006 Oil Removal Filter for Vortex Tubes up to 150 SCFM (4248 SLPM). The oil removal filter should be used downstream from the automatic drain filter separator. Filters should be used within 10 to 15' (3 to 4.6m) of each Vortex Tube. By regulating pressure, refrigeration produced can be matched to the application requirements. Use Model 9008 Pressure Regulator for Vortex Tubes up to 50 SCFM (1416 SLPM) or Model 9009 Pressure Regulator for Vortex Tubes up to 150 SCFM (4248 SLPM). Another method of temperature control is to supply the Vortex Tube with full line pressure, then cycle the air on and off with a solenoid valve controlled by a thermostat.
For replacement or repair filter and regulator parts contact Nimmo Fluid Power at 1-888-646-6097.

1/4"

3/8"

3/8"

1/2"

1/2"

5/8"

1/2"

5/8"

3/4"

7/8"

1"

1- 1/8"

COMPRESSED AIR SUPPLY For best performance, use line pressure 80 to 100 PSIG (5.5 - 6.9 BAR). Vortex Tubes are rated in SCFM (SLPM) at 100 PSIG (6.9 BAR) supply pressure. With proper filtration and separation of dirt, moisture and oil from the compressed air supply, the Vortex Tube will run for years with no maintenance required. Use a 25 micron or smaller filter separator that is sized to the SCFM (SLPM) rating of the Vortex Tube. The Model 9004 Automatic Drain Filter Separator is used for Vortex Tubes up to 40 SCFM (1133 SLPM), Model 9002 Automatic Drain Filter Separator for Vortex Tubes up to 150 SCFM (4248 SLPM).

USING THE VORTEX TUBE Each size Vortex Tube can produce a number of flow rates as determined by an internal plastic part called a generator. Each generator is marked with a number and a letter. The number indicates the capacity (SCFM of air consumption) and the letter indicates the type of operation (R for maximum refrigeration or C for maximum cold temperature). The Vortex Tube has one generator installed. If a different capacity is desired, other generators are available.

1250 Century Circle North Cincinnati, OH, USA 45246-3309 (513) 671-3322 Fax (513) 671-3363 E-mail: techelp@exair.com

TROUBLESHOOTING & MAINTENANCE

Generator Number Marked Here Cold Air Exhaust Compressed Air Supply Hot Air Exhaust

If The Vortex Tube Does Not Perform Properly, check for these common problems: 1. Loose Cold Cap or Cold Muffler - A loose cold cap or cold muffler will cause poor performance. Make sure it is tight. 2. Inlet Pressure - Low inlet pressure supply will cause poor performance. Measure the pressure at the compressed air inlet of the Vortex Tube while it is operating. Restrictions in the compressed air supply line can cause excessive pressure drops and deteriorate performance. 3. Inlet Temperature - A Vortex Tube provides a temperature drop from supply air temperature. In some cases, the supply air is warmer than ambient air due to compressed air lines running across ceilings, near furnaces, direct sun, etc. In this case, the cold air may be warmer than anticipated and adequate refrigeration may not be available for the application. 4. No Cold Flow - If the Vortex Tube is operated continuously for an extended period of time and is set for more than a 50F (28C) drop from the compressed air temperature, the cold end may freeze, blocking the cold outlet. If this happens, any one of the following will correct the problem: (a) Blow air (use an air gun) into the cold end with the Vortex Tube off. (b) Turn the Vortex Tube off for a few minutes. It will thaw. (c) Use dry air with an atmospheric dew point of -40 or less. 5. Back Pressure - The performance of a Vortex Tube deteriorates with back pressure on the cold air exhaust. Pressure up to 2 PSIG (.1 BAR) will not change performance. 5 PSIG (.3 BAR) will change performance by approximately 5F (2.8C). If cold air ducting is used, the total crosssectional area should be equal to or greater than the area of the Vortex Tube cold air exhaust. If you have any questions or problems, please contact an EXAIR Application Engineer at: 1-800-90-EXAIR Fax: (513) 671-3363 E-mail: techelp@exair.com http://www.exair.com
For more information about this product, visit "Frequently Asked Questions" at www.exair.com

Body Cold Cap "O" Ring Generator Sleeve (Small Vortex Tube Only) Washer (Small Vortex Tube Only) "O" Ring

Valve

The R type generators are used for most applications (part cooling, enclosure cooling, tool cooling and in applications where complete heat exchange is desired). R type generators should be used for temperatures down to 0F (-18C). If the Vortex Tube is set for 50F (28C) below the supply air temperature, it will be at 80% cold fraction (80% of the air is directed to the cold end). This produces a combination of cold flow volume and temperature drop that gives the best performance in most applications. C type generators are used for maximum cold temperature (cooling parts, liquids or gas samples to subzero temperatures, component testing, etc.). C type generators should be used for temperatures 80 to 120F (44 to 67C) below the supply air temperature. Any temperature drop greater than 50F (28C) may precipitate moisture that could freeze and plug the cold air exhaust (see 4 under "Troubleshooting"). SETTING THE VORTEX TUBE Hot and cold air temperatures produced by a Vortex Tube are infinitely variable by adjusting the slotted valve at the hot air exhaust. Opening the valve reduces the cold airflow and the cold air temperature. Closing the valve increases the cold airflow and the cold air temperature. Set the Vortex Tube with a thermometer. To measure temperature accurately, it should be inserted into the cold muffler or a piece of tubing on the cold end exhaust. NOISE MUFFLING Normally, muffling is not required if the hot and cold air is ducted. Mufflers are available for both the hot and cold exhaust for all Vortex Tubes. (For model number, see drawing on other side.) The cold cap on the medium and large Vortex Tubes must be removed to install the muffler.

2001

Corporation

LIT 3001

Controls Group 507 E. Michigan Street P.O. Box 423, Milwaukee, WI 53202 Code No. LIT-1927330
v47s whole Refrigeration Valves Rev: 1927330 9thcc:7-78

V47 Series

Temperature Actuated Modulating Valve

v47.tif Description
The V47 is a temperature actuated modulating valve that regulates the flow of water or glycol to maintain a desired temperature. Three temperature ranges for each valve size are available. Many valves come with a removable bypass plug that can be replaced by the bypass orifice provided separately with each valve. Valve action is open on temperature increase. For open on temperature decrease models, contact Application Engineering. V47

07/18/97 logo: JCI left ft: refrig right ft: standard Sect# = 7 seQ# = 60

Features
no close fitting sliding parts in water passages range spring does not come in contact with the cooling water easy manual flushing, if required valve design minimizes chatter and water hammer

To Order
Refer to the V47 Valve Sizing Information on the following page, and then specify the code number from the selection chart. For more information on Bulb Wells, refer to Bulb Wells.

flange.eps
Cast Iron

Ring Gasket (2)

Flange (2)

Accessories (Companion Flanges and Gasket)

Kit Number
Hex Nut (8) M achine Bolt (8)

Water Valve Size (in.)

1-1/2 in. 2 in. 2-1/2 in.

KIT14A-612 KIT14A-613 KIT14A-614

flange

Specifications
V47 Series Temperature Actuated Modulating Valves
Maximum Bulb Temperature Maximum Water Temperature Maximum Supply Water Pressure Capillary Length (a) Temperature Bulb Style 4
(b)

Metric Conversion F
75 to 115 75 to 135 115 to 160 115 to 180 160 to 205 160 to 230

20F (-6.7 C) above temperature range 170F (77C) 150 psig (1034 kPa) 6 ft (1.83 m) Nylon Armor (pictured) (1/2 in. NPT closed tank immersion)

C
24 to 46 24 to 57 46 to 71 46 to 82 71 to 96 71 to 110

(a) V47AC-8 Capillary Length 4 ft. (b) V47AB-2 Temperature Bulb Style 1 (no 1/2 in. NPT male fitting)

Selection Chart
Code Number
V47AA-1C V47AA-2C V47AA-3C V47AB-2C V47AB-3C V47AB-4C V47AB-5C V47AC-3C V47AC-4C V47AC-6C V47AC-8C V47AD-1C V47AD-2C V47AD-3C V47AE-1C V47AE-2C V47AE-3C

Pipe Size, in.

3/8 3/8 3/8 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 (b) 1 1 1 1 1/4 1 1/4 1 1/4

Range (Opening Point) F

115 to 180 Heating 160 to 230 Heating 75 to 135 Cross Ambient 75 to 135 Cross Ambient 115 to 180 Heating 160 to 230 Heating 75 to 135 Cross Ambient 115 to 180 Heating 160 to 230 Heating 75 to 135 Cross Ambient 75 to 135 Heating 75 to 135 Cross Ambient 115 to 180 Heating 160 to 230 Heating 75 to 135 Cross Ambient 115 to 180 Heating 160 to 230 Heating

Bulb Size, in. (Dia length)

11/16 x 3 1/4 11/16 x 3 1/4 11/16 x 6 11/16 x 10 (a) 11/16 x 3 1/4 11/16 x 3 1/4 11/16 x 10 11/16 x 3 1/4 11/16 x 3 1/4 11/16 x 10 11/16 x 3 1/4 11/16 x 16 1/4 11/16 x 6 11/16 x 6 11/16 x 16 1/4 11/16 x 6 11/16 x 6

Std Bypass Orifice Dia in.

0.062 0.062 0.062 0.062 0.062 0.062 0.062 0.062 0.062 0.093 0.093 0.093 0.093 0.093 0.093

Seat Repair Kit

STT14A-600R STT14A-600R STT14A-600R STT15A-602R STT15A-602R STT15A-602R STT15A-602R STT16A-601R STT16A-601R STT16A-601R STT16A-601R STT17A-609R STT17A-609R STT17A-609R STT17A-610R STT17A-610R STT17A-610R

Replacement Bulb Well Number Sensing Element Order Separately

SET29A-622R SET29A-623R SET29A-601R SET29A-602R SET29A-624R SET29A-625R SET29A-602R SET29A-626R SET29A-627R SET29A-604R SET98A-621R SET29A-605R SET29A-629R SET29A-630R SET29A-605R SET29A-629R SET29A-630R WEL18A-602R WEL18A-602R WEL17A-601R WEL17A-600R WEL18A-602R WEL18A-602R WEL17A-600R WEL18A-602R WEL18A-602R WEL17A-600R WEL18A-602R WEL17A-601R WEL17A-601R WEL17A-601R WEL17A-601R

(a) Style 1 bulb (does not include 1/2 in. male NPT fitting) (b) ASME Flange

v Universal Replacement

(R) For Refrigerants Not Listed, Contact Application Engineering

The performance specifications are nominal and conform to acceptable industry standards. For applications at conditions beyond t hese specifications, consult the local Johnson 08/02 Johnson Controls, Inc Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

1/2

Controls Group 507 E. Michigan Street P.O. Box 423, Milwaukee, WI 53202 Code No. LIT-1927330

V47 Series Temperature Actuated Modulating Valve (Continued)

Selection Chart (Continued)
Code Number
V47AR-1 V47AR-2 V47AR-3 V47AS-1 V47AS-2 V47AS-3 V47AT-1 V47AT-2 V47AT-3

Pipe Size, in.

1 1/2 (b) 1 1/2 (b) 1 1/2 (b) 2
(b)

Range (Opening Point) F

75 to 135 Cross Ambient 115 to 180 Heating 160 to 230 Heating 115 to 160 Heating 160 to 205 Heating 75 to 115 Cross Ambient 115 to 160 Heating 160 to 205 Heating 75 to 115 Cross Ambient

Bulb Size, in. (Dia length)

11/16 x 16 1/4 11/16 x 6 11/16 X 6 11/16 x 10 11/16 x 10 11/16 x 43 11/6 x 10 11/6 x 10 11/16 x 43

Std Bypass Orifice Dia in.

0.093 0.093 0.093 0.125 0.125 0.125 0.125 0.125 0.125

Seat Repair Kit

STT17A-610R STT17A-610R STT17A-610R STT18A-600R STT18A-600R STT18A-600R STT18A-601R STT18A-601R STT18A-601R

Replacement Bulb Well Number Sensing Element Order Separately

SET29A-605R SET29A-629R SET29A-630R SET29A-632R SET29A-633R SET29A-606R SET29A-632R SET29A-633R SET29A-606R WEL17A-601R WEL17A-601R WEL17A-600R WEL17A-600R WEL17A-600R WEL17A-600R

2 (b) 2 (b) 2 1/2 (b) 2 1/2 (b) 2 1/2 (b)

(a) Style 1 bulb (does not include 1/2 in. male NPT fitting) (b) ASME Flange
300

v47_flowchart.eps
1136 2-1/2 200 2 757

V47 Valve Sizing Information

To Select Water Valve Size, refer to flow chart for selection of water valves. Carefully follow the steps as outlined below.1
Determine the maximum water flow required. Draw a horizontal line through this flow across the upper half of the flow chart. Use the following method to determine the temperature rise above the opening point. a Valve closing point is the highest temperature at which it is desired to have no flow through the valve. b Valve opening point is about 5F above the closing point. c Determine the temperature the valve is to maintain, this is the operating temperature. d Subtract the opening temperature from the operating temperature. This is the temperature rise above the opening point. Determine the available system pressure for use with the valve by the following appropriate method: Open System: Available System Pressure = Inlet Pressure condenser pressure drop - friction losses in piping. Closed System: Available System Pressure = Inlet Pressure static head - condenser pressure drop-friction losses in piping. The available system pressure is represented by the curve in the lower half of the flow chart. In the lower half of the flow curve, draw a horizontal line from the temperature above the opening point (Step 2d) to the available system pressure (Step 3). If the point falls between two pressure drop curves, use the curve to the left (this gives an automatic factor of safety). From this point, draw a vertical line until it intersects the flow line from Step 1. If the intersection falls on a valve size curve, this is the valve size. If the intersection falls between two curves, use the curve to the left for the required valve size.

100 90 80 70 60 50 40 30 20 Water Flow Gal. / Min. 10 9 8 7 6 5 4 3 2

1-1/2 1-1/4 1 3/4 1/2

379 349 303 265 227 189 151 114 76 Water Flow L/Min. 38 34 30 26 23 19 15 11 7

3/8

36

2 (14)

5 (34)

10 (69)

20 (138)

30 (207)

40 (276)

50 (345)

3.8 2

30 Temperature Rise 24 Above Opening Point (oF) 18 60 (414)

-1 Temperature -4 Rise Above Opening Point (oC) -8

12

-11

-14

5 6 7

-18

v Universal Replacement

(R) For Refrigerants Not Listed, Contact Application Engineering

The performance specifications are nominal and conform to acceptable industry standards. For applications at conditions beyond t hese specifications, consult the local Johnson 08/02 Johnson Controls, Inc Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

2/2

FANs 121, 125 Valves, Miscellaneous Section V Repair Parts Bulletin V46, V47 Issue Date 0196

V46, V47, 246, and 247 Repair Parts and Service Instructions

A pplication Overview
The V46 pressure-actuated and V47 temperatureactuated water-regulating valves are used for water-cooled condensers, bypass service on refrigeration systems, engine cooling, and various industrial applications. IMPORTANT: All Series V46 and V47 valves are designed for use only as operating devices. Where system closure, improper flow, or loss of pressure due to valve failure can result in personal injury and/or loss of property, a separate pressure relief or safety shutoff valve (as applicable) must be added by the user.

M anual Flushing
To clear any sediment that may accumulate, valves may be manually flushed by inserting screwdrivers under both sides of the main spring and lifting upwards to flush the valve. Manual flushing does not affect valve adjustments.
Range Spring Valve Spring Guide

Insert screwdrivers underneath the valve spring guide.

Top Retainer

Adjustments
To raise the valve opening point on direct-acting valves, turn the adjusting screw counterclockwise. To lower the valve opening point, turn the range adjusting screw clockwise. See Figure 2. The closing point of the valve is not adjustable. Pressure-actuated valves close approximately 3 to 7 psi (21 to 48 kPa) below the opening point, and temperature-actuated valves close approximately 3 to 5F (1.7 to 2.8C) below the opening point. If the compressor operates in high ambient temperatures, head pressures may remain high enough during off cycles to prevent the valve from closing completely. In such instances, the opening point of the valve should be raised just enough to cause the valve to close during compressor standby periods. This will also raise the throttling point. The all-range pressure-actuated valve settings can be adjusted for both low pressure refrigerant ranges of R-134a and higher pressure refrigerant ranges of R-22 (R-502). Figure 1: Manual Flushing

I nspection and Service

After long periods of operation, the valve seat and rubber disc may become worn, pitted, or wiredrawn, preventing the valve from completely closing off when the pressure/temperature is below the setpoint.

WARNING: Personal injury hazard. Contents of liquid lines could be under pressure. Avoid possible personal injury by shutting off the liquid supply and relieving the pressure before servicing the valve.

1996 Johnson Controls, Inc. Part No. 24-8414-12, Rev. B Code No. LIT-121695

To inspect and replace internal parts, follow the procedures in this section. Note: Parts supplied in the renewal kit replace both V46 and V47 Series, and 246 and 247 Series valve assemblies.
Range Adjusting Screw

Figure 3: 246, 247, 2 in., and 2-1/2 in. Valves

Spring Housing Assembly

WARNING: Personal injury hazard. The housing contains a compressed spring. Disassembly could cause the spring to fly out resulting in personal injury or damage. For valve sizes 1 in. and larger, do not remove the two screws on the sides of the spring housing.

Valve Body

Sensing Element

1. Decrease the compression on the main spring by turning the range adjusting screw clockwise until it stops. Using excessive force to turn the screw beyond the stop point will strip the thread. 2. Remove the four screws holding the spring housing and remove the entire housing assembly. See Figure 2.

Figure 2: Valve Components

Servicing 246, 247, 2 in., and 2-1/2 in. Valves

3. To improve the performance on 3/8 in. directacting valves, install the ISO-loss washer that is supplied with the 3/8 in. valve repair kit as follows: Note: Reverse-acting 3/8 in. valves do not require the ISO-loss washer.

CAUTION: Equipment damage hazard. To decrease the pressure in the sensing element on 247 and V47 valves, cool the bulb by submerging it in ice water. Do not remove the bulb from the ice water until the element is reinstalled.

a. Slightly squeeze the spring housing assembly to remove the spring housing. b. Remove the range adjusting screw, spring, and valve spring guide (Figure 4). c. Clean off any excess grease on the valve spring guide.

d. Place the new ISO-loss washer over the guide plate.

Valve Assembly Screw Guide Post Valve Disc Retainer Diaphragm O -rin g (2 and 2-1/2 in. Valves)

e. Replace the valve spring guide, spring, range adjusting screw, and spring housing.

Valve Disc Valve Seat Extension Sleeve Bellows Push Rod Guide Plate Gasket

Bellows Sealing Ring Seat Wrench

O -rin g (2 a n d 2 -1 /2 in . V a lve s)

2 V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions

Range Spring Valve Spring Guide Guide Post ISO-loss Washer Guide Plate Top Retainer

Figure 4: ISO-loss Washer

V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions 3

4. Remove the valve assembly screw (Figure 3). 5. Remove the guide post and old diaphragms (Figure 3). 6. Remove the sensing element and the diaphragms between it and the valve body (Figure 3). 7. Pull the disc, disc retainer, and extension sleeve assembly from the valve (Figure 3). 8. Using the seat wrench supplied with the kit, remove old valve seat and replace with the new valve seat (Figure 3). (Seat wrench not provided for 2 and 2-1/2 in. valves, use 1-1/2 and 1-15/16 in. hex stock, respectively.) 9. Replace the diaphragms between the sensing element and valve body (Figure 5). Use two diaphragms on 3/8 in., 1/2 in., and 3/4 in. valves and three diaphragms on 1 in. and larger valves. 10. On 1 in. and larger pressure valves and all temperature valves, replace the guide plate gasket and bellows sealing ring (Figure 5). 11. Assemble the sensing element to the valve body with the bellows push rod, new diaphragms, guide plate gasket, and bellows sealing ring in place.

12. Assemble the new disc, disc retainer, and extension sleeve. a. On 2 and 2-1/2 in. valves, apply a small amount of grease to the grooves on the bottom of the new extension sleeve and the top of the new disc retainer. Place one O-ring into each groove. b. Place the subassembly into the valve. 13. Place two new diaphragms on the spring housing end of the valve body. 14. Screw the valve assembly screw through the guide post and into the bellows push rod (Figure 3). 15. Place the spring housing assembly over the guide post and secure in place with the four housing screws. 16. Adjust the valve to desired opening point. Then manually flush the valve. See the Manual Flushing section. 17. Before leaving the installation, run the system through at least one complete operating cycle to be sure the valve is operating correctly.

Valve Body Bellows Push Rod Bottom Retainer These parts are factory assembled for pressure valve sizes 3/8, 1/2, and 3/4 in. only. Rubber Diaphragms

Guide Plate Gasket Guide Plate

Sensing Element

Bellows Sealing Ring

Figure 5: Guide Plate Gasket and Bellows Sealing Ring Identification 4 V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions

Servicing V46 and V47 3/8 in. through 1-1/2 in. Valves

1. Decrease the compression on the main spring by turning the range adjusting screw clockwise until it stops. Using excessive force to turn the screw beyond the stop point will strip the thread. 2. Remove the four screws holding the spring housing and remove the entire housing assembly. See Figure 2. 3. To improve the performance on 3/8 in. directacting valves, install the ISO-loss washer that is supplied with the 3/8 in. valve repair kit as follows: Note: Reverse-acting 3/8 in. valves do not require the ISO-loss washer.

CAUTION: Equipment damage hazard. To decrease the pressure in the sensing element on V47 valves, cool the bulb by submerging it in ice water. Do not remove the bulb from the ice water until the element is reinstalled.

WARNING: Personal injury hazard. The housing contains a compressed spring. Disassembly could cause the spring to fly out resulting in personal injury or damage. For valve sizes 1 in. and larger, do not remove the two screws on the sides of the spring housing.

a. Slightly squeeze the spring housing assembly to remove the spring housing. b. Remove the range adjusting screw, spring, and valve spring guide (Figure 7). c. Clean off any excess grease on the valve spring guide.

d. Place the new ISO-loss washer over the guide plate. e. Replace the valve spring guide, spring, range adjusting screw, and spring housing.

Seat Guide Post Disc Stud Disc Cup

ISO-loss Washer (3/8 in. Only)

Range Spring Valve Spring Guide Seat Guide Post ISO-loss Washer Guide Plate Top Retainer

Diaphragm

Valve Disc Valve Seat Valve Stem Bellows Push Rod Bellows Sealing Ring Guide Plate Gasket

Figure 7: ISO-loss Washer

Seat Wrench

4. Remove the seat guide post (Figure 6). Figure 6: V46 and V47 3/8 in. through 1-1/2 in. Valves 5. Remove the rubber diaphragms (Figure 6). 6. Turn the disc stud counterclockwise to remove the valve stem assembly (Figure 6). 7. Remove the sensing element, bellows push rod, and diaphragms. See Figure 9.

V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions 5

8. Using the seat wrench supplied with the kit, remove old valve seat and replace with the new valve seat (Figure 6). 9. Assemble the new valve stem, disc, disc cup, and disc stud, and place into the valve body (Figure 6). 10. On 1 in. and larger pressure valves and all temperature valves, replace the guide plate gasket and bellows sealing ring (Figure 9). 11. If servicing a V47 or V46 valve other than low flow, place new diaphragms on the sensing element end of the valve stem assembly. Use two diaphragms on 3/8 in., 1/2 in., and 3/4 in. valves and three diaphragms on 1 in. and larger valves. Screw into place with the bellows push rod. Attach the sensing element to the valve body. See Figure 6. 12. If servicing a low flow valve, place the stem washer and new diaphragms on the sensing element end of the valve stem assembly. Use two diaphragms on 3/8 in., 1/2 in., and 3/4 in. valves and three diaphragms on 1 in. and larger valves. Screw into place with the bellows push rod. Attach the sensing element to the valve body. See Figure 8.

13. Place two new diaphragms on the spring housing side of the valve body. Screw into place with the seat guide post (Figure 8). 14. Place the spring housing assembly over the seat guide post and secure in place with the four housing screws. 15. Adjust the valve to desired opening point. Then manually flush the valve. See the Manual Flushing section. 16. Before leaving the installation, run the system through at least one complete operating cycle to be sure the valve is operating correctly.

Stem Washer 3/8 in. Low Flow Valve Only

Valve Body Seat Guide Post Disc Stud Disc Cup Diaphragm ISO-loss Washer Bellows Push Rod Bottom Retainer These parts are factory assembled for pressure valve sizes 3/8, 1/2, and 3/4 in. only. Rubber Diaphragms

Guide Plate Gasket Guide Plate

Stem Washer Valve Disc Valve Seat Valve Stem Bellows Push Rod Bellows Sealing Ring Seat Wrench Guide Plate Gasket Sensing Element

Bellows Sealing Ring

Figure 8: Low Flow Valves

Figure 9: Guide Plate Gasket and Bellows Sealing Ring Identification

6 V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions

Table 1: Renewal Kits

Commercial Type: V46A, V46D, V47A, V47N Old Construction: 246P, 246T Maritime and Diaphragm Navy Type: V46B, V46C Kits for Old Construction: 246MP, 246NP All Types

Individual Part Description

Seat Guide Post Disc Stud Disc Cup (Retainer) Valve Disc Valve Seat Valve Stem Rubber Diaphragm* Guide Plate Gasket Bellows Sealing Ring Valve Assembly Screw Guide Post Valve Disc Retainer Extension Sleeve Seat Wrench Sensing Element Stem Washer ISO-loss Washer** O-ring Seals
*

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 5 1 1

1 1 1 1 1 1 5 1 1

1 1 5 1 1 1 1 1 1

1 1 5 1 1 1 1 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 4 1 1

1 1 1 1 1 1 5 1 1

1 1 1 1 1 1 5 1 1

1 1 5 1 1 1 1 1 1 5 1 1 5 1 1

1 1 1

1 1 1 1 1 1 1 Contact Application Engineering at (414)-274-5535 1 2 2

3/8, 1/2, and 3/4 in. valves require two diaphragms on spring end and two diaphragms on sensing element end. 1 through 2-1/2 in. valves require two diaphragms on spring end and three diaphragms on sensing element end. ** Reverse-acting 3/8 in. valves do not require an ISO-loss washer.

V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions 7

Notes

8 V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions

Notes

Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53201

Printed in U.S.A.

V Valves, MiscellaneousV46, V47, 246, and 247 Repair Parts and Service Instructions 9