universal analyzers model 1190 vortex sample cooler-revd

5200 Convair Drive Carson City, NV 89704

775.883.2500 Fax 775.883.6388 www.universalanalyzers.com

See us on the WEB at http://www.universalanalyzers.com e-mail address: [email protected]

MAN1190 Rev C

1190 SERIES VORTEX SAMPLE

COOLER

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 CUSTOMER’S 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 CARSON CITY, NV 89706 TELEPHONE: (775) 883-2500 FAX: (775) 883-6388

1190 Text Rev -

UNIVERSAL ANALYZERS MODEL 1190 SAMPLE COOLER NON-ELECTRIC, COMPRESSED AIR OPERATION FOR NON-SPARK ATMOSPHERES

SPECIFICATIONS

GAS SAMPLE FLOW RATE: (TWO Impingers): 0 TO 16 L/M (at STP) (ONE Impinger ): 0 TO 8 L/M (at STP) MAXIMUM INLET TEMPERATURE: STAINLESS STEEL HEAT EXCHANGER: 700 DEGREES F. (351 C.) KYNAR/GLASS HEAT EXCHANGER: 280 DEGREES F. (138 C.) MAXIMUM INLET GAS DEWPOINT: 178 DEGREES F. ( 81 C.) MAXIMUM INLET WATER CONCENTRATION: 50 % * MIMIMUM AMBIENT TEMPERATURE: 34 DEGREES F. ( 1 C.) MAXIMUM AMBIENT TEMPERATURE: 105 DEGREES F. ( 41 C.) MAXIMUM COOLING POWER: 400 BTU’S PER HOUR (380 kJ/Hr.) (at 100 to 150 psig air pressure) COOLING POWER USING 80 psig AIR: 200 BTU’S PER HOUR (190 kJ/Hr.) MAXIMUM WATER REMOVAL CAPABILITY: 4 L/M at 50 % WATER BY VOLUME 10 L/M at 20 % or less WATER OUTLET SAMPLE DEW POINT: 41 DEGREES F. ( 5 C.) GAS SAMPLE INLET FITTING: 3/8” TUBING FITTING GAS SAMPLE OUTLET FITTING: 1/4” TUBING FITTING BOTTOM WATER DRAIN FITTING 3/8” TUBING FITTING

COMPRESSED AIR REQUIREMENT: 15 CFM @ 100 PSIG ELECTRICAL CLASSIFICATION: NOT APPLICABLE, AIRPOWERED DIMENSIONS: 16” HIGH x 14” WIDE x 8” DEEP WEIGHT: 20 LBS ( 9 KG) SOLUBLE GAS REMOVAL RATES: NO 0% LOSS NO2 <10% LOSS SO2 < 2% LOSS CO 0% LOSS * at reduced flow rate. CO2 < 2% LOSS

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) 883-2500 or (800) 993-9309 or FAX request to (775) 883-6388.

LEFT SIDE

FRONT

12345678

A

B

C

D

12345678

A

B

C

D

1100 SERIES VORTEX COOLEDSAMPLE COOLER OUTLINE &

MOUNTING DIMENSIONS

P0042

05/07/93 1 OF 11 : 2

1100 SERIES COOLERS

APVDDWNDESCRIPTIONDATEREVREVISIONS

FORPART NO.

H. MITCHELLAPVD BY

DRAWN BY DRAWING NO

CDATE SCALE SIZE SHEET

NOT ISSUED

UNIVERSAL ANALYZERS INC.1701 South Sutro TerraceCarson City, Nevada 89706 USA

T. BARBEN II

B 10/06/99 REDRAW FOR VORTEX HTSINK DETAILS EAM RD

8"

7 1/8"

8 11/16"

1/4"

7 1/2"

SAMPLEOUTLET

1/4" TUBETYP

SAMPLE INLET3/8" TUBE

COMPRESSED AIRINLET 1/2"NPT MIN 80

PSIG @ "X" SCFM(SEE TABLE)

VORTEXTUBE

VORTEXTEMPERATUREADJUST SCREW

MOUNTING HOLES FOR1/4" HARDWARE

(SUPPLIED BY OTHERS)4 TYP

VORTEX ADJUSTSCREW

(HOT AIR EXHAUST)

IMPINGER 10"(SEE TABLE FOR #

OF IMPINGERS)

CONDENSATEOUTLET3/8" NPT

MODELNO.

# OFIMPINGERS

COMPRESSED AIRREQUIRED "X"

TOTAL COOLINGCAPACITY @ 100PSIG (690 KPa)

1120114011601190

1 2CFM (0.06 M/MIN)4CFM (0.06 M/MIN)10CFM (0.06 M/MIN)15CFM (0.06 M/MIN)

55 B.T.U. / HR110 B.T.U. / HR260 B.T.U. / HR400 B.T.U. / HR

122

3

3

3

3

16 1/4"

A B C D

1

2

3

4

5

6

7

8

A B C D

1

2

3

4

5

6

7

8

WRENCH

PVC ADAPTERS SUPPLIED FOR1" NPT OR 1" SLIP FIT

(SUPPLIED BY OTHERS)

CLEAR PVCCONDENSATE RESERVOIR

1" PVC BALL VALVE

1" PVC BALL VALVE(SHOWN NORMALLY OPEN)

(SHOWN NORMALLY CLOSED)

FRONT VIEW

LEFT SIDE

FLATS

3/8" NPT

NUT

19"

DRAINCONDENSATE

1" PVC PIPE

NUT

TO OPEN

TO CLOSE

4955-0011

Carson City, Nevada 89706 USA1701 South Sutro Terrace

UNIVERSAL ANALYZERS INC.

SHEETSIZESCALEDATEC

DRAWING NODRAWN BY

APVD BYHARVEY MITCHELL

PART NO. FOR

REVISIONSREV DATE DESCRIPTION DWN APVD

1 : 1 1 OF 110/3/94

P0116

CONDENSATE REMOVAL POTOUTLINE

T. BARBEN II

A 02/02/00 UPDATE VORTEX COOLER OUTLINE EAM RD

TOP VIEW

A

A

SECTION A-A

B B

SECTION B-B

SAMPLE GAS INLET3/8" TUBE

PLUG1/16" NPT

VITON O-RINGP/N 4904-0013

INSULATEDINNER TUBE

ASSY

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

.305 I.D.OUTER TUBE

ASSY

CONDENSATEDRAIN 3/8"NPT

SAMPLEGAS

OUTLET1/4"

TUBE

"L"(SEE TABLE)

1). SEE SHEET 2 FOR ASSEMBLY INSTRUCTIONS.

12345678

A

B

C

D

12345678

A

B

C

D

HEAT EXCHANGER METALLICNON-TEMPERATURE SENSING

OUTLINE

P0147

12/11/95 1 OF 2NONE

SEE TABLE


FORPART NO.

EV MUSSELMANAPVD BY

DRAWN BY DRAWING NO


SEE TABLE


H. MITCHELL

A 02/09/99 REVISE P/N TABLE FOR TEFLON COATED EAM RD

APPROXLENGTH

"L"

HEATEXCHANGER

P/NOUTER TUBE MATERIAL

UNIVERSALANALYZERS

SERIES5" 5200-S050 316 S.S. 400/500

10" 5200-S010 316 S.S. 800/1000/1100/3000

5" 5200-T050 TITANIUM 400/5005" 5200-A050 ALLOY 20 400/5005" 5200-C050 HASTELLOY C-276 400/5005" 5200-S05T TEFLON COATED 316 S.S. 400/500

10" 5200-T010 TITANIUM 800/1000/1100/300010" 5200-A010 ALLOY 20 800/1000/1100/300010" 5200-C010 HASTELLOY C-276 800/1000/1100/300010" 5200-S01T TEFLON COATED 316 S.S. 800/1000/1100/3000

VITON O-RING#2-021

SEE NOTES OUTER TUBE ASSEMBLY METALLIC

INNER TUBE ASSEMBLY

NOTES:1). O-RING IS FACTORY INSTALLED INMETALLIC OUTER TUBE.2). LIGHTLY LUBRICATE O-RING WITHSILICONE GREASE BEFORE ASSEMBLY.

HEAT EXCHANGERSEPERABLE SPARE PARTS LIST

S

S

INNER TUBEMATERIALIDENTIFIER

OUTER TUBEMATERIALIDENTIFIER

"L"

12345678

A

B

C

D

12345678

A

B

C

D

HEAT EXCHANGER ASSEMBLYNON-TEMPERATURE SENSING

METALLIC

P0147

12/11/95 2 OF 2NONE

INSTRUMENT


FORPART NO.

EV MUSSELMANAPVD BY

DRAWN BY DRAWING NO


SEE TABLE


H. MITCHELL

A 02/09/99 REVISE TABLE TO INCLUDE TEFLON PARTS EAM RD

10" 5200-S01T 5201-0042 5201-0044 " "10" 5200-C010 " 5201-0021 " "10" 5200-A010 " 5201-0023 " "10" 5200-T010 " 5201-0025 " "10" 5200-S010 5201-0016 5201-0013 4904-0013 4951-0058

5" 5200-T050 " 5201-0024 " " 5" 5200-S050 5201-0015 5201-0012 4904-0013 4951-0058

APPROX"L"

LENGTHP/N

INNERTUBE ASSY

P/N

OUTERTUBE ASSY

P/N

VITON O-RING#2-021 P/N

PLUG1/16"NPT

P/N

5" 5200-A050 " 5201-0022 " " 5" 5200-C050 " 5201-0020 " " 5" 5200-S05T 5201-0041 5201-0043 " "

DRY GAS OUTLET1/4" TUBE

SAMPLE GAS INLET3/8" TUBE

SIDE VIEW

TOP VIEW

1). SEE SHEET 2 FOR ASSEMBLY INSTRUCTIONS.

CONDENSATE DRAIN3/8"NPT

INSULATED SECTION

0.300" INSIDE DIAMETER

CHILLED SURFACE

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

(SEE TABLE)

QTY OFEXCHANGERS PERSAMPLE COOLER

122412224

UNIVERSALANALYZERS

SAMPLE COOLERMODELS

520530540570

10401050106010801090

GLASS KYNAR HEATEXCHANGER

ASSEMBLY P/N

5200-K050

5200-K010

LENGTH"L"

5"

10"

" L "

PLUG1/16" NPT

1FGA25200-K01515"

12345678

A

B

C

D

12345678

A

B

C

D

HEAT EXCHANGER GLASS /KYNAR NON-TEMPERATURE

SENSING OUTLINE

P0149

12/11/95 1 OF 21 : 1

INSTRUMENT


FORPART NO.

EV MUSSELMANAPVD BY

DRAWN BY DRAWING NO


SEE TABLE


H. MITCHELL

C 01/19/04 Revision Per Sheet 2 RPH TB

COMPLETE GLASS KYNAR

#2-018 VITONO-RING

(SEE NOTE 2)

KYNAR DRAINFITTING

(SEE NOTE 1)

GLASS TUBE#2-120 VITONO-RING

(SEE NOTE 2)

KYNAR HEAD(SEE NOTE 1)

GLASS KYNARHEAT EXCHANGER

ASSEMBLYLENGTH "L" P/N

5200-K0505"

KYNARINSULATED

SECTION ASSYP/N

5110-2003

GLASSTUBE

5201-0002P/N

KYNARDRAIN

FITTINGP/N

5110-2002

#2-120VITON

O-RINGP/N

4904-0004

#2-018 VITONO-RING

P/N4904-0003

HEAT EXCHANGER ASSEMBLY

SPARE PARTS LIST

EXPLODED GLASS KYNAR HEAT EXCHANGER

1). O-RINGS ARE FACTORY INSTALLEDIN KYNAR HEAD AND KYNAR DRAINFITTINGS

2). LIGHTLY LUBRICATE O-RINGSWITH SILICONE GREASE BEFOREASSEMBLY.

NOTES:

7/8" WRENCHFLATS

KYNAR INSULATEDSECTION ASSEMBLY

5200-K01010" 5110-2004 5201-0001 " " "

KYNAR HEAD

P/N5201-0017

"

PLUG1/6"NPT

1/16" NPT PLUGP/N

4951-0066"

5200-K01515" 5110-2006 5201-0078 5201-0066 " " " "

12345678

A

B

C

D

12345678

A

B

C

D

HEAT EXCHANGER GLASS /KYNAR NON-TEMPERATURE

SENSING SPARE PARTINSTALLATION

P0149

12/11/95 2 OF 21 : 1

INSTRUMENT


FORPART NO.

EV MUSSELMANAPVD BY

DRAWN BY DRAWING NO


SEE TABLE


H. MITCHELL

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

KYNAR DRAINFITTING

15" VERSION

Universal Analyzers Inc. 1701 SOUTH SUTRO TERRACE CARSON CITY, NV 89706 TELEPHONE: (775) 883-2500 FAX: (775) 883-6388

1190 Spare Parts Rev A

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

UNIVERSAL ANALYZERS INC.

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

1250 Century Circle North • Cincinnati, OH, USA 45246-3309 • (513) 671-3322 • Fax (513) 671-3363 • E-mail: [email protected]

®

Corporation

VORTEX TUBE INSTALLATION & MAINTENANCE

LIT3001

COMPRESSED AIR LINE SIZESCompressed air lines should be sized to holdpressure drops to a minimum. Do not userestrictive fittings such as quick connects. Theycan “starve” the Vortex Tube by causing excessiveline pressure drop. The following chart givessuggested line sizes for pipe and hose.

COMPRESSED AIR SUPPLYFor best performance, use line pressure 80 to 100PSIG (5.5 - 6.9 BAR). Vortex Tubes are rated inSCFM (SLPM) at 100 PSIG (6.9 BAR) supplypressure.With proper filtration and separation of dirt,moisture and oil from the compressed air supply,the Vortex Tube will run for years with nomaintenance required. Use a 25 micron or smallerfilter separator that is sized to the SCFM (SLPM)rating of the Vortex Tube. The Model 9004Automatic Drain Filter Separator is used for VortexTubes up to 40 SCFM (1133 SLPM), Model 9002Automatic Drain Filter Separator for Vortex Tubesup to 150 SCFM (4248 SLPM).

To prevent problems associated with oil, useModel 9005 Oil Removal Filter for Vortex Tubesup to 30 SCFM (850 SLPM) or Model 9006 OilRemoval Filter for Vortex Tubes up to 150 SCFM(4248 SLPM). The oil removal filter should beused downstream from the automatic drain filterseparator. Filters should be used within 10 to 15'(3 to 4.6m) of each Vortex Tube.

By regulating pressure, refrigeration produced canbe matched to the application requirements. UseModel 9008 Pressure Regulator for Vortex Tubesup to 50 SCFM (1416 SLPM) or Model 9009Pressure Regulator for Vortex Tubes up to 150SCFM (4248 SLPM). Another method oftemperature control is to supply the Vortex Tubewith full line pressure, then cycle the air on and offwith a solenoid valve controlled by a thermostat.

For replacement or repair filter and regulatorparts contact Nimmo Fluid Power at1-888-646-6097.

USING THE VORTEX TUBEEach size Vortex Tube can produce a number offlow rates as determined by an internal plastic partcalled a generator. Each generator is marked witha number and a letter. The number indicates thecapacity (SCFM of air consumption) and the letterindicates the type of operation (“R” for maximumrefrigeration or “C” for maximum coldtemperature). The Vortex Tube has one generatorinstalled. If a different capacity is desired, othergenerators are available.

Line Sizes ForRuns Up To:

10 FT (3m)

10-50 FT(3 - 15.2m)

50-100 FT(15.2 - 30.5m)

Pipe Hose Pipe Hose Pipe Hose

Model 3202 thru 3208Model 3402 thru 3408

1/8" 1/4" 1/4" 3/8" 1/4" 3/8"


1/4" 3/8" 3/8" 1/2" 1/2" 5/8"


1/2" 5/8" 3/4" 7/8" 1" 1- 1/8"

®©2001 Corporation LIT

The “R” type generators are used for mostapplications (part cooling, enclosure cooling, toolcooling and in applications where complete heatexchange is desired). “R” type generators shouldbe used for temperatures down to 0°F (-18°C). Ifthe Vortex Tube is set for 50°F (28°C) below thesupply air temperature, it will be at 80% coldfraction (80% of the air is directed to the cold end).This produces a combination of cold flow volumeand temperature drop that gives the bestperformance in most applications.

“C” type generators are used for maximum coldtemperature (cooling parts, liquids or gas samplesto subzero temperatures, component testing, etc.).“C” type generators should be used fortemperatures 80° to 120°F (44° to 67°C) below thesupply air temperature. Any temperature dropgreater than 50°F (28°C) may precipitate moisturethat could freeze and plug the cold air exhaust (see4 under "Troubleshooting").

SETTING THE VORTEX TUBEHot and cold air temperatures produced by aVortex Tube are infinitely variable by adjusting theslotted valve at the hot air exhaust. Opening thevalve reduces the cold airflow and the cold airtemperature. Closing the valve increases the coldairflow and the cold air temperature.Set the Vortex Tube with a thermometer. Tomeasure temperature accurately, it should beinserted into the cold muffler or a piece of tubingon the cold end exhaust.

NOISE MUFFLINGNormally, muffling is not required if the hot andcold air is ducted. Mufflers are available for boththe hot and cold exhaust for all Vortex Tubes. (Formodel number, see drawing on other side.) Thecold cap on the medium and large Vortex Tubesmust be removed to install the muffler.

TROUBLESHOOTING & MAINTENANCE

If The Vortex Tube Does Not Perform Properly,check for these common problems:

1. Loose Cold Cap or Cold Muffler - A loosecold cap or cold muffler will cause poorperformance. Make sure it is tight.

2. Inlet Pressure - Low inlet pressure supply willcause poor performance. Measure the pressure atthe compressed air inlet of the Vortex Tube while itis operating. Restrictions in the compressed airsupply line can cause excessive pressure drops anddeteriorate performance.3. Inlet Temperature - A Vortex Tube provides atemperature drop from supply air temperature. Insome cases, the supply air is warmer than ambientair due to compressed air lines running acrossceilings, near furnaces, direct sun, etc. In thiscase, the cold air may be warmer than anticipatedand adequate refrigeration may not be available forthe application.4. No Cold Flow - If the Vortex Tube is operatedcontinuously for an extended period of time and isset for more than a 50°F (28°C) drop from thecompressed air temperature, the cold end mayfreeze, blocking the cold outlet. If this happens,any one of the following will correct the problem:

(a) Blow air (use an air gun) into thecold 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 VortexTube deteriorates with back pressure on the coldair exhaust. Pressure up to 2 PSIG (.1 BAR) willnot change performance. 5 PSIG (.3 BAR) willchange performance by approximately 5°F (2.8°C).If cold air ducting is used, the total crosssectionalarea should be equal to or greater than the area ofthe Vortex Tube cold air exhaust.If you have any questions or problems, pleasecontact an EXAIR Application Engineer at:1-800-90-EXAIRFax: (513) 671-3363E-mail: [email protected]://www.exair.com

Cold Cap

Cold AirExhaust

"O" Ring

Generator NumberMarked Here

Generator

Compressed Air Supply

Sleeve (Small Vortex Tube Only)

Body

Hot AirExhaust

Valve

Washer (Small Vortex Tube Only) "O" Ring

3001

For more information about this product, visit"Frequently Asked Questions" at www.exair.com

Controls Group 507 E. Michigan Street P.O. Box 423, Milwaukee, WI 53202

v47s who

V47 Series

The performance specControls office. Johns

▲ Universal Repla

le

ifications are nominal and conform to acceptable industry standards. For applications at conditions beyond these specificationon Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. ©

1/2

cement (R) For Refrigerants Not Listed, Contact Application Engineering

19273309thcc:7-78

07/1logoJCIleft refririghstan

Refrigeration Valv

Code No. LIT-19

es Rev

27330

:

s, consult the local Johns08/02 Johnson Controls,

8/97:

ft:gt ft:dard

Sect# = 7seQ# = 60

h

Temperature Actuated Modulating Valvev47.tif

V47

DescriptionThe 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.

Features• no close fitting sliding parts in water

passages

• range spring does not come in contact witthe cooling water

• easy manual flushing, if required

• valve design minimizes chatter and water hammer

To OrderRefer 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

flange

Ring

Gasket (2)

Cast Iron

Flange (2)

Machine

Bolt (8)

Hex

Nut (8)

Ac(C

KI

KI

KI

cessories ompanion Flanges and Gasket)

Kit Number Water Valve Size (in.)

T14A-612 1-1/2 in.

T14A-613 2 in.

T14A-614 2-1/2 in.

Metric Conversion

°F °C

75 to 115 24 to 46

75 to 135 24 to 57

115 to 160 46 to 71

115 to 180 46 to 82

160 to 205 71 to 96

160 to 230 71 to 110

SpecificationsV47 Series Temperature Actuated Modulating Valves

Maximum Bulb Temperature 20F° (-6.7 C°) above temperature range

Maximum Water Temperature 170°F (77°C)

Maximum Supply Water Pressure 150 psig (1034 kPa)

Capillary Length (a)

(a) V47AC-8 — Capillary Length 4 ft.

6 ft (1.83 m) Nylon Armor

Temperature Bulb Style 4 (b) (pictured)

(b) V47AB-2 — Temperature Bulb Style 1 (no 1/2 in. NPT male fitting)

(1/2 in. NPT closed tank immersion)

Selection Chart Code

NumberPipe

Size, in.Range

(Opening Point) °FBulb Size, in.(Dia length)

Std BypassOrifice Dia in.

Seat Repair Kit

Replacement Sensing Element

Bulb Well Number Order Separately

V47AA-1C 3/8 115 to 180 Heating 11/16 x 3 1/4 0.062 STT14A-600R SET29A-622R WEL18A-602R

V47AA-2C 3/8 160 to 230 Heating 11/16 x 3 1/4 0.062 STT14A-600R SET29A-623R WEL18A-602R

V47AA-3C 3/8 75 to 135 Cross Ambient 11/16 x 6 0.062 STT14A-600R SET29A-601R WEL17A-601R

V47AB-2C 1/2 75 to 135 Cross Ambient 11/16 x 10 (a) – STT15A-602R SET29A-602R WEL17A-600R

V47AB-3C 1/2 115 to 180 Heating 11/16 x 3 1/4 0.062 STT15A-602R SET29A-624R WEL18A-602R

V47AB-4C 1/2 160 to 230 Heating 11/16 x 3 1/4 0.062 STT15A-602R SET29A-625R WEL18A-602R

V47AB-5C 1/2 75 to 135 Cross Ambient 11/16 x 10 0.062 STT15A-602R SET29A-602R WEL17A-600R

V47AC-3C 3/4 115 to 180 Heating 11/16 x 3 1/4 0.062 STT16A-601R SET29A-626R WEL18A-602R

V47AC-4C 3/4 160 to 230 Heating 11/16 x 3 1/4 0.062 STT16A-601R SET29A-627R WEL18A-602R

V47AC-6C 3/4 75 to 135 Cross Ambient 11/16 x 10 0.062 STT16A-601R SET29A-604R WEL17A-600R

V47AC-8C 3/4 (b) 75 to 135 Heating 11/16 x 3 1/4 – STT16A-601R SET98A-621R WEL18A-602R

V47AD-1C 1 75 to 135 Cross Ambient 11/16 x 16 1/4 0.093 STT17A-609R SET29A-605R –

V47AD-2C 1 115 to 180 Heating 11/16 x 6 0.093 STT17A-609R SET29A-629R WEL17A-601R

V47AD-3C 1 160 to 230 Heating 11/16 x 6 0.093 STT17A-609R SET29A-630R WEL17A-601R

V47AE-1C 1 1/4 75 to 135 Cross Ambient 11/16 x 16 1/4 0.093 STT17A-610R SET29A-605R –

V47AE-2C 1 1/4 115 to 180 Heating 11/16 x 6 0.093 STT17A-610R SET29A-629R WEL17A-601R

V47AE-3C 1 1/4 160 to 230 Heating 11/16 x 6 0.093 STT17A-610R SET29A-630R WEL17A-601R

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

(b) ASME Flange

onInc

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

V47 Series Temperature Actuated Modulating Valve (Continued)

V47AR-1 1 1/2 (b) 75 to 135 Cross Ambient 11/16 x 16 1/4 0.093 STT17A-610R SET29A-605R –

V47AR-2 1 1/2 (b) 115 to 180 Heating 11/16 x 6 0.093 STT17A-610R SET29A-629R WEL17A-601R

V47AR-3 1 1/2 (b) 160 to 230 Heating 11/16 X 6 0.093 STT17A-610R SET29A-630R WEL17A-601R

V47AS-1 2 (b) 115 to 160 Heating 11/16 x 10 0.125 STT18A-600R SET29A-632R WEL17A-600R

V47AS-2 2 (b) 160 to 205 Heating 11/16 x 10 0.125 STT18A-600R SET29A-633R WEL17A-600R

V47AS-3 2 (b) 75 to 115 Cross Ambient 11/16 x 43 0.125 STT18A-600R SET29A-606R –

V47AT-1 2 1/2 (b) 115 to 160 Heating 11/6 x 10 0.125 STT18A-601R SET29A-632R WEL17A-600R

V47AT-2 2 1/2 (b) 160 to 205 Heating 11/6 x 10 0.125 STT18A-601R SET29A-633R WEL17A-600R

V47AT-3 2 1/2 (b) 75 to 115 Cross Ambient 11/16 x 43 0.125 STT18A-601R SET29A-606R –

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

(b) ASME Flange

Selection Chart (Continued)Code

NumberPipe

Size, in.Range

(Opening Point) °FBulb Size, in.(Dia length)

Std BypassOrifice Dia in.

Seat Repair Kit

Replacement Sensing Element

Bulb Well Number Order Separately

v47_flowchart.eps300

V47 Valve Sizing InformationTo Select Water Valve Size, refer to flow chart

for selection of water valves. Carefully follow the steps as outlined below.1Determine the maximum water flow required. Draw a horizontal line through this flow across the upper half of the flow chart.

2 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.

3 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.

4 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).

5 From this point, draw a vertical line until it intersects the flow line from Step 1.

6 If the intersection falls on a valve size curve, this is the valve size.

7 If the intersection falls between two curves, use the curve to the left for the required valve size.

The performance specifications are nominal and conformControls office. Johnson Controls, Inc. shall not be liable

▲ Universal Replacement (R) For Refrigeran

2

3

4

6

5

7

10

89

20

30

40

60

50

70

1009080

200

1136

757

379

227

349303265

189

151

114

76

38343026

23

1915

11

7

3.8

-18

-14

-11

-8

-4

-1

236

30

24

18

12

6

0

TemperatureRise

AboveOpening Point

( C)o

TemperatureRise

AboveOpening Point

(o

F)

Water FlowL/Min.

Water FlowGal. / Min.

2(14)

5(34)

10(69)

20(138)

30(207)

40(276)

50(345)

60(414)

3/8

1/2

3/4

1

1-1/4

1-1/2

2

2-1/2

ts Not Listed, Contact Application Engineering
to acceptable industry standards. For applications at conditions beyond these specifications, consult the local Johnson
for damages resulting from misapplication or misuse of its products. © 08/02 Johnson Controls, Inc 2/2

FANs 121, 125Valves, Miscellaneous Section V

Repair Parts Bulletin V46, V47Issue Date 0196

© 1996 Johnson Controls, Inc. 1Part No. 24-8414-12, Rev. BCode No. LIT-121695

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

Application Overview

The V46 pressure-actuated and V47 temperature-actuated water-regulating valves are used forwater-cooled condensers, bypass service onrefrigeration systems, engine cooling, and variousindustrial applications.

IMPORTANT: All Series V46 and V47 valves aredesigned for use only as operatingdevices. Where system closure,improper flow, or loss of pressure dueto valve failure can result in personalinjury and/or loss of property, aseparate pressure relief or safetyshutoff valve (as applicable) must beadded by the user.

Adjustments

To raise the valve opening point on direct-actingvalves, turn the adjusting screw counterclockwise. Tolower the valve opening point, turn the range adjustingscrew clockwise. See Figure 2. The closing point ofthe valve is not adjustable. Pressure-actuated valvesclose approximately 3 to 7 psi (21 to 48 kPa) below theopening point, and temperature-actuated valves closeapproximately 3 to 5°F (1.7 to 2.8°C) below theopening point.

If the compressor operates in high ambienttemperatures, head pressures may remain highenough during off cycles to prevent the valve fromclosing completely. In such instances, the openingpoint of the valve should be raised just enough tocause the valve to close during compressor standbyperiods. This will also raise the throttling point.

The all-range pressure-actuated valve settings can beadjusted for both low pressure refrigerant ranges ofR-134a and higher pressure refrigerant ranges ofR-22 (R-502).

Manual Flushing

To clear any sediment that may accumulate, valvesmay be manually flushed by inserting screwdriversunder both sides of the main spring and lifting upwardsto flush the valve. Manual flushing does not affectvalve adjustments.

Valve Spring Guide

Top Retainer

Range Spring

Insert screwdrivers underneath the valve

spring guide.

Figure 1: Manual Flushing

Inspection and Service

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

! WARNING: Personal injury hazard .Contents of liquid lines could beunder pressure. Avoid possiblepersonal injury by shutting offthe liquid supply and relievingthe pressure before servicingthe valve.

2 V Valves, Miscellaneous—V46, V47, 246, and 247 Repair Parts and Service Instructions

To inspect and replace internal parts, follow theprocedures in this section.

Note: Parts supplied in the renewal kit replace bothV46 and V47 Series, and 246 and 247 Seriesvalve assemblies.

Spring HousingAssembly

Valve Body

SensingElement

Range Adjusting Screw

Figure 2: Valve Components

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

! CAUTION: Equipment damage hazard .To decrease the pressure in thesensing element on 247 andV47 valves, cool the bulb bysubmerging it in ice water. Donot remove the bulb from the icewater until the element isreinstalled.

Diaphragm

Guide Plate Gasket

Bel lows Seal ingRing

Seat Wrench

GuidePost

Valve DiscRetainer

Valve Disc

Valve Seat

Extension S leeve

Bel lowsPush Rod

Valve Assembly

Screw

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

O -rin g (2 and 2-1/2 in. Valves)

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

! WARNING: Personal injury hazard .The housing contains acompressed spring.Disassembly could cause thespring to fly out resulting inpersonal injury or damage.For valve sizes 1 in. and larger,do not remove the two screws onthe sides of the spring housing.

1. Decrease the compression on the main spring byturning the range adjusting screw clockwise until itstops. Using excessive force to turn the screwbeyond the stop point will strip the thread.

2. Remove the four screws holding the springhousing and remove the entire housing assembly.See Figure 2.

3. To improve the performance on 3/8 in. direct-acting valves, install the ISO-loss washer that issupplied with the 3/8 in. valve repair kit as follows:

Note: Reverse-acting 3/8 in. valves do notrequire the ISO-loss washer.

a. Slightly squeeze the spring housing assemblyto 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 valvespring guide.

d. Place the new ISO-loss washer over the guideplate.

e. Replace the valve spring guide, spring, rangeadjusting screw, and spring housing.

V Valves, Miscellaneous—V46, V47, 246, and 247 Repair Parts and Service Instructions 3

Valve Spring Guide

Guide PostISO-loss Washer

Guide Plate

Top Retainer

Range Spring

Figure 4: ISO-loss Washer


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 diaphragmsbetween it and the valve body (Figure 3).

7. Pull the disc, disc retainer, and extension sleeveassembly from the valve (Figure 3).

8. Using the seat wrench supplied with the kit,remove old valve seat and replace with the newvalve seat (Figure 3). (Seat wrench not providedfor 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 sensingelement and valve body (Figure 5). Usetwo diaphragms on 3/8 in., 1/2 in., and 3/4 in. valvesand three diaphragms on 1 in. and larger valves.

10. On 1 in. and larger pressure valves and alltemperature valves, replace the guide plate gasketand bellows sealing ring (Figure 5).

11. Assemble the sensing element to the valve bodywith the bellows push rod, new diaphragms, guideplate gasket, and bellows sealing ring in place.

12. Assemble the new disc, disc retainer, andextension sleeve.

a. On 2 and 2-1/2 in. valves, apply a smallamount of grease to the grooves on the bottomof the new extension sleeve and the top of thenew disc retainer. Place one O-ring into eachgroove.

b. Place the subassembly into the valve.

13. Place two new diaphragms on the spring housingend of the valve body.

14. Screw the valve assembly screw through the guidepost and into the bellows push rod (Figure 3).

15. Place the spring housing assembly over the guidepost and secure in place with the four housingscrews.

16. Adjust the valve to desired opening point. Thenmanually flush the valve. See the Manual Flushingsection.

17. Before leaving the installation, run the systemthrough at least one complete operating cycle tobe sure the valve is operating correctly.

Rubber Diaphragms

Guide Plate Gasket

Bellows Sealing Ring

Guide Plate

These parts are factory assembled for pressure valve sizes 3/8, 1/2, and

3/4 in. only.

Bellows Push Rod

Bottom Retainer

Valve Body

SensingElement

Figure 5: Guide Plate Gasket and Bellows Sealing Ring Identification


Servicing V46 and V473/8 in. through 1-1/2 in. Valves

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

! WARNING: Personal injury hazard .The housing contains acompressed spring.Disassembly could cause thespring to fly out resulting inpersonal injury or damage. Forvalve sizes 1 in. and larger, donot remove the two screws onthe sides of the spring housing.

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

Diaphragm

Guide Plate Gasket

Bellows SealingRing

Seat Wrench

Seat GuidePost

Disc Stud

Disc Cup

Valve Disc

Valve Seat

Valve Stem

BellowsPush Rod

Figure 6: V46 and V473/8 in. through 1-1/2 in. Valves

1. Decrease the compression on the main spring byturning the range adjusting screw clockwise until itstops. Using excessive force to turn the screwbeyond the stop point will strip the thread.

2. Remove the four screws holding the springhousing and remove the entire housing assembly.See Figure 2.

3. To improve the performance on 3/8 in. direct-acting valves, install the ISO-loss washer that issupplied with the 3/8 in. valve repair kit as follows:

Note: Reverse-acting 3/8 in. valves do notrequire the ISO-loss washer.

a. Slightly squeeze the spring housing assemblyto 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 valvespring guide.

d. Place the new ISO-loss washer over the guideplate.

e. Replace the valve spring guide, spring, rangeadjusting screw, and spring housing.

Valve Spring Guide

Seat Guide PostISO-loss Washer

Guide Plate

Top Retainer

Range Spring

Figure 7: ISO-loss Washer

4. Remove the seat guide post (Figure 6).

5. Remove the rubber diaphragms (Figure 6).

6. Turn the disc stud counterclockwise to remove thevalve stem assembly (Figure 6).

7. Remove the sensing element, bellows push rod,and diaphragms. See Figure 9.


8. Using the seat wrench supplied with the kit,remove old valve seat and replace with the newvalve seat (Figure 6).

9. Assemble the new valve stem, disc, disc cup, anddisc stud, and place into the valve body (Figure 6).

10. On 1 in. and larger pressure valves and alltemperature valves, replace the guide plate gasketand bellows sealing ring (Figure 9).

11. If servicing a V47 or V46 valve other than low flow,place new diaphragms on the sensing element endof the valve stem assembly. Use two diaphragmson 3/8 in., 1/2 in., and 3/4 in. valves andthree 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 washerand new diaphragms on the sensing element endof the valve stem assembly. Use two diaphragmson 3/8 in., 1/2 in., and 3/4 in. valves andthree 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.

ISO-loss Washer

Diaphragm

Guide Plate Gasket

Bellows SealingRing

Seat Wrench

Seat GuidePost

Disc Stud

Disc Cup

Valve Disc

Valve Seat

Valve Stem

BellowsPush Rod

Stem Washer

Figure 8: Low Flow Valves

13. Place two new diaphragms on the spring housingside of the valve body. Screw into place with theseat guide post (Figure 8).

14. Place the spring housing assembly over theseat guide post and secure in place with thefour housing screws.

15. Adjust the valve to desired opening point. Thenmanually flush the valve. See the Manual Flushingsection.

16. Before leaving the installation, run the systemthrough at least one complete operating cycle tobe sure the valve is operating correctly.

Rubber Diaphragms

Guide Plate Gasket

Bellows Sealing Ring

Guide Plate

These parts are factory assembled for pressure valve sizes 3/8, 1/2, and

3/4 in. only.

Bellows Push Rod

Bottom Retainer

Stem Washer3/8 in. Low Flow

Valve Only

Valve Body

SensingElement

Figure 9: Guide Plate Gasket andBellows Sealing Ring Identification


Table 1: Renewal KitsCommercial Type: V46A, V46D,

V47A, V47NOld Construction: 246P, 246T

Maritime andNavy Type: V46B, V46C

Old Construction: 246MP, 246NP

DiaphragmKits for

All Types

Individual PartDescription

Seat Guide Post 1 1 1 1 1 1 1 1 1 1 1Disc Stud 1 1 1 1 1 1 1 1 1 1 1Disc Cup (Retainer) 1 1 1 1 1 1 1 1 1 1 1Valve Disc 1 1 1 1 1 1 1 1 1 1 1 1 1 1Valve Seat 1 1 1 1 1 1 1 1 1 1 1 1 1 1Valve Stem 1 1 1 1 1 1 1 1 1 1 1Rubber Diaphragm* 4 4 4 4 5 5 5 5 4 4 4 5 5 5 5 5Guide Plate Gasket 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1Bellows Sealing Ring 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1Valve Assembly Screw 1 1 1Guide Post 1 1 1Valve Disc Retainer 1 1 1Extension Sleeve 1 1 1Seat Wrench 1 1 1 1 1 1 1 1 1 1 1Sensing Element Contact Application Engineering at (414)-274-5535Stem Washer 1ISO-loss Washer** 1 1 1O-ring Seals 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.


Notes


Notes

Controls Group507 E. Michigan StreetP.O. Box 423Milwaukee, WI 53201 Printed in U.S.A.

universal analyzers model 1190 vortex sample cooler-revd

Documents

gas sample inlet fitting

maximum inlet gas dewpoint

gas components

warranty period

water drain fitting

limited warranty

stp maximum inlet temperature

maximum ambient temperature