VRS & VRSH

Twin Screw Compressor

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 Important Note:

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

The following instructions have been prepared to assist in installation, operation and removal of Vilter Twin Screw
Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation.

The entire manual should be reviewed before attempting to install, service or repair the compressor.

A refrigeration compressor is a positive displacement machine. It is designed to pump superheated vapor. The
compressor must not be subjected to liquid carry over. Care must be exercised in properly designing and maintain-
ing the system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing LLC is not responsible
for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing LLC cannot
warrant equipment damaged by improperly protected or operating systems.

Vilter Twin Screw Compressors components are thoroughly inspected at the factory, assuring the shipment of a
mechanically perfect piece of equipment. Damage can occur in shipment, however. For this reason, the units should
be thoroughly inspected upon arrival. Any damage noted should be reported immediately to the Transportation
Company. This way, an authorized agent can examine the unit, determine the extent of damage and take neces-
sary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilter representative or
the home office should be notified of any claim made.

All inquires should include the Vilter order number, compressor serial and model number. These can be found on
the compressor name plate on the compressor.

All requests for information, services and or parts should be directed to:

Vilter Manufacturing LLC

Customer Service Department
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: vilter@execpc.com
Equipment Identification Numbers:

Vilter Order Number: __________________________Serial Number: _____________

Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________

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 Table of Contents

INSTALLATION............................................................................................ 13
DELIVERY INSPECTION ...............................................................................................................................13
FOUNDATIONS ...........................................................................................................................................13
LOCATING UNIT - .......................................................................................................................................13
DRIVE COUPLING ALIGNMENT ....................................................................................................................13
SYSTEM PIPING ..........................................................................................................................................13
ELECTRICAL CONNECTIONS ........................................................................................................................14

TESTING REFRIGERATION SYSTEM FOR LEAKS .............................................................................................15

A. AMMONIA SYSTEMS ...................................................................................................................................15
B. HALOCARBON REFRIGERANT SYSTEMS .......................................................................................................15
C. EVACUATING THE SYSTEM...........................................................................................................................16
UNIT OIL CHARGING ...................................................................................................................................17
A. OIL FOR SCREW COMPRESSORS ..................................................................................................................17
SYSTEM REFRIGERANT CHARGING ..............................................................................................................17
A. LOW SIDE EQUIPMENT ................................................................................................................................17
B. COMPRESSORS ...........................................................................................................................................17
C. CONDENSERS..............................................................................................................................................18
D. CONTROLS ..................................................................................................................................................18
E. INITIAL CHARGING HIGH SIDE CHARGING .................................................................................................18
MAINTENANCE SUGGESTIONS ....................................................................................................................18
A. DAILY ..........................................................................................................................................................19
B. WEEKLY.......................................................................................................................................................19
C. MONTHLY ...................................................................................................................................................19
D. TRIMONTHLY ..............................................................................................................................................19
E. YEARLY .......................................................................................................................................................19
F. SYSTEM LEAKS ............................................................................................................................................20
G. YEAR ROUND OPERATION ...........................................................................................................................20
STOP CHECK INSTALLATION............................................................................................................................23

OPERATION................................................................................................ 24
NOTICE ON USING NON-VILTER OILS ...........................................................................................................24
OIL SYSTEM ...............................................................................................................................................25
A. OIL CHARGE ................................................................................................................................................25
B. OIL FILTERS .................................................................................................................................................25
C. OIL PRESSURE REGULATING .........................................................................................................................27
D. OIL COOLING ..............................................................................................................................................27
1. WATER COOLED OIL COOLER .......................................................................................................................27
2. LIQUID INJECTION OIL COOLING ..................................................................................................................28
3. V-PLUS OIL COOLING SYSTEM......................................................................................................................28
4. THERMOSYPHON OIL COOLING ..................................................................................................................28
CONTROL SYSTEM ......................................................................................................................................29
SCREW COMPRESSOR CONTROL AND OPERATION.............................................................................................29
SAFETY SETPOINTS ............................................................................................................................................30
INITIAL START-UP ....................................................................................... 30
SETTING OF CONTROLS ..............................................................................................................................30
VALVE SETTINGS ........................................................................................................................................30
OIL SEPARATOR ..........................................................................................................................................30
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 Table of Contents

V-PLUS OIL COOLING ..................................................................................................................................31

LIQUID INJECTION OIL COOLING..................................................................................................................31
WATER COOLED OIL COOLER ......................................................................................................................31
STOP/CHECK OPERATION ...........................................................................................................................32

COMPRESSOR PRE START-UP CHECK LISTS ............................................. 34-35

RECOMMENDED SERVICE INTERVALS .......................................................... 36

VENDOR DOCUMENTATION SECTION .......................................................... 39

COUPLING INFORMATION .............................................................................................................................

COMPRESSOR INFORMATION ........................................................................................................................

WRV & WRVI INSTALLATION ............................................................................................................................
WRV & WRVI SERVICE MANUAL .......................................................................................................................
HOWDEN SPARE PARTS ...................................................................................................................................
HOWDEN DRAWING R20737 ..........................................................................................................................

PUMP INFORMATION ....................................................................................................................................

HAIGHT...........................................................................................................................................................
VIKING ............................................................................................................................................................

STRAINER INFORMATION ..............................................................................................................................

DANFOSS ........................................................................................................................................................
PARKER ...........................................................................................................................................................
HANSEN ..........................................................................................................................................................

VALVE DOCUMENTATION ..............................................................................................................................

PARKER CHECK ...............................................................................................................................................
DANFOSS REGULATING ...................................................................................................................................
DANFOSS MOTORIZED ...................................................................................................................................
SPORLAN EXPANSION .....................................................................................................................................
SPORLAN PDA VALVE .......................................................................................................................................
HANSEN INLINE CHECK ...................................................................................................................................
HANSEN HA4AOAS..........................................................................................................................................
HANSEN BUTT WELD.......................................................................................................................................
HANSEN HA4A ................................................................................................................................................
HANSEN HAND EXPANSION ............................................................................................................................
HANSEN SOCKET WELD...................................................................................................................................

MISC .............................................................................................................................................................
HEATER ...........................................................................................................................................................
CAPACITY LPI ..................................................................................................................................................
LPI DESCRIPTION & INSTRUCTION ...................................................................................................................
2895 KEYPAD WIRING .....................................................................................................................................
COUPLINGS .....................................................................................................................................................
ACTUATOR .....................................................................................................................................................

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 Notes Page

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Notes Page

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 Long Term Storage
Requirements

The procedure described is a general recommendation for extended storage (over one month of no opera-
tion) of Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of
the commonly encountered situations, it is the responsibility of the installation firm and end user to address
any unusual conditions. We suggest using the accompanying Long Term Storage Log sheet for recording
purposes to validate the appropriate procedures.

Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification
of the system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system
before refrigerant is introduced. The oil circuit of any compressor is to be primed at initial start-up through
the oil gauge connection on reciprocating compressors and the pre-lube oil pump on screw compressors.

Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.

If the unit is designed for indoor duty, it must be stored in a heated building.

If the unit is designed for outdoor duty, and is to be stored outdoors, a canvas tarp is recommended
for protection until installation is imminent. Adequate drainage should be provided, by placing wood
blocks under the base skid, so that water does not collect inside the base perimeter or low spots in
the tarp.

All compressor stop valves are to be closed to isolate the compressor from the remainder of the
system. All other valves, except those venting to atmosphere, are to be open. It is essential that the
nitrogen holding charge integrity be maintained.

Cover all bare metal surfaces (coupling, flange faces, etc.) with rust inhibitor.

Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to be
energized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light
bulb. Use an approved electrical spray-on corrosion inhibitor for panel components (relays, switches,
etc.)

All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed
with desiccant bags inside.

System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5
psi above atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be neces-
sary to add a gauge to monitor the system holding charge pressure. If a drop in pressure occurs, the
source of leakage must be found and corrected. The system must be evacuated and recharged with
dry nitrogen to maintain the package integrity.

Motors (NOTE: The following are general recommendations. Consult the manufacturer of your
motor for specific recommendations.)

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 Long Term Storage
Requirements

1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into
the openings. Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets
and outlets of drip-proof type motors.

NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when the unit is
prepared for service.

2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.

3) If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent
plastic bag. Before sealing this bag, a moisture indicator should be attached to the side of the motor
and several bags of silica-gel desiccant put inside the bag, around the motor. When the moisture
indicator shows that the desiccant has lost its effectiveness, as by a change in color, the bag should
be opened and fresh replacement desiccants installed.

Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least
10F above the ambient temperature.

NOTE: There is a potential for damage by small rodents and other animals that will inhabit motors in
search of warm surroundings or food. Due to this, a possibility of motor winding destruction
exists. Sealing motor openings should restrict access to the motor.

4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat
spots on the bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all
oil line valves and run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue
running the oil pump while the compressor shaft is being turned to help lubricate the surfaces of the
shaft seal.

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 Installation
Section

INSTALLATION............................................................................................ 13
DELIVERY INSPECTION ...............................................................................................................................13
FOUNDATIONS ...........................................................................................................................................13
LOCATING UNIT - .......................................................................................................................................13
DRIVE COUPLING ALIGNMENT ....................................................................................................................13
SYSTEM PIPING ..........................................................................................................................................13
ELECTRICAL CONNECTIONS ........................................................................................................................14

TESTING REFRIGERATION SYSTEM FOR LEAKS .............................................................................................15

A. AMMONIA SYSTEMS ...................................................................................................................................15
B. HALOCARBON REFRIGERANT SYSTEMS .......................................................................................................15
C. EVACUATING THE SYSTEM...........................................................................................................................16

UNIT OIL CHARGING ...................................................................................................................................17

A. OIL FOR SCREW COMPRESSORS ..................................................................................................................17

SYSTEM REFRIGERANT CHARGING ..............................................................................................................17

A. LOW SIDE EQUIPMENT ................................................................................................................................17
B. COMPRESSORS ...........................................................................................................................................17
C. CONDENSERS..............................................................................................................................................18
D. CONTROLS ..................................................................................................................................................18
E. INITIAL CHARGING HIGH SIDE CHARGING .................................................................................................18

MAINTENANCE SUGGESTIONS ....................................................................................................................18

A. DAILY ..........................................................................................................................................................19
B. WEEKLY.......................................................................................................................................................19
C. MONTHLY ...................................................................................................................................................19
D. TRIMONTHLY ..............................................................................................................................................19
E. YEARLY .......................................................................................................................................................19
F. SYSTEM LEAKS ............................................................................................................................................20
G. YEAR ROUND OPERATION ...........................................................................................................................20
STOP CHECK INSTALLATION............................................................................................................................23

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 Installation

DELIVERY INSPECTION LOCATING UNIT -

DRIVE COUPLING ALIGNMENT
Vilter Twin Screw Compressor components are
thoroughly inspected at the factory, assuring the The Twin Screw Compressor units are shipped with
shipment of a mechanically perfect piece of equip- all major components mounted on structural steel.
ment. Damage can occur in shipment, however. Place the entire unit on the floor on a concrete pad
For this reason, the units should be thoroughly and securely bolt in place. Review local codes and
inspected upon arrival. Any damage noted should ASHRAE Safety Code for Mechanical Refrigeration.
be reported immediately to the transportation com- Bolt holes are located in the units mounting feet.
pany. This way, an authorized agent can examine When locating the unit, provide adequate space for
the unit, determine the extent of damage and take service work. When the compressor unit is in place
necessary steps to rectify the claim with no serious on the concrete pad, check both lengthwise and
or costly delays. At the same time, the local Vilter crosswise to assure it is level. Use shims and wedges
representative or the home office should be notified as needed under the mounting feet to adjust the
of any claim made. level of the unit.

TABLE 1 UNIT WEIGHTS On twin screw units, the motor and compressor have
been roughly aligned at the factory. The coupling
VILTER CFM WT# center section was shipped loose to allow a check
MODEL of proper electrical phasing, direction of rotation
VRS 400 398 4,200 of the motor and final coupling alignment. The dial
VRS 500 479 4,700 indicator alignment method is recommended. Final
VRS 600 568 5,300 alignment should be within 0.004 inches total indica-
VRS 700 772 5,400 tor reading in all direction for all models.
VRS 900 852 6,400
VRS 1000 959 7,500 SYSTEM PIPING
VRS 1200 1111 8,500
VRS 1300 1262 8,700 Refer to the ANSI/ASME B31.5 Code for Refrigeration
VRS 1500 1509 8,800 Piping. All compressor oil supply and oil return pip-
VRS 1700 1667 11,000 ing has been completed at the factory. The neces-
VRSH 1900 1879 11,400 sary connections to be made to the screw compres-
VRSH 2200 2222 12,000 sor unit will vary depending on the type of oil cooling
VRSH 2700 2670 16,800 method purchased. Main line refrigerant suction and
VRSH 3400 3337 17,500 discharge connections are always necessary.
VRSH 3700 3754 18,500
VRSH 4500 4510 19,500 Care must be taken to avoid trapping the lines ex-
Weights are approximate. cept for specific purposes. When traps are used, the
horizontal dimensions should be as short as possible
to avoid excessive oil trapping.
FOUNDATIONS
Lines for ammonia systems must be of steel pipe with
Vilter Twin Screw Compressor units are basically specially designed ammonia service fittings. Com-
vibration free machines, therefore, no elaborate mon pipe fittings must NEVER be used as they will
foundations are necessary. The floor or founda- not provide the same service. Steel pipe is generally
tion upon which the unit will be placed should be used in large installations when joints are welded.
designed to support the entire operating weight of
the unit. See Table 1 for unit weights. In making up joints for steel pipe, the following pro-
cedures should be followed:

For threaded connections, all threads on the pipe

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 Installation

and fitting should be carefully cleaned to remove all In larger pipe sizes, wrought fittings are not avail-
traces of grease or oil. Threads should then be wiped able. However, specially tested cast fittings are avail-
dry with a lintless cloth. Only thread filling com- able and these may be used with complete safety.
pounds suitable for refrigeration service should be
used for making steel pipe joints. These compounds When soldering copper tubing joints, only silver sol-
should be used sparingly, and on the pipe only. Do der should be used for Refrigerant-22 service. Soft
not put any on the first two threads to prevent any solder such as 50-50 should never be used, as its
of the compound from entering the piping system. melting point is to low, lacks mechanical strength,
Acetylene or arc welding is frequently used in mak- and tends to break down chemically in the presence
ing steel pipe joints, however, only a skilled welder of moisture.
should attempt this kind of work. Take care to see
no foreign materials are left in the pipes and remove A second method would be to install flexible pipe
all burrs formed when cutting pipe. couplings as close to the compressor unit as possible
with connections run in two different directions,
It is important to avoid short, rigid pipe lines that do 90 apart. These flexible connections should be
not allow any degree of flexibility. This must be done installed on both the high and low side lines of the
to prevent vibration being transmitted through the compressor unit.
pipe lines to the buildings. One method of provid-
ing the needed flexibility to absorb the vibration is Hangers and supports for coils and pipe lines should
to provide long lines that are broken by 90 Ells in receive careful attention. During prolonged op-
three directions. eration of the coils, they may become coated with
ice and frost, adding extra weight to the coil. The
Smaller Halocarbon and Hydroflourocarbon instal- hangers must have ample strength and be securely
lations use copper pipes with solder type fittings anchored to withstand the vibration from the com-
where possible. The use of screw type fittings in pressor and adequately support the pipe lines.
Halocarbon systems should be held to an absolute
minimum, as these refrigerants, due to their physi- Water supply and drain connections, and equipment
cal properties, will leak through screw type joints. using water, should be installed so all the water
may be drained from the system after the plant has
When drawn copper tubing is used for Halocarbon been shut down in cold weather. These precautions
lines, type K or L conforming to ASTM B88 will avoid costly damage to the equipment due to
should be used. Soft annealed copper tubing con- freezing.
forming to ASTM B280 can also be used for tube sizes
not larger than 1-3/8 in outside diameter. These This information is taken from ASHRAE 15-89 and
requirements are in accordance with the mechani- ANSI B31.5. The installing contractor should be
cal code for refrigeration ANSI B9.1-1971. The type thoroughly familiar with these codes, as well as any
of copper tubing to be used for a given pressure local codes.
is dependent on the strength of the copper at the
design temperature. Some local codes forbid the ELECTRICAL CONNECTIONS
use of Type L. Therefore, before installation, be
sure to check local requirements. Never use type The screw compressor units are shipped with all
M as it does not have adequate wall thickness to package mounted controls wired. The standard
withstand the operating pressures. In selecting fit- control power is 115 volts 60 Hertz, single phase.
tings for Halocarbon piping, only wrought copper If a 115 volt supply is not available, a control trans-
fittings should be used. Cast fittings as used for former may be required. The power source must
water service are porous and will allow the refriger- be connected to the control panel according to the
ant to escape. Note this exception: In larger pipe electrical diagrams.
sizes, wrought fittings are not available. However,
specially tested cast fittings are available and these The units are shipped without the compressor mo-
may be used with complete safety. tor starter. Field wiring is required between the field

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 Installation

mounted starters and package mounted motors. The gas may be put into the system through the
charging valve or any other suitable opening. Adjust
Additional control wiring in the field is also required. the pressure regulator on the bottle to prevent over-
Dry contacts are provided in the control panel for pressurization. Do not exceed the pressure rating on
starting the screw compressor motor. These con- the vessel with the lowest pressure rating.
tacts are to be wired in series with the starter coils.
A current transformer is supplied along with the Carbon Dioxide should NOT be used as a testing gas
compressor unit, and is located in the motor junction in a system where ammonia is already dissolved in
box. This transformer is to be installed around one any moisture remaining. This will cause ammonium
phase of the compressor motor starter. A normally carbonate to precipitate when the CO2 is added. If
open auxiliary contact from the compressor motor heavy enough, this precipitate may cause the ma-
starter is also required. chine to freeze and clog the strainer.

Terminal locations for this wiring can be found on the A mixture of four parts water to one part liquid soap,
wiring diagram supplied with this unit. Additional with a few drops of glycerin added, makes a good
aspects of the electrical operation of the screw units solution. Apply this mixture with a one inch round
are covered in the start up and operation section of brush at all flanges, threaded joints, and welds. Re-
this manual. pair all visible leaks. If possible, leave the pressure
on over night. A small pressure drop of 5 lbs. Over
this period indicates a very tight system.
TESTING REFRIGERATION SYSTEM FOR LEAKS
Remember to note the ambient temperature, as a
Vilter equipment is tested for leaks at the factory. change in temperature will cause a change in pres-
One the most important steps in putting a refrigera- sure.
tion system into operation is field testing for leaks.
This must be done to assure a tight system that will After the system is thoroughly tested, open all valves
operate without any appreciable loss of refrigerant. on the lowest part of the system so the gas will float
To test for leaks, the system pressure must be built away from the compressor. This prevents any dirt or
up. Test pressures for various refrigerants are listed foreign particles from entering the compressor and
in ANSI B9.1-1971 code brochure entitle Safety contaminating the working parts. The oil should
Code for Mechanical Refrigeration. These pressures then be charged into the compressor.
will usually suffice, however, it is advisable to check
local codes as they may differ. Before testing may Charge a small amount of ammonia into the system
proceed, several things must be done. and pressurize the system to its respective design
pressure. Pass a lit sulfur stick around all joints and
First, if test pressures exceed the settings of the connections. Any leaks will be indicated by a heavy
system, relief valves or safety devices, they must cloud of smoke. If any leaks are observed during this
be removed and the connection plugged during the test, they must be repaired and rechecked before
test. Secondly, all valves should be opened except the system can be considered tight and ready for
those leading to the atmosphere. Then, open all evacuation.
solenoids and pressure regulators by the manual
lifting stems. All bypass arrangements must also B. Halocarbon Refrigerant Systems
be opened. Because of differences in characteristics
of the various refrigerants, two different testing Oil pumped dry nitrogen, or anhydrous CO2 in this
methods are necessary. order of preference may be used to raise the pressure
to the proper level for testing.
A. Ammonia Systems
When the proper pressure is attained, test for leaks
Dry nitrogen may be used to raise the pressure in with the soap mixture previously described. After
an ammonia system to the proper level for the test. all leaks are found and marked, relieve the system

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 Installation

pressure and repair the leaks. Never attempt to low absolute pressure required for complete system
repair soldered or welded joints while the system is evacuation.
under pressure. Soldered joints should be opened
and re soldered. Connect the high vacuum pump into the refrigera-
tion system by using the manufacturers instructions.
Do not simply add more solder to the leaking joint. Connect the pump both to the high side and low side
After all the joints have been repaired and the sys- of the system, to insure system evacuation. Attach
tem is considered tight the system may be tested the vacuum gauge to the system in accordance with
with refrigerant. the manufacturers instructions.

Attach a drum of the refrigerant to be used in the A single evacuation of the system does not satisfacto-
system and allow the gas to enter until a pressure rily remove all of the non-condensable, air and water
of 5 psig is reached. vapor. To do a complete job, a triple evacuation is
recommended.
Remove the refrigerant drum and bring the pressure
to the recommended test level with oil pumped When the pump is first turned on, bring system
dry nitrogen or CO2. Then check the entire system pressure to as low a vacuum level as possible, and
again for leaks, using a halide torch or electronic continue operation for 5 to 6 hours.
leak detector. Be sure to check all flanged, welded,
screwed and soldered joints, all gasketed joints, and Stop the pump and isolate the system. Allow the unit
all parting lines on castings. If any leaks are found, to stand at this vacuum for another 5 to 6 hours. After
they must be repaired and rechecked before the this time, break, the vacuum and bring the system
system can be considered tight again, remembering pressure up to 0 psig with dry nitrogen.
that no repair should be made to welded or soldered
joins while the system is under pressure. To begin the second evacuation, allow the pump to
operate and reduce the pressure again to within 50
C. Evacuating The System to 1000 microns. After this reading is reached, allow
the pump to operate 2 or 3 hours. Stop the pump
A refrigeration system operates best when only re- and let the system stand with this vacuum. Again
frigerant is present. Steps must be taken to remove using dry nitrogen, raise the system pressure to zero.
all air, water, vapor, and all other non-condensables
from the system before charging it with refrigerant. For the third evacuation, follow the previous proce-
A combination of moisture and refrigerant, along dure with the pump operating until system pressure
with any oxygen in the system, can form acids or is reduced below the 1000 micron level. Run the
other corrosive compounds that corrode internal pump an additional 6 hours and hold the system for
parts of the system. approximately 12 hours at low pressure. After this,
again break the vacuum with dry nitrogen and al-
To properly evacuate the system, and to remove all low the pressure in the system to rise slightly above
non-condensables, air and water vapor, use a high zero pounds (psig). Install new drier cartridges and
vacuum pump capable of attaining a blanked off moisture indicators. Charge the system once more
pressure of 50 microns or less. Attach this pump to below the 1000 micron level and use the refrigerant
the system and allow it to operate until system pres- designed for the system.
sure is reduced somewhere below 1000 microns.
Evacuation should not be done unless the room When properly evacuating the system as outlined
temperature is 60F or higher. above, the system is dry, oxygen-free and free of non-
condensables. The piping should not be insulated
Attach vacuum gauge(s), reading in the 20 to before the evacuation process is started. If moisture
20,000 micron gauge range, to the refrigerant sys- is in the system before evacuating, it condenses in
tem. These gauge(s) should be used in conjunction low places and freezes. If this happens, it can be re-
with the high vacuum pump. The reading from the moved by gently heating the trap farthest away from
gauge(s) indicates when the system has reached the
16
 Installation

the vacuum pump. This causes the ice to melt and A. Oil For Screw Compressors
water to boil. Water vapor collects in the next trap
towards the vacuum pump. This process should be Due to the need for adequate lubrication, Vilter
repeated until all pockets of water have been boiled recommends only the use of Vilter lubricants, de-
off, and the vacuum pump has had a chance to re- signed specifically for Vilter compressors. With the
move all the water vapor from the system. extensive research that has been performed, we are
able to offer refrigerant specific lubricating oils. Use
UNIT OIL CHARGING of oil not specified or supplied by Vilter will void the
compressor warranty.
The compressor unit is shipped from Vilter with no
oil charge. The initial oil charge can be made through Please contact your local Vilter representative or the
the drain valve at the oil receiver/separator. Vilter Home Office for further information.
motor driven and manually operated oil chargers
are available for this purpose. Once the unit has SYSTEM REFRIGERANT CHARGING
been started and is operating above 50% capacity,
oil may have to be added to bring the oil level to the CAUTION
normal operating point. With the unit operating, oil When charging the system, make sure the compres-
should be added through the charging connection sor unit is pressurized from the discharge side of the
at the suction strainer. The normal operating level compressor. Pressurizing the compressor from the
is between the (2) sight glasses on the oil separator. suction side may cause rotation of the compressor,
See Table 2 for approximate oil charge requirements. without oil supply, which could lead to internal dam-
age.
TABLE 2. OIL CHARGE
After the system is leak-free and evacuation has
Oil Sep. *Approximate Oil been completed, it is ready for charging. Before
Size Charge Gallons actual charging, however, the entire operation of
VRS Models the refrigeration system should be inspected as
16 20 to 27 outlined below:
20 22 to 31
A. Low Side Equipment
24 40 to 50
30 60 to 75 1. Fans on air handling equipment running.
36 95 to 105 2. Pumps on water cooling equipment running.
42 145 to 165 3. Proper location and attachment of thermo-
VRSH Models static expansion valve bulb to suction line.
36 95 to 105 4. Correct fan and pump rotation.
42 145 to 165 5. Evaporator pressure regulators and solenoid
48 valves open.
54 6. Water pumps and motors correctly aligned.
7. Belt drives correctly aligned and tensioned.
* Based on nember of oil filters method of oil cooling 8. Proper voltage to motors.

The oil level may be above the top sight glass at this B. Compressors
time. Later, when the unit is placed in operation,
there will be some drop in the oil level as the various 1. Proper oil level.
oil lines, oil filter and other piping becomes charged 2. Voltage agrees with motor characteristics.
with the normal amount of oil that will be in circula- 3. Properly sized motor fuses and heaters.
tion. This drop in oil level should bring the level in 4. Direct drivers aligned and couplings tight.
the oil receiver/separator into the normal operating 5. All suction and discharge valves open.
range. Do not mix oils. 6. All transducers and RTDs calibrated and reading
correctly.
17
 Installation

C. Condensers Water freezing in a chiller can rupture the tubes

and cause extensive damage to the system. It
1. Water available at water cooled condensers and would be desirable to charge the initial amount
supply line valve open. of refrigerant without water in the shell and tube
2. Water in receiver of evaporative condenser and equipment to eliminate the possibility of freeze
makeup water available. up.
3. Correct rotation of pump and fan motors.
4. Belt drives aligned and tensioned correctly. 3. After some refrigerant has entered the system,
5. Pump, fans and motors lubricated. the compressor unit starting procedure may be
followed. See Start-Up and Operation Section
D. Controls of this manual.

Controls should be at the initial set points. See 4. Continue charging refrigerant into the system
microprocessor manual for further information. until the proper operating requirements are
satisfied. Then, close the liquid charging con-
E. Initial Charging High Side Charging nection and open the liquid line valve allowing
the system to operate normally. To check that
There are two methods of charging refrigerant enough refrigerant has been added, the liquid
into the system, through the high side or sight glass should show no bubbles, and there
through the low side. High side charging is will be a liquid seal in the receiver. If these two
usually used for initial charging as filling of the conditions are not satisfied, additional refriger-
system is much faster. Low side charging is usu- ant must be added.
ally reserved for adding only small amounts of
refrigerant after the system is in operation. 5. When sufficient refrigerant has been charged
into the system, close the charging and drum
High side charging of refrigerant into the system valves. Then remove the drum from the system.
is accomplished as follows:
6. During the charging period, observe the gauge
1. Connect a full drum of refrigerant to the liquid carefully to insure no operating difficulties.
charging valve. This valve is generally located Watch head pressures closely to make sure the
in the liquid line immediately after the king or condensers are functioning properly.
liquid line valve. Purge the air from the charging
line. Since it is usually necessary to use several drums
when charging a system, follow the procedures
2. Invert the refrigerant drum if the drum is not in paragraphs E1 and E2 of the above description
equipped with Liquid and Vapor valves, and when attaching a new drum. After charging,
place in such a position so the liquid refrigerant the refrigerant drums should be kept nearby for
only can enter the system. Close the liquid line several days as it is sometimes necessary to add
or king valve, if it is not already closed. Open more refrigerant as the system settles down.
the Liquid charging valve slowly to allow re-
frigerant to enter the system. The vacuum in MAINTENANCE SUGGESTIONS
the system will draw in the refrigerant.
Careful checking of a refrigeration system for leaks
It is important that, during this operation, air and proper operation of all components upon instal-
handling units be running and water is circulat- lation will start the system on its way to a long life of
ing through the chillers. The low pressures on satisfactory service. To ensure the desired trouble-
the system can cause the refrigerant to boil at free operation, however, a systematic maintenance
low temperature and possibly freeze the water program is a prerequisite. The following mainte-
if it is not kept circulating. nance schedule is suggested.

18
 Installation

A. Daily D. Trimonthly
(About 2000 operating hours)
1. Check oil levels.
Check movement of compressor rotor at drive
2. Check all pressure and temperature readings. coupling end to determine bearing float. (Refer
to Service Section.)
3. Check micronic oil filter inlet and outlet pres-
sures for excessive pressure drop. Change filter E. Yearly
when pressure drop exceeds 15 psi or every (Items 1 thru 13 and D above plus 14 thru 28)
six months, whichever occurs first. For proper
procedure for changing micronic oil filter and 14. Check entire system thoroughly for leaks.
for charging oil into the system, see Operation
Section. 15. Remove all rust from equipment, clean and
paint.
4. Clean strainers each time filter cartridge if re-
placed. 16. Flush out sediment, etc. from water circuits.

5. Check compressor sound for abnormal noises. 17. Clean all oil strainers.

6. Check shaft seals for excessive oil leakage. A 18. Clean suction strainer compressors.
small amount of oil leakage is normal. This al-
lows lubrication of the seal faces. 19. Check motors and fans for shaft wear and end
play.
B. Weekly
(Items 1 thru 6 above plus 7 thru 9) 20. Check operation and general condition of mi-
croprocessor and other electrical controls.
7. Check the refrigeration system for leaks with a
suitable leak detector. 21. Clean all water strainers.

8. Check oil pressures and review microprocessor 22. Check drains to make sure water will flow away
log and log sheets. from equipment.

9. Check refrigerant levels in vessels. 23. Drain and clean entire oil system at receiver
drain. Recharge with new clean moisture free
C. Monthly oil. For proper procedure for changing micronic
(Items 1 thru 8 above plus 9 thru 13) oil filter and charging oil into the system, see
Start-Up and Operation section.
10. Oil all motors and bearings. Follow manufac-
turers instructions on lubrication. 24. Check compressor coupling. For integrity and
alignment.
11. Check calibration and operation of all controls,
particularly safety controls. 25. Check oil pump for wear.

12. Check oil cooler for any evidence of corrosion, 26. Check the calibration of the microprocessor
scaling or other fouling. pressure transducers and RTDs for accuracy.

13. Operate compressor capacity through the range 27. Check mounting bolts for compressor and mo-
both automatically and manually. tor.

19
 Installation

System Leaks Coupling Information

There are any number of reasons why leaks All coupling information can be found in the vnedior
develop in a refrigeration system (i.e. such as section of this manual.
drying out of valve packing, yielding of gaskets,
improper replacement of valve caps and loosen-
ing of joints due to vibration). For these reasons,
the need for periodic leak testing cannot be over-
emphasized. Similarly, when any service opera-
tions are performed on the system, care should
be exercised to insure all opened flanges are
tightened, all plugs that were removed are re-
placed with a suitable thread filling compound,
all packing glands on valve stems are tightened,
and all valve caps are replaced. When operation
is restored, all joints opened or any valves moved
during the servicing should be checked for leaks.

G. Year Round Operation

On a continual basis:

1. Guard against liquid slugging of compressor.

2. Maintain unit in clean condition and paint as

necessary.

3. Grease valve stems and threads for the valve

caps.

When refrigeration equipment is operated 24

hours a day year round, it is highly recommend-
ed that a yearly check of all internal parts be
made (see Service Section). While the highest
material standards are maintained throughout
all Vilter compressors, continuous operation
and any presence of dirt may prove injurious to
the machine. To forestall needless shutdowns
or prevent possible machine breakdowns, the
side covers should be removed yearly, and a
visual inspection be made of the internal parts.
In this way, a small amount of time spent check-
ing machine conditions once a year may prevent
extensive shutdowns later with subsequent
product loss and expensive repairs.

20
 Stop Check Installation
Name

Name

Stem should always be

positioned upwards.

Correct Correct

Wrong

Wrong
Wrong

Verify the location of spring.

The spring should be positioned
below the stem.

Installation: The new design will apply only to the 2 thru 4 stop valves. Retrofitting a field instal-
lation will require replacing the bonnet assembly.

The bonnet must be installed with the spring towards the bottom (see illustrations above), the spring should
be positioned below the stem. The drill fixture is designed so that the hole for the spring will always be
drilled on the opposite side from the cast-in Vilter name on the bonnet. From the outside of the valve, the
casting numbers must always be towards the top of the valve.

See Operation Section on Stop Check Operation.

21
22
 Operation

OPERATION ............................................................................................... 24
NOTICE ON USING NON-VILTER OILS .......................................................................................................... 24

OIL SYSTEM .............................................................................................................................................. 25

A. OIL CHARGE ................................................................................................................................................ 25
B. OIL FILTERS ................................................................................................................................................. 25
C. OIL PRESSURE REGULATING ......................................................................................................................... 27
D. OIL COOLING .............................................................................................................................................. 27
1. WATER COOLED OIL COOLER ....................................................................................................................... 27
2. LIQUID INJECTION OIL COOLING ..................................................................................................................28
3. V-PLUS OIL COOLING SYSTEM......................................................................................................................28
4. THERMOSYPHON OIL COOLING ..................................................................................................................28

CONTROL SYSTEM ..................................................................................................................................... 29

SCREW COMPRESSOR CONTROL AND OPERATION.............................................................................................29
SAFETY SETPOINTS ............................................................................................................................................30

INITIAL START-UP ....................................................................................... 30

SETTING OF CONTROLS .....................................................................................................................................30
VALVE SETTINGS ................................................................................................................................................30
OIL SEPARATOR .................................................................................................................................................30
V-PLUS OIL COOLING ......................................................................................................................................... 31
LIQUID INJECTION OIL COOLING ........................................................................................................................ 31
WATER COOLED OIL COOLER ............................................................................................................................. 31
STOP/CHECK OPERATION .................................................................................................................................. 32

23
 Operation

Notice on using Non-Vilter Oils

Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOT APPROVE
non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available it is not possible
for us to test all oils offered in the market place, and their effects on our equipment, as we can with our own
lubricants.

We realize that customers may choose compressor lubricants other than Vilter branded oil. This is certainly
within the customers right as owners of the equipment. When this choice is made, however, Vilter is unable
to accept responsibility for any detrimental affects those lubricants may have on the equipment or system
performance and durability.

Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty upon
evaluation of the issue. This includes any parts failure caused by inadequate lubrication.

Certainly, there are many good refrigeration lubricants in the market place. The choice of a lubricant for a
particular application involves consideration of many aspects of the lubricant and how it and its additive
package, will react in the various parts of the entire refrigeration system. It is a complex choice that depends
on a combination of field experience, lab and field-testing, and knowledge of lubricant chosen. Vilter will not
accept those risks other than for our own compressor lubricants.

24
 Operation

OIL SYSTEM block and bleed assembly, or at the bleed valve

for the oil filter housing. Be sure to follow all Lo-
A. Oil Charge cal, State and Federal ordinances regarding the
recovery of refrigerants.
Charge the combination oil receiver/separator
with the proper quantity of lubricating oil (see
Installation Section).

CAUTION
It is imperative you charge the oil into the receiver/
separator prior to energizing the control panel to
prevent burning out the immersion heater in the
separator/receiver.

During operation, maintain the receiver/separator

oil level in the normal operating range between the
two bullseye sight glasses. If the oil level is visible
only in the lowest sight glass, add oil to the operat-
ing compressor through the connection located at
the compressor suction inlet. Pump oil into the FIGURE 1.
compressor until the oil level in the separator is TYPICAL CANISTER TYPE FILTER CROSS SECTION
between the two bullseye sight glasses. Watch this
level carefully to maintain proper operation. Never
allow the oil to reach a level higher than indicated Drain the filter bowl or housing in to an appropri-
on the highest sight glass, since this may impair ate container and dispose of the oil in a appropri-
the operation and efficiency of the oil separator ate manner following all Local, State and Federal
portion of this combination vessel. ordinances regarding the disposal of used refrig-
eration oil.
B. Oil Filters
Loosen and remove the locking ring on filter tank
Change the oil filter after the first 200 hours of by turning in a counter clockwise direction. Re-
operation, as noted on the hour meter. Thereafter, move filter tank with the used element.
replace the filter every six months, or when the oil
pressure drop through the filter reaches 15 psi, Remove the filter element from the tank. Be-
whichever occurs first. The pressure drop across fore reassembling, thoroughly clean the tank to
the filter is read on the microprocessor panel. lengthen the life span of the filter element.
Check the pressure drop and record it daily.
Wet the threads and O-ring on the head and the O-
To prepare for the removal of the filter, shut down ring in the new element with clean refrigeration oil.
the compressor. Isolate the filter housing ap-
propriately. If unit is equipped with duplex filter CAUTION
housings the unit does not have to be shut down, Do not use a pipe wrench, hammer or any other
however the filter to be serviced must be isolated tool to tighten the locking ring.
before the tank or bowl can be opened.
Insert new element into the filter tank with the
1. Filter Removal and installation, all VRSH open end visible. Attach tank to head and HAND
Units. TIGHTEN the locking ring.

Release the pressure in the oil filter housing by The filter housing can be evacuated and then
opening the bleed valves at the stop valve in the slowly pressurized to check for leaks before return-
ing to service.
25
 Operation

2. Filter Removal, VRSH (after 5/1/00) when Loosen and remove the cover on the bowl of the
using Vilter Part Numbers 3111A (16 Simplex), filter tank by turning it in a counter clockwise
or 3112A (39Simplex) oil filter housings. direction. Remove the used element.

Release the pressure in the oil filter housing by Wet the O-ring in the new element with clean
opening the bleed valves at the stop valve in the refrigeration oil. Insert the new element into the
block and bleed assembly, or at the bleed valve filter tank with the close end visible and attach
for the oil filter housing. Be sure to follow all Lo- the cover to the bowl. HAND TIGHTEN the cover.
cal, State and Federal ordinances regarding the
recovery of refrigerants. The filter housing can be evacuated and then
slowly pressurized by opening the commuter valve
Drain the filter bowl or housing in to an appropri- on handle. This will pressurize the housing. Check
ate container and dispose of the oil in a appropri- for leaks. The filter can now be returned to service.
ate manner following all Local, State and Federal Repeat for other filter bowl if needed.
ordinances regarding the disposal of used refrig-
eration oil. 4. Filter Removal, VRSH Units using Vilter Part
Number 1833C oil filter elements.
Loosen and remove the cover on the bowl of the
filter tank by turning it in a counter clockwise Release the pressure in the oil filter housing by
direction. Remove the used element. opening the bleed valves at the stop valve in the
block and bleed assembly, or at the bleed valve
Wet the O-ring in the new element with clean for the oil filter housing. Be sure to follow all Lo-
refrigeration oil. Insert the new element into the cal, State and Federal ordinances regarding the
filter tank with the closed end visible and attach recovery of refrigerants.
the cover to the bowl. HAND TIGHTEN the cover.
Drain the filter bowl or housing in to an appropri-
The filter housing can be evacuated and then ate container and dispose of the oil in a appropri-
slowly pressurized to check for leaks before return- ate manner following all Local, State and Federal
ing to service. ordinances regarding the disposal of used refrig-
eration oil.
3. Filter Removal, VRSH Units (after 5/1/00)
when using Vilter Part Numbers 3109A (16 Unscrew the bolts holding the cover flange to the
Duplex), or 3110A (39 Duplex) oil filter hous- tank. Remove the cover flange and spring plate.
ings. Pull out the filter element(s). Before reassem-
bling, thoroughly clean the tank and spring plate
Isolate the bowl to be worked on by turning to lengthen the life span of the filter element(s).
handle. The handle will cover the drain valve of
active element. Close commuter valve in center of
handle. Release the pressure in the isolated bowl
by bleeding through the stop valve on the oil filter
cover for Duplex (Vilter Part #3109A or 3110A),
or through the stop valve for the oil filter hous-
ing. Be sure to follow all Local, State and Federal
ordinances regarding the recovery of refrigerants.

Drain the filter bowl or housing in to an appropri-

ate container and dispose of the oil in a appropri-
ate manner following all Local, State and Federal
ordinances regarding the disposal of used refrig-
eration oil.

26
 Operation

C. Oil Pressure Regulating

On units with a full time oil pump, the back pres-

sure regulator, in the oil supply line from the
separator, controls upstream pressure to the com-
pressor bearings and should be adjusted to hold
the oil pressure at 30 psi above discharge pressure.
Excess oil not required for bearing lubrication is
passed through the regulator and flows into the
separator.

D. Oil Cooling

1. Water Cooled Oil Cooler

In lieu of the three way oil temperature valve to

control the temperature of the oil used for lubrica-
tion and cooling of the compressor, it is required to
install a water regulating valve and solenoid valve
combination to control the water supply to the oil
cooler. The water inlet connection should be made
on the bottom and the outlet connection on the
FIGURE 3. top. The water supply is controlled by the water
1833C FILTER ELEMENT TANKS regulating valve to maintain the oil temperature
at approximately 120F.

To replace the filter element(s), on single element

tanks, insert the element and make sure it fits onto
the outlet connection. Install spring plate, and bolt
the cover assembly in place. On units equipped
with dual element tanks, insert inner element and
make sure it fits onto the outlet connection. Put
the centering piece on the outer element and slide
into tank making sure the center piece fits into the
inner element. Put spring plate on outer element
and bolt the cover assembly in place.

FIGURE 4.
CAUTION TYPICAL WATER COOLED OIL COOLER DIAGRAM
When changing filter, discard clogged filter only.
Save and reuse spring plate and centering piece. The solenoid valve provides positive water shut-off
This filter MUST be installed with the spring plate. when the compressor is not in operation.
A compressor that is allowed to operate without
the spring plate is running with unfiltered oil. A temperature of 150F is considered high in most
circumstances and the compressor is protected by
The filter housing can be evacuated and then a safety control to prevent operation of the com-
slowly pressurized to check for leaks before return- pressor above this temperature. Unless otherwise
ing to service. specified, the oil cooler is sized for an 85F water
inlet temperature and 10F temperature rise.

27
 Operation

2. Liquid Injection Oil Cooling line. In some cases to reduce excessive oil foaming
in the separator, the liquid may be injected directly
The components are furnished with liquid injec- into the compressor. With the Sporlan expansion
tion for a typical system. The liquid solenoid valve valve the high pressure gas source normally used
opens whenever the compressor is in operation. for the pressure regulator would be compressor
The thermostatic expansion valve controls the discharge pressure. Since, on a booster unit, this
flow of liquid refrigerant to the compressor injec- intermediate pressure is very rarely as high as the
tion port in response to the discharge tempera- nominal setting of 70 psig, high stage discharge
ture. The discharge temperature is maintained gas is used.
at 130F for ammonia and 140F for R-22, R-507,
R-404a and R-134 and R-290. The discharge On high stage compressors, the liquid is injected
temperature can be adjusted either of two ways directly into the compressor. However, there is
if there is a Sporlan expansion valve. Note that if a horsepower penalty when the liquid is injected
there is a Danfoss expansion valve the outlet pres- into the compressor. This will vary with refriger-
sure regulator is not included and not required. ant and operating condition. The liquid is injected
First, the small outlet pressure regulator can be into the compressor at a point in the compressor
used to adjust superheat. Normally, this regulator cycle that minimizes the brake horsepower penalty
should be adjusted to maintain 70 psig pressure
at the external equalizing port of the expansion 3. V-PLUS Oil Cooling System
valve. Raising the pressure beyond 70 psig tends
to raise the discharge temperature, while lowering This system consists of a liquid pump, shut-off
the pressure lowers the discharge temperature. valves, motor, solid state variable speed controller
Secondly, the standard superheat adjusting screw and solid state temperature controller.
on the thermostatic expansion valve can be used
to adjust the discharge temperature. The pump and solenoid valve cycle on and off in
parallel with the compressor drive motor. The
temperature controller receives a temperature
signal from the sensor located in the discharge and
oil lines and in turn, sends a signal to the motor
speed controller. As the oil and desupserheating
load varies, the temperature controller adjusts
the speed of the pump/motor combination to
maintain a constant oil temperature.

NOTE:
See separate V-PLUS instruction manual for de-
1/4 Fine tailed start-up and operation.
Adjustment Valve

4. Thermosyphon Oil Cooling

Using a brazed plate or an one pass shell and tube

FIGURE 5. type vessel, similar to the water cooled oil cooler,
TYPICAL LIQUID INJECTION OIL COOLING SCHE- oil is circulated on the shell side and liquid refrig-
MATIC DIAGRAM erant from the receiver is circulated through the
tubes.Thermosyphon systems use a 3-way tem-
Liquid injection cooling on booster compressors perature sensing control valve to regulate oil at
is handled in the following manner. Using high 120F. Oil is bypassed around the thermosyphon
pressure liquid, the point of injection can be the oil cooler. When oil is higher than 120F, the oil
discharge line and no horsepower penalty is paid is passed through the thermosyphon oil cooler.
by injecting liquid into the compressor discharge A 1/4 tubing line w/valve adds high pressure gas

28
 Operation

to the oil to quiet the sound of injection. Open setpoints must be in a normal condition, and the
this valve in small amounts, until noise subsides. suction pressure must be above the low suction
pressure setpoint to assure that a load is present.
The closed type cooling circuit is free from the When the On-Off switch or Manual-Auto but-
fouling problems associated with open circuit ton is pressed, the oil pump will start. When suf-
water cooling. Since the oil cooling load is rejected ficient oil pressure is built up and the compressor
in the condenser, this type of cooling is practical. capacity control and volume ratio slide valves are
The temperature limits here are the same as those at or below10%, the compressor unit will start.
regarding the water cooled oil coolers.
If the compressor is in the automatic mode, it will
CONTROL SYSTEM now load and unload in response to the system
demands.
Equipped for automatic operation, the screw
compressor unit has safety controls to protect it Stopping the compressor unit can be accom-
from irregular operating conditions, an automatic plished a number of ways. Any of the safety set-
starting and stopping sequence, capacity and points will stop the compressor unit if an abnormal
volume ratio control systems. operating condition exists. The compressor unit
On-Off or stop button will turn the compressor
Check all pressure controls with a remote pressure unit off as will the low pressure setpoint. If any of
source, to assure that all safety and operating these conditions turns the compressor unit off,
control limits operate at the point indicated on the capacity slide valve unloader will immediately
the microprocessor. energize to drive the slide valve back to 5% limit.
If there is a power failure, the compressor unit will
The unit can be equipped with optional block and stop. If the manual start on power failure option is
bleed valves that are used to recalibrate the pres- selected (see appropriate Microprocessor Instruc-
sure transducers. To use the block and bleed valves tion Manual), restarting from this condition is ac-
to recalibrate the pressure transducers, the block complished by pushing the reset button to insure
valve is shut off at the unit and the pressure is al- positive operator control. If the auto start on
lowed to bleed off by opening the bleed valve near power failure option is selected (see appropriate
the pressure transducer enclosure. The transducer Microprocessor Instruction Manual), the compres-
can then be calibrated at atmospheric pressure (0 sor unit will start up after a waiting period. With
psig), or an external pressure source with an ac- both options, the compressor slide valve must
curate gauge may be attached at the bleed valve. return below their respective 5% limit before the
compressor unit can be restarted.
The discharge pressure transducer cannot be
isolated from its pressure source, so it is equipped 2. Oil Separator Heater
with only a valve to allow an accurate pressure
gauge to be attached and the pressure transducer The oil separator heater keeps the oil in the separa-
calibrated at unit pressure. tor from becoming too viscous and helps to boil
off refrigerant entrained in the oil in the receiver
Recheck the transducers periodically for any drift section of the separator.
of calibration.
The heater is automatically turned on/off by a
Screw Compressor Control And Operation setpoint in the micro-processor.

1. Starting, Stopping and Restarting the Com- 3. Econ-O-Mizer Controls

pressor
Econ-O-Mizer systems are of three types: direct
Before the screw compressor unit may start, expansion, flooded or flash. Systems include a
certain conditions must be met. All of the safety back pressure regulator to control intermediate
pressure.
29
 Operation

Safety Setpoints Valve Settings

A detailed explanation of all safety setpoints can be 1. The suction stop/check valve is designed to
found in the appropriate Microprocessor Instruc- operate as a stop valve (manually open or closed)
tion Manual. or a check valve. The valve is normally positioned
in the automatic mode during unit operation.
1. Oil Pressure Please refer to the tag on the valve to set it in the
automatic position.
Low oil pressure differential stops the compres-
sor unit when there is an insufficient difference in 2. The valve by passing the suction stop or
pressure between the oil manifold and suction. check valve should be partially open during op-
eration. The valve is to be set to equalize the unti
2. Discharge Pressure within 10-15 min. This valve must be adjusted to
minimize oil loss when compressor stops.
High discharge pressure cutout stops the compres-
sor unit, when the discharge pressure in the oil 3. The discharge stop/check valve is designed to
separator exceeds the setpoint. operate as a stop valve (manually open or closed)
or a check valve. The valve is normally positioned
3. Suction Pressure in the automatic mode during unit operation.
Please refer to the tag on the valve to set it in the
Low suction pressure cutout stops the compres- automatic position.
sor unit when the suction pressure drops below
the setpoint. 4. Manually open the oil isolating valve at the oil
separator outlet connection.
4. Oil Filter Differential
5. Open the isolating valve(s) before and after the
High oil filter differential cutout stops the com- oil filter housings.
pressor unit when the difference between the
outlet and inlet of the filter exceeds the setpoint. 6. On packages with a full time oil pump, make
sure the manual opening stem on the oil regulating
5. Oil Temperature valve is in the auto position. See manufacturers
literature for details.
The oil temperature cutout stops the compressor
unit when the oil temperature is too high or too Oil Separator
low.
7. Manually open the stop valve on the oil bleed
6. Discharge Temperature return line from the element section and open
the expansion valve 1/3 of a turn or until no oil is
The high discharge temperature cutout stops the backing up in sight glass.
compressor unit when the discharge temperature
exceeds the setpoint.
8. The purpose of the oil bleed return assembly
INITIAL START-UP is to collect any oil that passes through the oil
separating element and returns that oil to the
Setting of Controls compressor. The hand expansion valve should be
adjusted to prevent an oil level from forming in the
Refer to the appropriate Microprocessor Instruc- sight glass when the compressor is at 100% capac-
tion Manual for a list of initial settings. ity. Generally 1/3 to 1 turn open is satisfactory.
(See Figure 7)

30
 Operation

to the Vendor Section on details of how to adjust

regulator.) The regulator should be adjusted to
maintain approximately 70 psig on the external
equalizing connection of the TX valve. The dis-
charge temperature is maintained at 130F for
Stop Valve ammonia and 140F for R-22, R-507, R-404a and
R-134 and R-290.

To adjust oil temperature up or down, raise or

lower the pressure setting on the regulator. It
should not be necessary to adjust the superheat
setting on the TX valve.

FIGURE 7. Water Cooled Oil Cooler

OIL SEPARATOR BLEED LINE
*** Applies only to units with water cooled oil
V-PLUS Oil Cooling cooler.

* Applies only to units with V-PLUS oil cooling. ***9. The water supply to the cooler should
be opened.
Refer to V-PLUS manual for detailed instructions.
***10. Verify the water solenoid valve does open
*9. Manually open the stop valve at the inlet with the compressor motor starter. (if supplied)
and outlet of the V-PLUS system.
***11. Open 1/4 high pressure gas line valv
*10. Open the needle valve in the oil supply piped to oil injection line just enough to quiet
line to the V-PLUS pump. compressor at 100% capacity.

Compressor Pre Start-Up Check List

*11. The manual opening stem on the sole-
noid valve should be in the automatic position Before proceeding with actual starting of the
(turned counter clockwise or out). compressor, the items listed on the Pre Start-Up
Check List must be verified. Time and money will
Liquid Injection Oil Cooling be saved before the Vilter start-up man arrives.

** Applies only to units with Liquid Injection Oil

Cooling.

**9. Open the stop valve at the inlet of the

pressure regulator.

**10. Open the metering valve 1/8 to 1/4 of a

turn.

**11. Adjust the manual opening stem to the

liquid line solenoid. (Refer to Vendor Section for
details.)

**12. The pressure regulator may require ad-

justment after the compressor is running. (Refer

31
 Stop Check Operation

AUTO
In the Auto Position, the stop valve is op-
erating as a check valve, allowing flow in the
directions of the arrows.

To set the valve to the automatic position, fully

close the valve, and turn the stem out as indi-
cated by the chart below.

CLOSED
In the manually Closed Postion, the stop
check is operating as a conventional stop
valve, not allowing flow in either direction.

OPEN
In the manually Open Position, with the valve
stem fully back seated, the valve disc is lifted
slightly, allowing flow in either direction.

For Normal Operating Position

Valve Size 1.5 2 2.5 3 4 5 6 8
Number of Turns
Open 2 2.25 2.75 3.25 4.5 3.75 5.75 7.75
(from closed position)

32
Pre-Start Up
Check List

33
 PRE START-UP CHECKLIST
FIELD PIPING AND MECHANICAL REQUIREMENTS

NOTE: If start-up service has been purchased, the following items should be completed before the start-up
man arrives. This will help save time and money.

_____ 1. The unit should be leveled and secured to the mounting pad or floor.

_____ 2. The suction and Discharge line must be piped and properly supported, independent of the
unit.

_____ 3. The Discharge Stop/Check Valve is shipped loose and must be installed in a vertical up
flow direction or in a horizontal line with the valve stem pointing upward at a 45 angle.
During off periods, refrigerant can condense in the line downstream of the Discharge Stop/
Check Valve. It is recommended the Stop/Check Valve be located to minimize the quantity
of liquid that can accumulate downstream of the valve.

_____ 4. A Dual Safety Relief Valve is shipped loose for field installation. A connection is provided on
the oil separator for the relief valve. Refer to ASHRAE/ANSI Standard 15 (Safety Code for
Refrigeration) for proper sizing and installation of Relief Valves and Vent Lines.

_____ 5. Piping For Oil Cooling

a) Liquid Injection
An adequate, or dedicated, liquid line is required for the Liquid Injection System. A high pressure liquid source
must be piped to the stop valve at the inlet of the Thermostatic Expansion Valve. On booster units, an additional
3
/8 line must be piped to the regulator from high stage discharge gas for the Thermostatic Expansion Valve.

b) V-PLUS
A high pressure liquid source must be run to the V-PLUS inlet. Some subcooling is desirable. A high pressure
float must be installed at the inlet of the pump and a 3/8 vent line must be returned to a suction trap. Refer
to the V-PLUS manual for additional information.

c) External Oil Cooler

On thermosyphon oil coolers, the refrigerant lines must be connected to the front head of the oil cooler. On
water cooled oil coolers, the water lines must be connected to the front head of the oil cooler. Installation of
water regulating and solenoid valves are recommended.

_____ 6. The oil separator should be provided with oil until the oil level is between the (2) sight
glasses. An oil charging connection is provided on the bottom of the oil separator.

_____ 7. The center member of the compressor coupling is shipped loose to help facilitate final
field alignment and allow for motor rotation check. The motor alignment should be within
0.004 total indicator reading in all directions.
a) Both the compressor and motor hubs should be checked for concentricity and perpendicu-
larity.
b) The motor should be checked and shimmed for soft foot prior to attempting final alignment.
c) The center section of the coupling should be left out to allow the start-up technician to
verify the final alignment and motor rotations.

_____ 8. The unit should be pressure tested, evacuated and a system load should be available at the
time of start-up.
Order #_______________________________Compressor Serial #________________________
34
 PRE START-UP CHECKLIST
FIELD WIRING REQUIREMENTS

FIELD WIRING REQUIREMENTS FOR UNITS WITH FACTORY WIRED VISSION MICROPROCESSORS

NOTE: If startup service has been purchased, to save time and money, the following items should be completed
before the startup technician arrives.

The unit is pre-wired at the factory. The necessary field wiring connections are described below.

1. Control power of 115 VAC 50/60 HZ must be wired to the left side terminals of the digital I/O board inside
the ViSSion cabinet. Line power (L1) is brought in to a 10-amp fuse via the terminal marked L1 on the
appropriate connector. The neutral (L1A) is brought in and connected to any of the N terminals located
on left connectors. Two separate line power feeds for the oil heaters are brought to two additional 10
amp fuses via the terminals marked L2 and L3 on the same connector just below the L1 terminal.
The neutrals for these circuits (L2A and L3A) are also connected to any of the N terminals. For units
with V-PLUS oil cooling, L1 must also be brought to the fuse in the V-PLUS panel, and L1A must also be
brought to the terminal #2B in the V-PLUS panel.

2. An auxiliary contact from the compressor motor starter is required. This isolated contact is connected to
the K-1 input relay using any of the L terminals on the strip of connectors, and returned to the terminal
marked Motor Starter Aux. Safety at the very top connector.

3. A dry contact from control relay K-22 must be wired to the compressor motor starter coil. This dry contact
is wired to terminals marked Compressor Start N.O. #1A and Compressor Start N.O. #1B. Control
power for this coil should come from a source, which will be de-energized with the compressor disconnect.

4. A dry contact from control relay K-19 must be wired to the oil pump motor starter coil. This dry contact
is wired to the two terminals marked Oil Pump Starter. Control power for this coil should come from a
source, which will be de-energized with the compressor disconnect.

5. An auxiliary safety cutout is available to shut down the compressor package using the K-2 input relay. A
dry contact must be supplied and wired to one of the L terminals on any of the connectors, and returned
to the terminal marked Auxiliary #1 Safety at the top connector. The jumper to the Auxiliary #1 Safety
terminal must be removed to use this cutout. The contact, if closed, will allow the compressor to run. If
this contact opens at any time, the compressor will shut down.

6. Indication of the compressor alarm or shutdown status is also available via two control relays. Relay K-20
is provided for remote trip indication and relay K-21 is provided for remote alarm indication. Each relay
has three terminals available: a common input, a normally open contact, and a normally closed contact.
For both relays, the energized state represents a trip or alarm condition. Loss of voltage to the relay
coil and the resultant return to normal state indicates safe condition.

7. The current transformer supplied in the compressor motor conduit box should be checked to insure that
the motor leads of one leg are pulled through the transformer. Note that there is a dot on one side of the
current transformer. This dot must face away from the motor. Typically, a wye delta started motor should
have leads 1 and 6 pulled through this transformer for a 6 lead motor. However, this should always be
checked as different motors and starting methods will require different leads to be used.

Order #_______________________________Compressor Serial #________________________

35
 SERVICE INTERVAL REQUIREMENTS
FOR VILTER EXTENDED WARRANTY

The following service intervals are based on the usage of Vilter Manufacturing LLC Premium Grade refrigeration oil.

Inspection SERVICE INTERVAL (HOURS)

Or

100,000
110,000
120,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
5,000
Group Maintenance
200
Item

OIL CIRCUIT
Oil Change (1) R R R R R R R
Oil Analysis (2) S S S S S S S S S S S S S
Oil Filters (3) R R R R R R R R R R R R R R
Oil Strainer I I I I I I I I I I I I I I
PACKAGE
Coalescing Elements R R R R
Suction Screen I I I I I I I I I I I I I I
Liquid Line Strainers I I I I I I I I I I I I I I
Coupling Alignment &
Integrity I I I I I I I I I I I I I I
CONTROL
CALIBRATION Transducers I I I I I I I I I I I I I I
RTDs I I I I I I I I I I I I I I
COMPRESSOR
Inspect Compressor I I I I R I I I I R I
Bearings I

Key I Inspect.
R Replace.
S Sample.

Notes: (1) The oil should be changed at these intervals, unless oil analysis results exceed the allowable limits.
The frequency of changes will depend on the system cleanliness.

(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysis will depend on
system cleanliness.

(3) The oil filter(s) on a minimum must be changed at these intervals or annually if not run continuously.
However, the oil filter(s) must be changed if the oil filter differential exceeds 12 psi or oil analysis re -
quires it.

36
 Vendor Assessories
Section

VENDOR DOCUMENTATION SECTION .......................................................... 39

COUPLING INFORMATION .............................................................................................................................

COMPRESSOR INFORMATION ........................................................................................................................

WRV & WRVI INSTALLATION ............................................................................................................................
WRV & WRVI SERVICE MANUAL .......................................................................................................................
HOWDEN SPARE PARTS ...................................................................................................................................
HOWDEN DRAWING R20737 ..........................................................................................................................

PUMP INFORMATION ....................................................................................................................................

HAIGHT...........................................................................................................................................................
VIKING ............................................................................................................................................................

STRAINER INFORMATION ..............................................................................................................................

DANFOSS ........................................................................................................................................................
PARKER ...........................................................................................................................................................
HANSEN ..........................................................................................................................................................

VALVE DOCUMENTATION ..............................................................................................................................

PARKER CHECK ...............................................................................................................................................
DANFOSS REGULATING ...................................................................................................................................
DANFOSS MOTORIZED ...................................................................................................................................
SPORLAN EXPANSION .....................................................................................................................................
SPORLAN PDA VALVE .......................................................................................................................................
HANSEN INLINE CHECK ...................................................................................................................................
HANSEN HA4AOAS..........................................................................................................................................
HANSEN BUTT WELD.......................................................................................................................................
HANSEN HA4A ................................................................................................................................................
HANSEN HAND EXPANSION ............................................................................................................................
HANSEN SOCKET WELD...................................................................................................................................

MISC .............................................................................................................................................................
HEATER ...........................................................................................................................................................
CAPACITY LPI ..................................................................................................................................................
LPI DESCRIPTION & INSTRUCTION ...................................................................................................................
2895 KEYPAD WIRING .....................................................................................................................................
COUPLINGS .....................................................................................................................................................
ACTUATOR .....................................................................................................................................................

39
 Coupling Information

B. Straight Bore:

1. Install key(s) in the shaft. If the hub is an interfer-

ence fit, heat the hub in an oil bath or oven until bore
is sufficiently larger than the shaft. 350 F. is usually
sufficient. An open flame is not recommended. How-
ever, if flame heating is necessary, use a very large
rose bud tip to give even heat distribution. A thermal
Type DB Z- A heat stick will help determine hub temperature. DO
NOT SPOT HEAT THE HUB OR DISTORTION MAY OC-
CUR. With the hubs expanded, slide it up the shaft to
the desired axial position. A pre-set axial stop device
can be helpful.

NOTE:
All DBZ hubs have pressed in bushings. Make sure the
bushings are facing the disc pack.

Ex te nd ed Hu bE Ce nt er As se mb ly xt en de dH ub C. Taper Bore:
an dH DW R (Newer models have only straight bore)

1. Put the hub on the shaft without key(s) inplace.

COUPLINGS INSTALLATION AND ALIGNMENT Lightly tap hub up the shaft with a soft hammer. This
will assure a metal-to-metal fit between shaft and
These instructions are intended to help you to instal- hub. This is the starting point for the axial draw. Re-
land align the coupling. Covered here will be general cord this position between shaft and hub face with
information, hub mounting, alignment, assembly, a depth micrometer. Mount a dial indicator to read
locknut torquing, discpack replacement, and part axial hub movement. Set the indicator to 0. Re-
numbers. The coupling as received, may or may not move hub and install key(s). Remount hub, drawing
be assembled. it up the shaft to the 0 set point. Continue to ad-
*If assembled, the locknuts are not torqued. vance hub up the taper to the desired axial position.
*If coupling is assembled, remove the bolts that at- Use the indicator as a guide only. A pre-set axial stop
tach the hubs to the disc packs. Remove both hubs. device can be helpful. Check the final results with a
Leave the disc packs attached to the center member. depth micrometer. The hub may have to be heated in
order to reach the desired position on the shaft. DO
A. Hub Mounting: NOT SPOT HEAT THE HUB OR DISTORTION MAY OC-
CUR. Install shaft locknut to hold hub in place.
1. Clean hub bores and shafts. Remove any nicks
or burrs. If bore is tapered, check for good contact D. Shaft Alignment.
pattern. If the bore is straight, measure the bore
and shaft diameters to assure proper fit. The key(s) Move equipment into place.
should have a snug side-to-side fit with a small clear-
ance over the top. a. Soft Foot. The equipment must sit flat on its base.
Anysoft foot must be corrected now.
NOTE:
If the DBZ hub position on the shaft does not allow b. Axial Spacing. The axial spacing of the shafts
enough room to install the short bolts in the hub af- should be positioned so that the disc packs (flexing
ter hub mounting, install the bolts and disc pack be- elements) are flat when the equipment is running
fore mounting hub on shaft. under normal operating conditions. This means
there is a minimal amount of waviness in the disc
40
 Coupling Total Indicator Torque
Size Reading (T.I.R.) Ft.-Lbs.
Angle Parrallel Min Max (In.-Lbs.)

50 .004 .004 1.36 1.37 (24)

62 .004 .004 1.74 1.75 (36)
75 .004 .004 1.77 1.78 (36)
101 .004 .004 2.08 2.10 (96)
126 .004 .004 2.46 2.48 (156)
163 .004 .004 2.46 2.48 (156)
201 .004 .004 2.96 2.98 25
226 .004 .004 3.83 3.83 30
263 .004 .004 4.33 4.35 40
301 .004 .004 4.90 4.93 95
351 .004 .004 5.90 5.93 175
401 .004 .004 6.71 6.75 150*
451 .004 .004 7.27 7.31 190*

pack when viewed from the side. This will re- b. Remove the long bolts. Mount the disc packs
sult in a flexing element that is centered and paral- on the hubs with one bolt through the disc pack
lel to its mating flange faces. Move the connected aligned with a clearance hole in the hub. Install the
equipment to accomplish the above. short bolts through the hub, disc pack, bevel wash-
er or link, and secure with a lockout.
NOTE:
The disc pack is designed to an optimal thickness and NOTE:
is not to be used for axial adjustments. All bolt threads should be lubricated. A clean mo-
tor oil is recommended. On size 226 and larger, a
As a guide, maximum and minimum values for di- link must be put on bolt first. Remove the disc pack
mension E are given. These dimensions are sug- alignment bolt. Proceed to mount the second disc
gested for initial installation. Additional capacity is pack to the other hub in the same way.
available to compensate for thermal and structural
movement. Maximum axial capacity values for these c. Position one set of short bolts in each hub on top.
couplings are also given. See chart above. Now slide the center ring down into place strad-
dling the short bolts with the center ring bushings.
E. Final assembly . If coupling is dynam-ically balanced, the center ring
match marks must lineup with both hub match
With the coupling in good alignment the bolts will fit marks. When one bushing is in-line with the hole in
through the holes in the flanges and the disc packs the disc pack, slide one long bolt through washer or
more easily. link, disc pack, center ring, disc pack, washer or link,
and then secure with a locknut.
a. If the coupling arrived assembled, the disc packs
are still attached to the center ring. Before taking d. Torque the long bolt locknuts at this time. See
the discs packs off, first install one hub bolt through Table on page 31 for torque values.
each disc pack and secure with lock out. This will
help when the pack is reinstalled late. If the coupling NOTE:
was shipped disassembled, the bolt through the With the coupling in good alignment, the bolts will
pack is not required as the discs in the pack are fac- fit through the holes in the flanges and the disc pack
tory taped together. more easily. It is recommended that all locknuts be
retightened after several hours of initial operation.

41
For further help with the installation or alignment,
consult your Vilter representative.

F. Disc Pack Replacement.

If it becomes necessary to replace the disc pack, it

can be done as follows:

a. Remove all the long bolts and lower the center ring
by sliding it our from between the two disc packs.

b. Remove one short bolt from the disc pack/hub

connection and reinstall it through a hub clearance
hole and into the hole in the disc pack. Put the nut
on. This will keep the discs together and maintains
the disc orientation for later reinstallation. Remove
the rest of the short bolts and takeoff the disc pack.
Repeat for the second disc pack.

c. Replace the pack(s) if required. Recheck align-

ment per Section D. Reassemble per Section E

42
Compressor Documentation
WRV & WRVi Compressor Range

Installation Manual
INDEX TO SECTIONS

SECTION 1 Foreword & Contact Information

SECTION 2 Description
2.1 The WRV/WRVi Compressor
2.2 Typical Sectional Arrangement Drawing

SECTION 3 Lubrication Oil Specification

SECTION 4 Installation
4.1 Alignment of Compressor Couplings
4.2 Coupling Alignment - Basic Rules
4.3 Alignment Tolerance
4.4 Piping

SECTION 5 First Start Up

5.1 First Start
5.2 Adjusting Manual Vi (WRVi Compressor Only)
5.3 Slide Valve Stop Settings
5.4 Linear Position Indicator Operation & Calibration
5.5 Linear Position Indicator Operation & Calibration - ATEX
6.3 Max and Min Limit Switches Assembly and Adjustment
6.4 Procedure for Fitting Potentiometer

SECTION 6 Normal Operation

6.1 Normal Start
6.2 Normal Stop

SECTION 7 Procedures During Shutdown

7.1 Precautions during shutdown

SECTION 8 Maintenance
8.1 General Comments
8.2 Compressor Record
SECTION 1 FOREWORD

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR

This manual relates to WRV and WRVi Compressors.

These instructions have been prepared to ensure that your compressor gives long and satisfactory service.

The entire manual should be read before reverting to any one specific section for information.

One copy should be given to the personnel responsible for installing and operating the compressor.

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be
accepted by Howden Compressors Limited for loss, damage, injury or consequential costs of any kind
caused by any errors in, or omissions from, the information given.

All requests for information, service or spares should be directed to:

HOWDEN COMPRESSORS LIMITED

Compressor Business Unit
133 Barfillan Drive
Glasgow, G52 1BE
UNITED KINGDOM

Telephone number: +44 (0)141 882 3346

Fax number: +44 (0)141 883 5901
E-mail: sales@howdencompressors.co.uk
Web site: www.howden.com

Alternatively contact our North American Sales Office at:

HOWDEN COMPRESSORS LLC

1850B N Gravers Road
Plymouth Meeting
PA 19462
USA

Telephone number: 01 610 313 9800

Fax number: 01 610 313 9215
E-mail: sales@howdencompressors.com
Web site: www.howden.com

All enquiries should be accompanied by the Howden Compressors Ltd Contract Number and the
Compressor Serial Number taken from the nameplate on the side of the compressor body.
SECTION 2 DESCRIPTION

2.1 THE WRV/WRVi COMPRESSOR

The Howden WRV/WRVi Oil Injected Compressor is a positive displacement, capacity controlled,
oil flooded, rotary machine.

A feature of the WRVi compressor range is the facility to adjust the volume ratio by altering the
size of the discharge port to obtain the desired ratio in the range 2.2:1 to 5.0:1.

The WRVi compressors are supplied with two oil injection ports on the side of the main casing. If
no oil injection is required due to the duty then it is not necessary to pipe up to these connections
and the plugs can remain fitted to the casing. Older compressor models, which had no oil
injection, were identified as WCV units on the name plates.

Note: The plugged WRVi is the direct replacement for a WCV unit.

The accurately machined helical rotors are called Male and Female. The Male (driving) rotor has
four lobes that mesh with six flutes in the Female (driven) rotor, both rotors having the same
outside diameter. Each rotor is supported by two plain white metal thick walled journal bearings
fitted adjacent to the compression chamber.

As the lubricating oil is at discharge pressure plus 2.1 bar (30 psi) for standard range compressors
and at 3.1 bar (45 psi) for the 'H' designated compressors, the bearings act as shaft seals within
the compressor.

Rotor end thrust is accommodated by angular contact ball bearings on both male and female
rotors and balance pistons at both ends of the male rotor. One side of each balance piston is
subject to pressure from lubricating oil and the other side at suction pressure. The balance pistons
therefore, oppose the normal rotor end thrust, and as a result, the angular contact bearings are
lightly loaded and have a long life.

In the case of the WRViT model, the thrust bearings are white metal lined tilting pads with balance
piston fitted at the inlet end of the male rotor only.

Compression is achieved by the meshing of the two helical rotors on parallel shafts housed in a
casing.

The male rotor has lobes formed helically along the rotor length and these mesh with
corresponding flutes on the female rotor. The meshing and disengaging of the lobes and flutes
within the compressor casing creates enclosed spaces which expand in volume (the suction
phase) to a point determined by the shape of the suction port where the interlobe space is sealed.
As the rotors continue their rotation and the rotor lobes and flutes remesh, the gas now trapped in
the interlobe spaces is compressed. At a point determined by the discharge port shape, the
decreasing interlobe space is opened to discharge and the gas escapes at pressure.
SECTION 2 DESCRIPTION

2.1 THE WRV/WRVi COMPRESSOR (continued)

Capacity control is achieved by means of a slide valve in the casing operated by a piston in a
hydraulic cylinder mounted on the compressor. Movement of the slide valve alters the point at
which gas compression begins by allowing the gas from the start of the compression phase to re-
circulate back to suction. This in effect decreases the volume of gas compressed. At the same
time, the slide valve alters the size of the outlet port to keep the compression ratio constant. By
this means, stepless capacity control is provided with an approximately proportionate saving in
power.

The piston is actuated by lubricating oil fed from the lubricating oil manifold to one or other side of
the piston. As oil is fed to the cylinder, the slide valve will move on load (towards the inlet end).
When the oil feed is stopped, the slide valve will be locked in position. To off load the
compressor, the oil trapped in the cylinder is allowed to escape to the oil return connection on the
compressor and the slide valve will move off load (towards the outlet end) as oil is pumped to the
opposite side of the piston.

The WRVi model, in addition to the above, also has the facility of selecting manually, a Vi ratio
most suitable to the operating duty.

2.2 TYPICAL SECTIONAL ARRANGEMENT DRAWING:

INLET

OUTLET

MANUAL Vi ADJUSTMENT-WRVi
SECTION 3 - LUBRICATION OIL SPECIFICATION

Howden compressors are fitted, as standard, with neoprene O rings.

These O rings are compatible with the majority of standard refrigerants and many oils, but compatibility
with all possible combinations of refrigerant and oil cannot be guaranteed.

Should you wish to review this matter, please do not hesitate to contact Howden Compressors Limited,
who will be pleased to provide recommendations and costs for any special O ring materials which may be
required.

Typical Standard Refrigerants:

R717, R22, R134a, R404A, R407C, R410A, R507

Typical Oils:

Mineral Oil
Polyol Ester Oil
Poly Alkylene Glycol Oil
Alkyl Benzene Oil

Oil Viscosity:

For the majority of ammonia refrigeration applications, oil viscosity of 68 centistokes at 40oC is the
appropriate selection. However, with many other refrigerants, eg; R134a with high condensing
temperatures, or applications involving hydrocarbon gases, a specific oil selection is required.

Howden Compressors Limited offers a consultancy service to all users of HCL product. Please
consult the applications department of HCL who will be happy to advise on grade of oil applicable
to the refrigerant or gas at the specific duty application.
SECTION 4 INSTALLATION

4.1 ALIGNMENT OF COMPRESSOR COUPLINGS

Misalignment causes a vibration which affects other parts of the compressor, leading to premature
failure of bearings, seals, etc. Drive couplings fitted to WRV compressors must be aligned
correctly.

The coupling alignment tolerance figures can be seen under Section 5.2

Coupling gap dimensions should be set with the coupling held in a repeatable position, i.e. hard
together or hard apart. This ensures that each coupling half is moved to the same axial position as
each check is made.

The actual coupling gap should be correct when the shafts are in their normal running condition.

When setting the gap, the axial float of each shaft should be determined and the "hard together" or
"hard apart" dimensions calculated.

Example: Compressor driven directly by turbine

Compressor shaft float 0.000mm (0.000")

Turbine shaft float 0.250mm (0.010")

The normal running position of the compressor shaft is thrusting towards the turbine and the
turbine thrusting towards the compressor.

Required coupling gap 3.175mm (0.125")

If the gap is checked with the coupling "hard apart" it should be:

Required coupling gap 3.175mm (0.125")

plus Compressor shaft float 0.000mm (0.000")
plus Turbine shaft float 0.250mm (0.010")
====================== =============
= "Hard apart" gap 3.425mm (0.135")

If the gap is checked with the coupling "hard together" ie in the normal running condition, it should
be equal to the required gap 3.175mm (0.125").
SECTION 4 INSTALLATION

4.2 COUPLING ALIGNMENT - BASIC RULES

1. Compressor to be mounted on baseframe and mounting feet checked for soft foot and
corrected where necessary.

2. Alignment to be set before connecting any pipework to the compressor.

Allowable TIR = +/- 0.15mm Radially and Axially.

3. Under no circumstances should suction and discharge piping be strained into position.
Distortion of the casing will cause premature failure of the compressor. A vertical and
horizontal clock gauge must be mounted on the compressor input shaft/coupling hub to
ensure no alteration occurs when pipes are being connected. Only after this is completed
should the coupling hubs be connected.

Note: Coupling hubs must not be hammered onto the compressor shaft.

4.3 ALIGNMENT TOLERANCE

The maximum acceptable line-up tolerance for couplings on compressor installations is as follows:

RADIAL TOLERANCE FACE TOLERANCE

Application Radial Tolerance Face Tolerance

A) Motor to Gearbox or Compressor ie A) 0.15mm (0.006) TIR A) TIR 0.005mm/cm

Couplings operating up to 3,600 rpm. Dia. Of coupling

B) Gearbox to Compressor ie couplings B) 0.10mm (0.004)TIR B) TIR 0.005/inch

Operating above 3,600 rpm. Dia. Of coupling.

Radial Tolerance
Eccentricity = TIR on circumference
TIR denotes Total Indicator Reading obtained by Clock Gauge
SECTION 4 INSTALLATION

4.4 PIPING

Before installing the piping, the compressor inlet and outlet ports should be inspected to ensure no
dirt is present.

Note that the pipes and fitting used should not restrict flows. To avoid this, always use piping with
a bore larger than the thread diameter of the compressor port, eg, WRVi 255 oil connection to
actuator cylinder thread is 1/2 BSP and so a 3/4 OD pipe should be used.

All piping should be supported so that no strain is transmitted to the compressor casings.

The piping should be inspected for cleanliness before installation. As each pipe is connected to
the compressor, the coupling alignment should be checked to ensure that no alteration has taken
place.

If alignment has altered, the compressor is being strained and the piping supports must be
adjusted.

It is not sufficient merely to re-align the drive unit, as this will not correct the strain being imposed
on the compressor. Oil injected refrigeration compressors must have a suction strainer
permanently fitted directly on the compressor inlet.

Note that the oil pipes and fittings used should not restrict flows. To avoid this, always use piping
with an OD 1/4" (6mm) larger than the thread diameter of the compressor port, eg, connection
thread is 3/4" BSP and so a 1"OD pipe or metric equivalent should be used.

Before installing the piping, the compressor gas inlet and outlet ports and oil injection holes should
be inspected to ensure no dirt is present.

Note: All piping should be supported so that no strain is transmitted to the

compressor casing.

The piping should be inspected for cleanliness before installation. As each pipe is connected to
the compressor, the coupling alignment should be checked to ensure that no alteration has taken
place.

If alignment has altered, the compressor is being strained. The pipes should be corrected and the
supports adjusted accordingly.
It is not acceptable to re-align the drive unit as this will not correct the strain being imposed on the
compressor.

Oil injected refrigeration compressors must have a suction strainer permanently fitted on the
compressor inlet.

The set pins supplied with the suction and discharge flanges are for transport only and should be
replaced with contract set pins or studs having correct thread engagement length.

When fitting the suction flange to the compressor, ensure that the tapped holes in the casing are
cleaned out and free from water. Fit setpins/studs, coating the threads with pipe sealer to prevent
ingress of water into tapped holes.
SECTION 5 - FIRST START UP

5.1 FIRST START UP

Installation of the compressor will have been carried out in accordance with Section 5 of this
manual. The commissioning engineer should, however, ascertain that the correct procedures
have been followed, in particular the coupling alignment must be checked, then proceed as
follows:

1. Disconnect the coupling between the drive and the compressor and check that the motor
rotation is correct for the compressor drive looking on the compressor input shaft.

WRV and WRVi compressors - CLOCKWISE

MRV compressors - ANTI-CLOCKWISE

2. Fill the oil tank with lubricating oil of the correct grade to the required level, as indicated on
the tank level sight glass.

3. Ensure that the pipe from the oil filter to the manifold, the manifold and oil pipes to the
compressor are clean and that new clean filter elements are fitted.
4. The lubricating oil pressure differential relief valve should be set to give a 2.1 bar (30 psi)
oil manifold differential pressure for standard range compressors and 3.1 bar (45 psi) oil
manifold differential pressure for 'H' range compressors at the correct operating
temperature and with clean oil filter elements fitted.

5. Check the operation of any safety trips fitted by running the drive unit disconnected from
the compressor and mechanically operating the trips.

Check that the trips are set to act at a point which will protect the compressor from
damage. The lubricating oil differential trip can be set at 0.83 bar (12 psi) on the standard
range and 1.5 bar (22 psi) on 'H' range by partially closing the oil filter isolation valve to
reduce the differential oil pressure to the point where the trip operates. As the filters
become dirty, the differential oil pressure will drop to this figure, which is the minimum
acceptable pressure.

6. Check that the compressor turns freely by hand and reconnect the coupling between the
drive unit and the compressor.

7. Check that the cooling water is turned on to the lubricating oil cooler, if fitted.

8. Check that all gas inlet and outlet isolating valves are open.

9. Check that the Volume ratio Vi screw is in the minimum position.

Rotate screw in a clockwise direction for minimum (2.2) Vi type only.
SECTION 5 - FIRST START UP

5.1 FIRST START UP (continued)

Notes:

1. Do not adjust the volume ratio Vi screw when compressor is on load.

2. The compressor should be in the unloaded position prior to start up.

If the compressor is started without first being unloaded, a higher starting torque will be
required.

10. Start the auxiliary lubricating oil pump.

11. Check that the volume ratio Vi screw is in the required operating position.
See section 6.2 for details.

12. Calibrate the Capacity Linear Position Indicator as per Section 6.4
Note: Linear Position Indicator not available on Auto Vi compressors.

13. Start the drive unit and check that all gauges are indicating correctly.

14. Run the compressor for 30 minutes at minimum gas flows and check that all readings are
normal, then operate the capacity control valve to the required position. This position will
be indicated on the dial mounted on the hydraulic cylinder.

15. If possible, check the slide valve control over the full range of capacity.

5.2 MANUAL Vi ADJUSTMENT (Vi type compressor)

1. The Volume Ratio can be adjusted between 2.2 and 5.0 by rotating the square drive screw
below the input drive shaft. Turn clockwise for minimum load (2.2) and anticlockwise for
maximum load (5.0).
Refer to graphs under section 6.3 for number of turns.

Note: Before making any adjustments to the Volume Ratio, the slide valve must be fully
unloaded. From a safety aspect, it is recommended that the compressor be stationary.
SECTION 5 - FIRST START UP

5.3 SLIDE VALVE STOP SETTINGS

SECTION 5 - FIRST START UP

5.3 SLIDE VALVE STOP SETTINGS WRVi 321

SECTION 5 - FIRST START UP

5.3 SLIDE VALVE STOP SETTINGS FOR WRVi365/193

Compressor Slide Stop Movement
5.0

Compressor - WRVi365/193
4.5 Max Vi = 5.0
Approximate Volume Ratio (Vi)

4.0

3.5

3.0

2.5

2.0
0 2 4 6 8 10 12 14 16 18 20 22

Number of Turns from 2.1 Vi Position

Compressor Slide Stop Movement

5.5

Compressor - WRVi365/193
Max Vi = 5.8
5.0
Approximate Volume Ratio (Vi)

4.5

4.0

3.5

3.0

2.5

2.0
0 2 4 6 8 10 12 14 16 18 20 22

Number of Turns from 2.1 Vi Position

SECTION 5 - FIRST START UP

5.3 SLIDE VALVE STOP SETTINGS FOR WRVi365/165

Compressor Slide Stop Movement

5.0

Compressor - WRVi365/165
4.5
Approximate Volume Ration (Vi)

4.0

3.5

3.0

2.5

2.0
0 2 4 6 8 10 12 14 16 18

Number of Turns from 2.1 Vi Position

SECTION 5 - FIRST START UP

5.4 LINEAR POSITION INDICATOR (LPI)

General:
An electronic device called a Linear Potentiometer gives an indication of the position of the slide
valve which can be used by the compressor control system.
The Linear Position Indicator (LPI) is an electronic contact-less displacement sensor inserted
into a sensor well which allows the LPI to be removed from compressor without loss of oil or gas
from the compressor.

The LPI has several usable options built into one device.

The slide valve position can be indicated in three different ways:

Visual Light emitting diodes (LED)
Visual and by an analogue output 4-20mA
Visual and by a digital 24 V DC signal output on minimum and maximum slide valve position

Part Load LED

Maximum Load
Minimum Load LED
LED
Calibration
Button Cover

Visual:

It is always possible to see the position of the slide valve.

At minimum load a yellow LED is illuminated at the lowest light on the left of the LPI.
At maximum load a blue LED is illuminated at the lowest light on the right of the LPI.
At part load only some of the LED are illuminated, eg, At 50% load only half of the LED will be
illuminated.

Note: The compressor can only be allowed to start with the slide valve in the minimum load
position. Therefore a signal from the minimum load electronic position switch is always
required or if the 4 20 mA signal is being used, then a 4 mA signal is required.
SECTION 5 - FIRST START UP

5.4 LINEAR POSITION INDICATOR (LPI)

Visual and by an Analogue Output (4-20mA):

The minimum load position is given by the 4 mA output and the maximum load position is given by
the 20 mA output. (White Wire)

Part load positions are indicated by intermediate values between 4 and 20 mA.
The LEDs on the indicator also give a visual indication of part load operation. It should be noted
that part load slide valve position is not a direct indication of actual compressor capacity at part
load. Use of the 4 20 mA signal is common for many control systems and may be used on its
own, if required, for all control functions for single and multiple compressor installations, subject to
a suitable control system.

Connections:
Wiring Plug Connections Function
1= Brown Supply Voltage + 24V DC
2- White Output Signal 4-20 mA
3=Blue Common 0 VDC

Visual and by a Digital 24V Output on Minimum and Maximum load:

There is also another option that can be used to control and get the minimum signal for start-up.
This option works the same as the mechanical micro-switches but instead uses the electronic
switches incorporated in the LPI unit. These electronic switches give a 24 V DC output.
A digital output is given on the Minimum and Maximum position of the slide valve and an
interposing relay, which must be incorporated in the control panel in place of each mechanical
micro-switch, is activated by the digital signal completing the control circuit signal. This interposing
relay must have contacts with suitable ratings. The interposing relay replaces the original switch
function.
The LEDs only give a visual indication of the slide valve position.

If the slide valve is in the minimum position and the LED for minimum is illuminated, there will be a
digital output on the green/yellow wire.
If the slide valve is in the maximum position and all the LEDs are illuminated, there will be a digital
output on the black wire.

Existing installations equipped with the mechanical micro-switches can use this option.

Connections:

Wiring Plug Connections Function

1= Brown Supply Voltage + 24V DC
3=Blue Common 0 VDC
4=Black Digital Output Max. Load
5=Green/Yellow Digital Output Min. Load

Choose the best way for giving a start signal and connect the wires according to the table.
SECTION 5 - FIRST START UP

5.4 LINEAR POSITION INDICATOR OPERATION & CALIBRATION

All compressors with variable Vi are despatched from Howden Compressors facility with Vi set at
2.2 and the LPI calibrated to suit Vi 2.2.
When the Slide Valve is in the unloaded position, the 10% minimum load LED should be
illuminated.
To check that the LPI indicates maximum load when the slide valve is in the fully loaded position,
ie all LEDs are illuminated, the following checks should be made.

Move the slide valve to 100% (by using the oil pump or if the system is shut down, use a manual
oil pump or air pressure). By pressurising the outboard side of the actuator piston the slide valve
will be moved to the fully loaded position. The LPI should indicate 100% by illuminating all LEDs.

If this is not the case please repeat the calibration procedure as follows:

Linear Position Indicator (LPI) Calibration Procedure

1. Move slide valve to Minimum Load position.

2. Remove calibration button cover.

3. Connect power supply to LPI, 24v DC max.

4. With slide valve in Minimum Load position, push calibration button once. Red LED will light,
after 15-20 seconds light will turn to Flashing Red.

5. Move slide valve to Full/Maximum Load position.

6. With slide valve in Full/Maximum Load position, push calibration button once, Red LED will
light for 15 seconds and then go off. Green LED will now light.

7. Calibration is now complete and sensor should now red maximum or 100% capacity.

8. Refit button cover.

Note:
1. If Vi is changed, LPI must be re-calibrated.
2. The Minimum Load position gives a 4mA output and the Maximum Load gives a 20mA
output.
SECTION 5 - FIRST START UP

The LPI Linear Position Indicator

Red LED
Green LED

Calibration
Button

LPI Wiring Diagram

SECTION 5 - FIRST START UP

5.5 ATEX TYPE LINEAR POSITION INDICATOR (LPI)

General:
An electronic device called a Linear Position Indicator gives an indication of the position of the
slide valve which can be used by the compressor control system.
The Linear Position Indicator (LPI) is an electronic non contact transmitter inserted into a sensor
well which allows the LPI to be removed from compressor without loss of oil or gas from the
compressor.
The slide valve position can be indicated by an analogue output 4-20mA signal.
Note: The compressor should only be allowed to start with the slide valve in the minimum load
position.

Analogue Output (4-20mA):

The minimum load position is given by the 4 mA output and the maximum load position is given by
the 20 mA output.
Part load positions are indicated by intermediate values between 4 and 20 mA.
Use of the 4 20 mA signal is common for many control systems and may be used on its own, if
required, for all control functions for single and multiple compressor installations, subject to a
suitable control system.
Connections:
Plug Connections Function
1 Supply Voltage + 24V DC
2 Common 0 VDC
3 Output Signal 4-20 mA
Note: ATEX LPI Sensors are supplied with an Intrinsic safety barrier, and installation must be
carried out according to the standards in force for the country in question.

Checking the ATEX LPI Calibration

All compressors with variable Vi are despatched from Howden Compressors facility with Vi set at
2.2 and the LPI calibrated to suit.
When the Slide Valve is in the unloaded position a 4mA output signal is achieved, and at
maximum load a 20mA output signal. However, if the factory Vi setting is not appropriate and
needs to be adjusted, re-calibration of the LPI sensor will be required.

ATEX Linear Position Indicator (LPI) Calibration Procedure

1. Move slide valve to Minimum Load position.

2. Apply supply voltage for 5 minutes before commencing calibration.

3. Push the calibration button for 5 seconds to enter calibration mode, the red LED will change
from normally flashing to off.

4. Move the slide valve to the minimum position, and then push the calibration button ONCE. The
red LED is now illuminated constantly, when the red LED switches off it is ready for the 100%
slide valve position calibration.

5. Move slide valve to the 100% maximum load position, and push the calibration button TWICE.

6. The red LED will flash quickly for a few seconds, once the LED returns to normal flash the
calibration is complete.

The green LED indicates slide valve maximum and minimum valve travel end positions.
SECTION 5 FIRST START UP

5.5 ATEX LPI SENSOR DRAWINGS

SECTION 5 - FIRST START UP

5.6 ASSEMBLY PROCEDURE FOR MAXIMUM AND MINIMUM LIMIT SWITCHES

1. Assemble the maximum switch support bracket and the minimum switch support bracket.
The holes for these brackets are pre-drilled.

2. Assemble the switches to the brackets.

3. Ensure the slide valve is in the minimum position (off load, ie, indicator spindle turned fully
anti-clockwise) slip the spaces onto the cam spindle.

4. Assemble the two cams on the spindle.

5. Turn the inner cam anti-clockwise until it operates the minimum micro-switch, lock the cam
in this position with the grub-screw.

6. Move the slide valve to the maximum position (on load, ie, the indicator spindle turned fully
clockwise) and turn the outer cam clockwise onto its peak position until it operates the
maximum switch, lock the cam in this position with the grub screw. The switches can be
heard to click when the peak on the cams pass over the contact on the switch.

7. The slide valve can be moved to maximum and minimum position by introducing air under
pressure to the actuator cylinder through the tapped holes provided. Introducing air to the
hole furthest away from the compressor body will move the slide valve to the Max-load
position.

8. Move the slide valve to the Max-load position as described in 7. Fit and lock the
indicator knob on the cam shaft with the slot on the knob in line with the MAX mark on
the indicator plate.

9. Check the full travel of the valve against the indicator plate and ensure the slot on the
indicator knob indicates the maximum (100%) and minimum (approximately 20%)
positions.

10. Connect wires to switch terminals.

SECTION 5 - FIRST START UP

5.7 PROCEDURE FOR FITTING POTENTIOMETER

1. Power down electrical supply.

2. Disconnect the three wires to the potentiometer.

3. Mark gear mesh point on both gears.

4. Looking on the gear, rotate it in an anti-clockwise direction until the potentiometer shaft
reaches the minimum position. Now mark the gear and the potentiometer to fix their
orientation to each other.

5. Rotate the shaft of the new potentiometer to the same minimum position and mark the
potentiometer same as original, fit the gear and align its mark to the mark on the new
potentiometer and tighten the grub screw to fix their orientation.

6. Mark the potentiometer shaft where it has to be shortened, remove gear and cut shaft.
Now fit potentiometer to mounting bracket and refit gear, line up marks on gear and
potentiometer to correct orientation and secure grub screw.

7. Refit the assembly to the cylinder cover with the potentiometer still in the same minimum
position and ensure the original marks on the gear teeth are in the correct mesh.

8. Lightly press down the assembly when tightening the bracket to the cylinder end cover to
reduce gear backlash.

9. Re-connect the three wires to the potentiometer.

SECTION 7 - NORMAL OPERATION

7.1 NORMAL START

1. Check the level in the oil tank.

2. Check that all necessary gas, oil and water valves are open.

3. Start the lubricating oil pump motor.

4. Ensure the capacity control valve is in the fully unloaded position.

Adjust the volume ratio Vi screw to the required setting. Vi type only.
(Turning fully clockwise sets Vi = 2.2). Refer to graphs under 6.3 for number of turns.

5. After the oil pump has been running for approximately 15 20 seconds, start the drive unit
and check that all gauges are indicating normal readings.
6. Load the compressor - oil to outer end cylinder ports activates compressor slide valve to
go "on load " position.

Note: A log should be kept of the instrument readings so that deviations

from the normal running can easily be seen by the Engineer in charge of the installation.

7.2 NORMAL STOP

1. Stop the drive unit.

2. After the compressor stops, the control system should be operated to move the slide valve
into the off load position, unless the control system does this automatically.

3. After the compressor stops rotating, stop the lubricating pump motor

The compressor is now ready for the next start-up sequence.

SECTION 8 - PROCEDURES DURING SHUT DOWN

8.1 PRECAUTIONS DURING SHUTDOWN

The Howden WRV screw compressor operates on an oil/gas mixture and short periods of
shutdown will not adversely affect the unit.

If the compressor is shut down for an extended period, the suction and discharge valves should be
closed and the lubricating oil pump should be run for approximately 10 minutes each week to
distribute oil through the set.

Turn the compressor driveshaft a few times every week by hand. This will help to avoid Brinelling
of the anti friction bearings.

If the shutdown period is three months or more, the above procedure should be continued, and in
addition, the compressor set should be run for one hour every three months. See Section 7.1 -
Normal Start.

During a shutdown period in cold conditions, any water cooled items of the plant should be drained
or the cooling water flow maintained to prevent frost damage.

Users may use suitable inhibiting oils in the Howden Screw Compressor prior to a long shutdown.

If you have any doubts about the compatibility of any inhibiting oil with your gas or existing
lubrication oil, please contact the manufacturer or your dealer.
SECTION 9 MAINTENANCE

9.1 GENERAL COMMENTS

The compressor is designed to give long periods of trouble free operation with the minimum of
maintenance.

A yearly inspection is recommended for all Howden compressor installations. Some installations
may require an annual statutory insurance survey. An Annual Inspection kit will be required for
this inspection.

The purpose of the yearly inspection survey is to check if there is any wear of the journal and
thrust bearings, slide valve guide block, PTFE seals and Actuator piston and seals, and if any wear
is found, for these components to be renewed.

The following are the maximum acceptable floats in the Thrust Bearings:

WRV 163 and 204, 0.003mm (0.0001")

WRVi 255 and 321 & 365 0.003mm (0.0001)
WRVT 255/110 and 130 0.160mm (0.0063")
WRVT 255/145,165,193 and 220 0.200mm (0.0079")
WRVT 321 0.275mm (0.0108")
WRVT 365 0.425mm (0.0167)
WRVT 510 0.450mm (0.0177")

After four years of operation it is recommended that an approved Howden service engineer
completes a major overhaul on the compressor. After this time, the thrust bearings must be
renewed. The bearings may still be serviceable, but all bearings have a finite lifespan and
replacement at this point may forestall an expensive compressor breakdown at a later date.

When the compressor is being inspected or overhauled it must be in a clean area.

On WRV and WRVi compressors the inspection overhaul procedure is different between the 163
and the 204/255/321 compressor due to construction variations.
On all WRVT compressors the inspection procedure is different to the WRV compressor due to the
thrust bearing configuration. Please ensure that the correct procedure is used for the size and
type of compressor involved.

Alternatively, Howden Compressors Limited have a specialist Overhaul Department where

compressors are inspected, a report sent, and only on receipt of clients instructions the
compressor will be overhauled. Prior to despatch, the compressor is fully tested and supplied with
a one year warranty.

The following are all available for the WRV and WRVi Compressor range:

SERVICE MANUALS SPARES KITS OVERHAUL KITS

Special tools to ease dismantling and reassembly

Please contact Howden Compressors Ltd, Compressor Business Unit, for further
information. Address in the foreword of this manual.
SECTION 9 MAINTENANCE

9.2 COMPRESSOR RECORD

COMPRESSOR TYPE / CONTRACT COMMISSIONING

SERIAL No No DATE

CLIENT / USER

OPERATING DUTY
COMP. SUCTION PRESSURE
COMP. DISCHARGE PRESS.
OIL SUPPLY PRESSURE
OIL SUPPLY TEMPERATURE
PRODUCT / GAS TYPE
INPUT SPEED

TYPE OF LUBRICATING OIL

SERVICE HISTORY
HOURS DATE PARTS REPLACED
1st SERVICE

HOURS DATE PARTS REPLACED

2nd SERVICE

HOURS DATE PARTS REPLACED

3rd SERVICE
Our Compressor Business Unit can offer you a comprehensive range of facilities to ensure the continued
reliable operation of your Howden compressor.

We can supply:

1. A comprehensive range of direct replacement compressors, supplied with a warranty.

2. Approved parts and technical information to allow urgent repairs to be carried out on site.

3. A field engineer to service or supervise the installation and commissioning of the

compressor.

4. Quotations for price and delivery of spare parts.

5. A comprehensive service contract or survey incorporating full vibration analysis tailored

specifically to meet customer requirements and time schedules.

For further information and details of the above please contact the Compressor Business
Unit directly at the address in the foreword of this Manual.

July 2007
Howden Compressors Limited Howden Compressors LLC
Compressor Business Unit 1850B North Gravers Road
133 Barfillan Drive Plymouth Meeting
Glasgow G52 1BE PA 19462
UNITED KINGDOM USA

Tel: +44 (0)141 882 3346 Tel: 001 610 313 9800
Fax: +44 (0)141 883 5901 Fax: 001 610 313 9215
e-mail: sales@howdencompressors.co.uk e-mail: sales@howdencompressors.com
Web: www.howden.com Web: www.howden.com
WRV & WRVi
COMPRESSOR RANGE

SERVICE MANUAL
INDEX TO SECTIONS
Page Number

SECTION 1 FOREWORD 2

SECTION 2 DESCRIPTION 4
2.1 The WRV / WRVi Compressor 5
2.2 Compression Cycle 6
2.3 Gas System 7
2.4 Oil System 7
2.5 Oils 8

SECTION 3 INSTALLATION 9
3.1 Alignment of Compressor Couplings 10
3.2 Alignment Tolerance 11
3.3 Dowelling 12
3.4 Piping 12

SECTION 4 FIRST START UP 13

4.1 First Start 14

SECTION 5 NORMAL OPERATION 15

5.1 Normal Start 16
5.2 Normal Stop 16

SECTION 6 PROCEDURES DURING SHUT DOWN 17

6.1 Procedure on Shut Down 18
6.2 Inhibiting Oils 18

SECTION 7 MAINTENANCE 19
7.1 General Comments 20
7.2 Preparation for Annual Inspection 21
7.3 Dismantling Procedure for Annual Inspection 21
7.4 Checking Clearances 28
Guide Block 28
Thrust Bearing 29
7.5 Re-assembly after Annual Inspection 30

SECTION 8 OVERHAUL 32
8.1 General Procedure 33
8.2 Dismantling 163 Compressor for Major Overhaul 34
8.3 Re-assembly 163 Compressor after Overhaul 38
Rotor to Main Casing Outlet End Clearance 39
8.4 Dismantling 204, 255 & 321 Compressors for
Major Overhaul 41
Journal Bearing Clearances 42
Rotor Weights 45
8.5 Re-assembly 204, 255 & 321 Compressors after
Overhaul 46
Thrust Bearing Nip 46
Rotor to Main Casing Outlet End Clearance 47

SECTION 9 SPECIAL INSTRUCTIONS 49

9.1 Torque Specifications 50
9.2 Procedure for Fitting Lockwashers 53
9.3 Special Tool List 54

SECTION 10 SPARES 56
10.1 Recommended Spares List 57

1
SECTION 1

FOREWORD

2
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR

These instructions have been prepared to ensure that your compressor gives long and satisfactory service.

Detailed instructions for carrying out an annual inspection or overhaul procedure is included for the following
range of compressors:

MK1G-1H/WRV163

MK6-6A-6B/WRV204

MK6-6A-6B/WRVi255

MK6-6A/WRVi321

MK1/WRVi365

The entire manual should be read before reverting to any one section for specific information.

One copy should be given to the personnel responsible for installing and operating the compressor.

All requests for information, services or spares should be directed to:

HOWDEN COMPRESSORS or HOWDEN COMPRESSORS LLC

Compressor Business Unit 1850B North Gravers Road
133 Barfillan Drive Plymouth Meeting
Glasgow PA 19462
G52 1BE USA
UK

Telephone: 0044 (0)141 882 3346 Telephone: 001 610 313 9800
Fax: 0044 (0)141 882 8648 Fax: 001 610 313 9215
E-mail: hcl@aftersales@howden.com E-mail: sales@howdencompressors.com
Website: www.howden.com Website: www.howden.com

All enquiries should be accompanied by the Howden Compressors Contract Number and the Compressor
Serial Number, taken from the nameplate on the side of the compressor body.

HOWDEN
COMPRESSORSCOMPRESSORS

3
HOWDEN

SECTION 2

DESCRIPTION

4
2.1 THE WRV COMPRESSOR

The Howden WRV & WRVi Oil Injected Compressor is a positive displacement, capacity controlled,
oil flooded, rotary machine.

Compression is achieved by the meshing of two helical rotors on parallel shafts housed in a casing.

The accurately machined helical rotors are called Male and Female. The Male (driving) rotor has
four lobes which mesh with six flutes in the female (driven) rotor, both rotors having the same
outside diameter. Each rotor is supported by two plain white metal, thick walled, journal bearings
fitted adjacent to the compression chamber. Angular contact bearings, offloaded by internal balance
pistons accommodate the axial thrust load.

Capacity control is achieved by means of a hydraulically controlled slide valve in the compressor.
This allows internal gas re-circulation, thus controlling the capacity from 100% down to nominally
10% with power saving.

Various methods of hydraulic cylinder control are available and the appropriate literature provided by
the compressor set supplier, should be studied before carrying out any work on this equipment.

5
2.2 THE COMPRESSION CYCLE (DIAGRAMMATIC ONLY)

1. Gas is drawn in to fill the 2. As the rotors rotate, the interlobe space moves past
interlobe space between the inlet port so sealing the interlobe space.
adjacent lobes on top side of Viewed from the top side of rotors at Inlet End.
rotors at Inlet End.

3. Continued rotation progressively 4. When the interlobe space becomes exposed

reduces the space occupied by the to the outlet port the gas is discharged.
gas, causing compression. Viewed Viewed from the underside of rotors at
from underside of rotors at Discharge Discharge End.
End.

6
2.3 DESCRIPTION OF A GAS SYSTEM FOR A TYPICAL REFRIGERATION COMPRESSOR SET

Gas is drawn into the compressor through a non-return valve and then a strainer is fitted directly on
the inlet flange and discharged into an oil tank/separator. The non-return valve is necessary to
prevent the compressor being motored in the reverse direction when it is stopped with high gas
pressure at the outlet.

If necessary, a second non-return valve is positioned at the outlet of the tank to prevent the entry of
gas or liquid refrigerant.

Primary separation of the oil mixed with the gas is achieved in the tank, secondary separation takes
place in a wire mesh element separator positioned close to the tank outlet.

In some separator designs the wire mesh is replaced by a separator cartridge.

The separated oil drains into the oil tank. A further secondary separator vessel may also be fitted
where a very high separation efficiency is required. The oil separated is usually drained into the
compressor through a small bore pipe which can be fitted with a protective filter and an isolating
valve.

2.4 DESCRIPTION OF AN OIL SYSTEM FOR A TYPICAL REFRIGERATION COMPRESSOR SET

Oil at outlet pressure is drawn from the tank by the oil pump, passed through a cooler and micronic
filters to the manifold where it is fed to the bearings, balance piston, shaft seal, compression
chamber and hydraulic actuator.

When liquid refrigerant injection is used there is no oil cooler.

A differential pressure relief valve in the system before the filters maintains a manifold pressure in
the range of 30 psi (2 kg/cm) for a standard range compressor set and 40 psi (2.7 kg/cm) for an H
designated compressor set. When the compressor operates on a continuous duty, duplex micronic
filters may be fitted, allowing one filter element to be changed while the other is in operation.

Approved lubricating oils for refrigeration compressors are listed under Section 2.5.

7
2.5 RECOMMENDED LUBRICATING OILS

Howden compressors are fitted, as standard, with neoprene O rings.

These O rings are compatible with the majority of standard refrigerants and many oils, but
compatibility with all possible combinations of refrigerant and oil cannot be guaranteed.

Should you wish to review this matter, please do not hesitate to contact Howden Compressors
Limited, who will be pleased to provide recommendations and costs for any special O ring materials
which may be required.

Typical Standard Refrigerants:

R717, R22, R134a, R404A R407C, R410A, R507

Typical Oils:

Mineral Oil
Polyol Ester Oil
Poly Alkylene Glycol Oil
Alkyl Benzene Oil

Oil Viscosity:

For the majority of ammonia refrigeration applications, oil viscosity of 68 centistokes at 40C is the
appropriate selection. However, with many other refrigerants, eg; R134a with high condensing
temperatures, or applications involving hydrocarbon gases, a specific oil selection is required.

Howden Compressors Limited offer a consultancy service to all users of HCL product.
Please consult the applications department of HCL who will be happy to advise on grade of oil
applicable to the refrigerant or gas at the specific duty application.

8
SECTION 3

INSTALLATION

9
3.1 ALIGNMENT OF COMPRESSOR COUPLINGS

The couplings supplied with this compressor must be aligned using the method described below:

If a compressor only is supplied the coupling alignment tolerance figures can be seen under Section
3.2.

During alignment checks, both half couplings should be rotated together from 0 to 90, 180, 270
and 360 and readings of radial and facial alignment recorded. Turning both half couplings together
ensures that readings are recorded at the same point on each half coupling, thus eliminating the
effect of any irregularities on the outside diameters, or faces of the half coupling.

Commence alignment by setting the faces of the coupling halves parallel in the vertical plane. The
axes will now be parallel in the horizontal plane and further adjustment to obtain the correct centre
heights will require equal shimming under each foot of the unit being adjusted. The units are now
positioned vertically and horizontally.

Further adjustment to obtain the correct coupling gap, radial and facial alignment, will only require
movement of one unit on the existing shim size.

Coupling gap dimensions should be set with the couplings held in a repeatable position, ie, hard
together or hard apart. This ensures that each coupling half is removed to the same axial position as
each check is made.

The actual coupling gap should be correct when the shafts are in their normal running condition. If
the combined float of the driving and driven shaft exceeds the coupling gap tolerance, the value and
direction of float for both shafts will be shown on the General Arrangement Drawing.

When setting the gap the axial float of each shaft should be determined and the hard together or
hard apart dimension calculated.

Example: Compressor driven directly by a turbine.

Compressor shaft float 0.050mm (0.002)

Turbine shaft float 0.250mm (0.010)
The normal running position of the compressor shaft is towards the turbine and the turbine normally
runs thrusting towards the compressor.
Required gap 3.175mm (0.125)
If the gap is checked with the couplings hard apart it should be:
Plus Compressor shaft float 0.000mm (0.000)
Plus Turbine shaft float 0.250mm (0.010)
= Hard apart gap 3.425mm (0.135)

10
3.1 ALIGNMENT OF COMPRESSOR COUPLINGS (Continued)

If the gap is checked with the couplings hard together, ie, in the normal running condition, it should
be equal to the required coupling gap: 3.175mm (0.125).

NOTE: If a limited float coupling is used with an electric motor whose shaft has no thrust bearing,
the gap must be correct with the motor shaft on its magnetic centre. In this instance the
facial alignment check should be made, rotating the driven half coupling only as the drive
(motor) half coupling is not located axially, or preferably by a double-clock method, which
avoids the problem of repeated axial position.

3.2 ALIGNMENT TOLERANCE

The maximum acceptable line-up tolerance for couplings on compressor installations is as follows:

RADIAL TOLERANCE FACE TOLERANCE

Application

A. Motor to Gearbox or Compressor ie couplings operating up to 3,600 rpm

Radial Tolerance Face Tolerance

0.15mm (0.006) TIR TIR 0.005mm/cm or 0.005/in Dia. Of coupling

B. Gearbox to Compressor i.e. couplings operating above 3,600 rpm

Radial Tolerance Face Tolerance

0.10mm (0.004) TIR TIR 0.005mm/cm or 0.005/inch Dia. Of coupling

Radial Tolerance
Eccentricity = TIR on circumference

TIR denotes Total Indicator Reading obtained by Clockgauge

11
3.3 DOWELLING

Only one unit of any assembly will be dowelled before despatch. Dowels should be fitted to ease re-
alignment when components are removed for overhaul.

3.4 PIPING

Before installing the piping the compressor inlet and outlet ports should be inspected to ensure no
dirt is present.

Note that the pipes and fitting used should not restrict flows. To avoid this always use piping with a
bore larger than the thread diameter of the compressor port, eg, WRV 204 oil injection
connection thread is BSP and so a 1 OD pipe should be used.

NOTE: All piping should be supported so that no strain is transmitted to the compressor casings.

The piping should be inspected for cleanliness before installation. As each pipe is connected to the
compressor, the coupling alignment should be checked to ensure that no alteration has taken place.

If alignment has altered the compressor is being strained and the piping supports must be adjusted.

It is not sufficient merely to re-align the drive unit as this will not correct the strain being imposed on
the compressor. Oil injected refrigeration compressors must have a suction strainer permanently
fitted directly on the compressor inlet.

12
SECTION 4

FIRST START UP

13
4.1 FIRST START

Installation of the compressor will have been carried out in accordance with Section 3 of this manual.
The Commissioning Engineer should however ascertain that the correct procedures have been
followed, in particular the coupling alignment must be checked, then proceed as follows:

1. Disconnect the coupling between the drive and the compressor and check that the direction
of rotation is correct to drive the compressor in a clockwise direction, looking on the
compressor input shaft. (Anti-clockwise if compressor MRV model).
2.
3. Fill the oil tank with lubricating oil of the correct grade to the required level as indicated on
the tank level sight glass.

4. Ensure that the manifold and oil pipes to the compressor are clean then start the lubricating
pump motor to circulate the oil and clean the system.

5. The lubricating oil pressure differential control valve should be set to give a 30 psi (2 kg/cm)
oil manifold differential pressure for a standard range compressor and 40 psi (2.7 kg/cm) oil
manifold differential pressure for an H designated compressor at correct operating
temperature, with clean oil filter elements fitted.

6. Check the operation of any safety trips fitted by running the drive unit disconnected from the
compressor and mechanically operating the trips, check that the actual settings are in
accordance with the contract specification. The lubricating oil differential pressure trip can
be set at 12 psi (0.85 kg/cm) on a standard range compressor and 22 psi (1.54 kg/cm) on
H designated compressors by partially closing the oil filter outlet isolation valve and thereby
reducing the differential oil pressure. As the filters become dirty the differential oil pressure
will drop to these figures, which are the minimum accepted value.

7. Check that the compressor turns freely by hand and reconnect the coupling between the
drive unit and the compressor.

8. Check that the cooling water is turned on to the lubricating oil cooler, if fitted.

9. Check that all gas inlet and outlet isolating valves are open.

10. Start the lubricating oil pump motor.

NOTE: The compressor should be unloaded prior to start up. If the compressor is started
without first being unloaded a higher starting torque will be required.

11. Start the drive unit and check that all gauges are indicating correctly.

12. Run the compressor for 30 minutes at minimum gas flows and check that all readings are
normal, then operate the capacity control valve to the required position. This position will be
indicated on the dial mounted on the hydraulic cylinder.

13. If possible, check the slide valve control over the full range of capacity.

14
SECTION 5

NORMAL
OPERATION

15
5.1 NORMAL START

1. Check the level of the oil in the tank.

2. Check that all the necessary gas, oil and water valves are open.

3. Start the lubricating oil pump motor.

4. Ensure the capacity control valve is in the fully unloaded position.

5. Start the drive unit and check that all gauges are indicating normal readings.

5.2 NORMAL STOP

1. Stop the drive unit.

2. After the compressor stops, the control system should be operated to move the slide valve
into the off load position unless the control system does this automatically.

3. After the compressor stops rotating, stop the lubricating oil pump motor.

4. Close all gas and water isolating valves.

The compressor is now ready for the next start up sequence.

NOTE: A log should be kept of the instrument readings so that deviations from normal running
conditions can be easily seen by the Engineer in charge of the installation.

16
SECTION 6

PROCEDURES
DURING SHUTDOWN

17
6.1 PROCEDURES DURING SHUTDOWN

The Howden WRV Screw Compressor operates on an oil/gas mixture and short periods of shutdown
will not adversely affect the unit.

If the compressor is shut down for an extended period the lubricating oil pump should be operated
for approximately ten minutes weekly, to distribute oil throughout the set.

Turn the compressor driveshaft a few times every week by hand. This will help to avoid Brinelling of
the anti-friction bearings.

If the shutdown period is three months or more the above procedure should be continued and, in
addition, the compressor set should be run for one hour every three months.

Alternatively, for greater corrosion protection, the normal lubricating oil can be drained off, replaced
with inhibiting oil and the set run for one hour initially, then one hour every three months.

NOTE: Before the compressor set is returned to normal use, the inhibiting oil must be
removed and the system filled with regular oil.

During a shutdown period in cold conditions any water cooled items of plant should be drained, or
the cooling water flow maintained to prevent frost damage.

6.2 INHIBITING OILS APPROVED FOR USE WITH HOWDEN SCREW COMPRESSORS

A list of approved inhibiting oils suitable for use on the Howden Screw Compressor prior to a
prolonged shutdown is shown in Fig. 1.

If you have any doubts about the compatibility of these oils with your gas please contact the
manufacturer or your dealer.

SHELL ENSIS ENGINE OIL 10W

ESSO RUST-BAN 335 OR 337

MOBIL MOBILARMA 524

CALTEX CALTEX PRESERVATION OIL 10W

Fig. 1

18
SECTION 7

MAINTENANCE

19
7.1 GENERAL COMMENTS

The compressor is designed to give long periods of trouble free operation with the minimum of
maintenance. A yearly inspection is recommended for all Howden Compressor installations. Some
installations may require an annual statutory insurance survey.

The purpose of the yearly inspection survey is to check if there is any significant wear of the thrust
bearings, slide valve guide block or PTFE seals and, if any wear is found, for these components to
be renewed.

Where axial movement condition monitoring equipment is fitted to the compressor, a continuous
indication of the thrust bearing condition is monitored and the bearing check can be extended to
once every two years.

It is not anticipated, however, that a major overhaul will be required until approximately after four
years operation. After this time the thrust bearings must be renewed.

When the compressor is being inspected or overhauled it must be dismantled in a clean area.

The inspection overhaul procedure is different between the WRV163 & WRV204 compressors and
the, WRVi255, WRVi321 & WRVi365 compressors due to construction variations. Please ensure
that the correct procedure is used for the size of compressor involved.

Always refer to the sectional and external arrangement drawings.

All fasteners should be torqued to the value specified as stated under Torque Specifications in
Section 9.1 using appropriate torque wrenches.

All lockwashers, tabwashers, O rings and PTFE seals must be renewed on assembly. Section 9.2
describes lockwasher assembly procedure.

Special tools to ease dismantling and re-assembly can be provided, as listed in Section 9.3. Details
of these can be obtained from the Compressor Business Unit, Howden Compressors. Section 10
details all Part Numbers of normally replaceable components.

20
7.2 PREPARATION FOR ANNUAL INSPECTION

Before dismantling the compressor, certain precautions should be taken in the interests of safety:

1. Isolate the drive unit.

2. Depressurise and purge the system.

3. Disconnect the drive unit coupling from the compressor.

4. Place a receptacle under the outlet end of the compressor to catch any oil which may drip
from the hydraulic cylinder when the cylinder cover is removed or when the outlet end cover
is removed.

5. Ensure all lifting equipment, ie, eye bolts, slings, and shackles are safe and serviceable.

To enable a check to be made of floats and condition of seals and guide block on the compressor
during annual maintenance, a certain amount of dismantling is required. This differs slightly between
the 163 compressor and the 204, 255, 321 & 365 compressors.

7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION

Commence at discharge end with the Hydraulic Actuator

No matter which size compressor is involved, extract the 3 off cap screws holding the Aluminium
cover to the cylinder cover, if fitted, and remove. Extract the cap screws securing the Cylinder Cover
to the Hydraulic Cylinder and remove the cover, including the limit switches and indicator spindle
which are attached to it (Fig. 2).

NOTE: Some compressors will have a LPI sensor fitted as an option instead of switches, and will
not have the cylinder switch cover fitted.

21
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Fig. 2

Fig. 3

NOTE: The indicator spindle has to clear a dowel pin which moves along the spiral groove in the
spindle, therefore this cover must be kept in an axial position when withdrawing until the spindle
clears the dowel pin (Fig 3). The LPI Sensor is housed inside a sensor well attached to the cover
and this must also be removed axially.

IMPORTANT: It is essential that the spiral groove engaging the dowel pin is marked for correct re-
assembly to avoid damage to the potentiometer.

Move the slide valve to bring the actuator piston to the outer end of the cylinder. Do not move the
slide valve past its minimum position at the capacity stop as it may come off the guide block at the
inlet end of the compressor when unlocking the piston lockwasher and locknut.

Fig. 4 Fig. 5

Unlock the piston lockwasher and locknut and remove (Fig. 4).
Remove the actuator stop sleeve, if fitted, from the cylinder bore (Fig. 5).
Withdraw the piston (Fig. 6) using the appropriate tool listed for the compressor size. See Section
9.3.

22
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Removing the Combined Outlet Cover/Cylinder 163 Compressor

Fit an eyebolt to the tapped hole at the top of the outlet cover, attach a sling to the eyebolt to support
the weight of the cover (Fig. 7).

Fig. 6 Fig. 7

23
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Extract the set pins securing the discharge cover to the main casing body. (Fig. 8) Push the piston
rod to the bottom of the cylinder.

Carefully draw the cover clear of the piston rod/valve spindle. Care should be taken to prevent
damage to the actuator cylinder which is part of the cover.

At this stage, the slide valve can be withdrawn from the compressor for a visual inspection. (Fig. 9)

Fig. 8 Fig. 9

A light shone from the slide valve bore will permit a visual inspection of the rotors. (Fig. 10-11)

Fig. 10 Fig. 11

24
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Removing the Cylinder and End Cover WRV204, WRVi255, WRVi321 & WRVi365 Compressors

The hydraulic cylinder and end cover are separate items in the above compressor and are removed
as follows:

Removing the Hydraulic Cylinder

Extract the cap screws or setscrews securing the cylinder to the end cover (Fig. 12). Support the
cylinder with a sling and using the jacking holes provided in the cylinder flange, jack out the cylinder
(Fig. 13).

Fig. 12 Fig. 13

Removing the End Cover

Extract most of the set pins securing the outlet end cover to the main casing (Fig. 14).

Fig. 14

25
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Fit an eye bolt to the top of the outlet cover flange and use suitable lifting equipment to support the
weight of the cover (Fig. 15).
Remove the set pins locating the cover to the main casing and remove the cover.

Fig. 15 Fig. 16

Take care to avoid damage to the piston rod/valve spindle (Fig. 16).

Removing the Slide Valve

Withdraw the slide valve using suitable lifting equipment to support the weight of the valve,
especially on WRVi255, WRVi321, & WRVi365 compressors (Fig. 17).

Fig. 17

26
7.3 DISMANTLING PROCEDURE FOR ANNUAL INSPECTION (Continued)

Now that the slide valve has been removed by shining a light from the valve bore, a visual inspection
of the rotors can be achieved (Figs. 18 - 19).

Fig. 18 Fig. 19

PTFE Seals.
The compressor has now been dismantled enough to permit the inspection and replacement of the
PTFE seals and O rings in the actuator cylinder, (Fig. 20) also the piston, should they be required
(Fig. 21).

Fig 20 Fig 21

Fig. 20 Fig. 21

27
7.4 CHECKING CLEARANCES

Guide Block

The guide block which locates the slide valve should also be checked for wear every 30,000 hours or
every 4 years whichever comes first. See Fig. 22 and relative table for dimensions.

Guide Block to Slide Valve Slot

Compressor Size
Fig. 22
by Dimension W Clearance
Rotor Diameter
163 mm 24.987/24.975 mm 0.046/0.013 mm
(0.984/0.9833) (0.0018/0.005)
204mm 29.987/29.975 mm 0.046/0.013 mm
(1.181/1.180) (0.0018/0.005)
255mm 41.262/41.250 mm 0.050/0.013 mm
(1.625/1.624) (0.002/0.005)
321mm 44.990/44.965 mm 0.060/0.010mm
(1.771/1.770) (0.0024/0.004)

365mm 49.991/49.965mm 0.065/0.009mm

(0.0025/0.004)

28
7.4 CHECKING CLEARANCES (Continued)

To check the Thrust Bearing Float

To check the thrust bearing float, set a dial indicator up axially on the shaft end. Access must be
gained to the inlet end of the female rotor by removing the rotor cover. Push or pull the rotor, to its
limit in either direction.

Record the indicator reading and then push or pull the rotor to its limit in the opposite direction. The
difference in indicator readings is the thrust bearing axial float. This procedure must be followed for
both male and female rotors. This reading should not exceed 0.025mm (0.001). Any increase over
this reading will necessitate replacement of the thrust bearings. The thrust bearings are fitted with a
small pre-load, the maximum float permitted is 0.025mm (0.001). If in excess of this the bearings
must be changed.

NOTE: Should the thrust bearing float be within limits, no further work on the rotors is
recommended, i.e. journal bearing clearances would not necessarily be measured.
Any increase on this figure will necessitate replacement of the thrust bearings, the procedure for
which is described per Section 8.2-8.3 or 8.4-8.5.

Maximum Thrust Bearing Float

Please note that due to a change in bearing

selection, which now means that bearings are fitted
with a pre-load condition, the maximum float
permitted is 0.025mm (0.001) regardless of
compressor size.

Fig. 23

NOTES:

It is extremely important that the fasteners on the thrust bearing retaining plates of the WRV163 and
WRV204 compressors are torqued exactly to the specified setting of 14Nm. Over-torquing will not
permit correct operation of the thrust bearing, resulting in premature failure.

Should the thrust bearing float be within limits, no further work on the rotors is recommended, ie,
journal bearing clearances would not necessarily be measured. Where the thrust bearing float is
outside limits and, therefore, the thrust bearings have to be slackened off and removed, the
opportunity would then be taken to measure journal bearing condition, and proceed as for major
overhaul.

Where a compressor is fitted with condition monitoring, no check on the thrust bearings will be
required. See Section 7.1. A 4 yearly check on the guide block wear, and an annual check on the
PTFE seal condition is all that is necessary.

29
7.5 RE-ASSEMBLY AFTER ANNUAL INSPECTION

When all checks and corrections have been made, and assuming no major problems have
developed, the compressor can be re-assembled. (Refer to the Sectional Arrangement drawing
supplied and torque specifications as advised under Section 9.1)

WRV163 Compressor

Ensure the guide block is in position in the slide valve bore, insert the slide valve and push it all the
way to the on load position (Fig. 24).
Insert an eyebolt into the outlet end cover flange and with the aid of suitable lifting equipment re-
assemble the outlet end cover/hydraulic cylinder (Fig. 25).
Secure with set pins to the main casing. Remove the lifting sling and eyebolt.

Fig. 24 Fig. 25

Refit the piston into place in the hydraulic cylinder. Secure with new lockwasher and locknut (Fig.
26). Replace the actuator stop sleeve. Fit the cylinder end cover, taking care to ensure the dowel is
properly located in the spiral groove of the indicator spindle (Fig. 27).

Fig. 26 Fig. 27

Secure the cover with cap screws. Ensure the limit switches are in position securely fastened,
assemble the limit switch cover, if fitted, and secure with cap screws.

For compressors fitted with LPI sensors, refit the cylinder end cover and secure the cover with
capscrews. Refit and secure the LPI sensor.

30
7.5 REASSEMBLY PROCEDURE FOR ANNUAL INSPECTION (Continued)

WRV204, WRVi255, WRVi321 & WRVi365

Ensure the guide block is in position in the slide valve bore, insert the slide valve and push it all the
way to the on load position (Fig. 28).
Insert an eyebolt into the outlet end cover flange and with the aid of suitable lifting equipment re-
assemble the outlet end cover and secure (Fig. 29).

Fig. 28

Fig. 29

Attach a sling to the hydraulic cylinder, re-assemble to the outlet end cover and secure with cap
screws (Fig. 30).

Refit the piston into place in the hydraulic cylinder. Secure with new lockwasher and locknut (Fig.
31). Replace the actuator stop sleeve. Fit the cylinder end cover taking care to ensure the dowel is
properly located in the spiral groove of the indicator spindle (Fig. 32).

Fig. 31

Fig. 30 Fig. 32

Secure the cover with cap screws. Ensure the limit switches are in position securely fastened,
assemble the limit switch cover, if fitted, and secure with cap screws.

For compressors fitted with LPI sensors, refit the cylinder end cover and secure the cover with
capscrews. Refit and secure the LPI sensor.

31
SECTION 8

OVERHAUL

32
8.1 GENERAL PROCEDURES

Although a yearly inspection and maintenance programme is recommended if no condition

monitoring equipment is fitted, it is essential that a major overhaul is carried out after approximately 4
years operation or earlier, dependant on site conditions.

To carry out a major overhaul proceed as follows:

1. If necessary, isolate, depressurise and purge the system.

2. Disconnect the driving and driven half coupling.
3. Disconnect all gas and oil pipes attached to the compressor.
4. Remove the or 1 BSP taper plug from the bottom of the inlet end cover, and collect the
oil which drains off.
5. Remove the gas inlet strainer.
6. Remove the dowel pins (if fitted) and the holding down bolts from the compressor feet.
7. Lift the compressor to the location, which should be a clean, dry area, where dismantling
and assembly will take place.

Notes about Dismantling and Re-assembly

The dismantling and assembly method varies slightly between the WRV163 & WRV204 compressors
and the WRVi255, WRVi321 & WRVi365 compressors due to differences in construction. It is,
therefore, essential the correct procedure is used for the size of compressor involved.

Reference should always be made to the Sectional Arrangement drawing supplied.

Use only proper locknut spanners to avoid damage to the locknut slots.

Special tools to facilitate assembly and dismantling operations can be supplied on request.

A list of special tools is located in Section 9.3 of this manual.

All lockwashers, tabwashers, O rings and PTFE seals must be renewed on assembly.

All lockwashers must be assembled according to the procedure as described per Section 9.2.

All fasteners should be torqued to the specified values as stated under Section 9.1.

33
8.2 DISMANTLING 163 COMPRESSOR FOR MAJOR OVERHAUL

The compressor to be dismantled as per procedures for Annual Inspection under Section 7.3
then proceed:

Checking Journal Bearing Clearance (163mm)

At this point in the dismantling procedure the journal bearing clearance should be checked to
determine whether the journal bearings need to be replaced as part of the compressor overhaul.

Ensure the thrust retaining plate on the WRV163 compressor is removed (Figs. 33-34).

Fig. 33 Fig. 34

Procure a piece of round bar (13mm) diameter and approximately 14 (355mm) long. Set up a
dial indicator in a convenient position on the main casing to allow the spindle of the dial indicator to
lie on the rotor or rotor locknut.

Set the dial indicator to zero.

Insert the short piece of bar into the hole on the end of the rotor shaft.
By raising and lowering the bar, a reading is shown on the dial indicator. This reading is the shaft lift,
by removing 0.001 (0.025mm) from this reading because of the angle of lift, you are left with the
bearing clearance.
Check this figure against the table of bearing clearances shown on Fig. 35.

34
8.2 DISMANTLING 163 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Repeat the procedure on both rotors. If there is any doubt about the clearance of a bearing, renew
the bearing.

As the inlet end bearings are more lightly loaded they then only require to be inspected if the outlet
end bearings require to be replaced.

Compressor Drawing Drawing Maximum

Size Clearance Clearance Allowable
mm inches Clearance
163 0.070/0.1102 0.0028/0.0043 0.150mm/0.006
Fig. 35 WRV163 Bearing Journal Clearances

Carry on the dismantling procedure by unlocking the lockwashers and locknuts securing the thrust
bearings (Figs.36 & 37) and remove. The adjusting ring behind the thrust bearing has threaded
extensions which enable the ring to be extracted by the use of jacking screws, the operation of
jacking out the adjusting ring withdraws the thrust bearing with it (Figs. 37-39).

Fig. 36 Fig. 37

Fig. 38 Fig. 39

35
8.2 DISMANTLING 163 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Removing the Inlet Shaft Seal (163mm)

Withdraw the driven half coupling key from the input shaft. Extract the cap screws (Fig. 40) from the
shaft seal cover and, using the jacking screw holes provided in conjunction with the T-bar jacking
tools, remove the shaft seal cover. Follow on with the removal of the Input Shaft Seal Assembly
(Figs. 41-42), ie, the stationary seat with O ring seal, the shaft seal and balance piston/labyrinth
seal. Jacking holes are provided for withdrawing the balance piston using T bar tools.

Fig. 41

Fig. 40

Fig. 42

36
8.2 DISMANTLING 163 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Removing the Inlet End Cover (WRV163mm)

Fit an eyebolt into the tapped hole at the top of the inlet cover flange.

Attach a sling to the eyebolt and support the weight of the cover using some form of lifting gear (Fig.
43).

Fig. 43 Fig. 44

Extract most of the screws securing the inlet cover to the main casing. Remove the dowel pins
locating the inlet cover to the main casing (Fig.44). Remove the rest of the screws and carefully
slide the inlet cover over the extended shaft of the male rotor, taking the O ring seal with it taking
great care to avoid damaging the inlet end journal bearings, which are situated in the inlet end cover
(Fig. 45).

Fig. 45

37
8.2 DISMANTLING 163 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Removing the Rotors (163mm)

Now that the inlet and outlet end casings and the thrust bearings have been removed as described
previously, the rotors can be withdrawn from the main casing as shown in Figs.46-47. See table Fig.
48 for estimated rotor weight.

Fig. 46 Fig. 47

ESTIMATED WEIGHTS OF ROTORS

Rotor Male Female
Size lbs kg lbs kg
163/1.80 93 42 71 32
163/1.45 79 36 59 27
Fig. 48

The journal bearings can now be extracted from the Main and Inlet casings using an extractor tool.
See Tool List Section 9.3.

Fit new journal bearings using assembly tool in preparation for re-assembly.

The journal bearings are located by a dowel pin and are retained by circlips.

8.3 RE-ASSEMBLY 163 COMPRESSOR AFTER OVERHAUL

When repair or rectification work has been completed the compressor should be assembled as
follows.

1. Lubricate the bearing bores with lubricating oil and lift in the rotors, ensure the lobes mesh at the
serial numbers on the rotors.
2. Assemble the inlet casing to the main casing, locate with the dowel pins, and secure with set
pins. (See Torque Specification in Section 9.1)
3. Locate the thrust bearing adjustment plates over the rotor shafts at the outlet end and slide them
into position. Heat the angular contact thrust bearings using an oil bath or induction heater to a
temperature of approx 100C and assemble to the rotors.
4. Prior to wire locking the thrust retaining plate in place, it is necessary to check that the rotor
outlet end clearance is correct.
5. Fit lockwasher/locknut and secure (Fig. 36).

38
8.3 RE-ASSEMBLY 163 COMPRESSOR AFTER OVERHAUL (Continued)

Checking Rotor to main casing Outlet End Clearance (163mm)

1. Remove the thrust retaining plate (if fitted).

2. The adjusting plate behind the thrust bearings has two lugs with tapped holes for withdrawal
purposes.
3. Insert jacking screws into the lugs and lightly tension the screws until resistance if felt (Fig.
49).
4. The action of tightening the screws draws the rotors hard against the outlet end of the main
casing.
5. Remove the jacking screws.
6. Replace the thrust retaining plate and the retaining screws (Figs. 33-34).
7. Fit a clock gauge in a suitable point on the casing with the spindle of the gauge touching the
end of the rotor (Fig 50).
8. Set the clock dial to zero.
9. Torque up the plate retaining screws using a torque wrench to 14Nm.
10. Note the movement on the clock gauge. This is the rotor outlet end clearance and should
correspond to the table as per Fig. 51.
11. Adjustment, if necessary, is carried out by machining of the thrust bearing withdrawal plates.

Fig. 49 Fig. 50

Rotor Outlet End Maximum

Clearance Allowable
163 Compressor Clearance
0.050/0.075mm 0.100mm
0.002/0.003 0.004

Fig. 51 WRV 163 Outlet End Clearance

39
8.3 RE-ASSEMBLY 163 COMPRESSOR AFTER OVERHAUL (Continued)

When the clearances are finalised, the retaining cap screws on the Thrust Retaining Plate should be
wire locked using the following method:

The grade of wire used should be 1/16 diameter Annealed S.S. Safety Wire.

Adjustment, if necessary, is carried out by machining of the adjusting plate behind the thrust
bearings (Fig. 52).

Re-assemble the combined outlet cover/cylinder (163mm)

Re-assembly as described per Section 7.5 for 163 compressor, then proceed:

Re-assemble the input shaft seal (163mm)

Re-assemble the components in the following sequence:

1. Assemble the balance piston on the rotor shaft, locating dowel with the driving pin facing
outward.
2. Lubricate the shaft seal and assemble to the rotor shaft, locate in the outward facing
dowel/driving pin of the balance piston.
3. Assemble the stationary seat with a new O ring fitted on the outside diameter recess.
4. Fit the seal housing with new O ring and secure with capscrews, tightening them in a
systematic order to avoid tilting.

The torque setting of the cap screws is 35lbs ft (48Nm).

To complete the assembly fit the coupling key and compressor driven half coupling.

40
8.4 DISMANTLING WRV204, WRVi255, WRVi321 & WRVi365 COMPRESSORS FOR MAJOR
OVERHAUL

The compressor to be dismantled as per procedure for Annual Inspection under Section 7.2, then
proceed:

Checking Journal Bearing Clearance (WRV204) As per procedure for WRV163 Section 8.2

Checking Journal Bearing Clearance (WRVi255, WRVi321 & WRVi365)

Slacken back the set pins securing the thrust housing end cover, to ensure it is not binding on the
outer rim of the thrust bearing (Figs. 53-54).
This necessitates the use of a slightly different technique for measuring bearing lifts, since there is
no longer a hole in the rotor end in which to insert a lever to lift the rotor.
In this case, the dial indicator must be mounted on top of the rotor. The rotor end must be jacked or
levered up at the bottom of the thrust retaining plate to obtain a reading.
The bearing clearance is equal to the indicated reading minus 0.001 (0.025mm).
Repeat the procedure on the other rotor. If there is any doubt about the clearance of a bearing,
renew the bearing. As the inlet end bearings are more lightly loaded they only require to be
inspected if the outlet end bearings show signs of wear.

Fig. 53 Fig. 54

41
8.4 DISMANTLING 204, 255, 321 & 365 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

If the journal bearing clearance inspection shows the bearing diametrical clearance is less than the
maximum allowable, (see Fig. 55), the advantages of a further period of trouble free running with
new journal bearings should be considered before deciding to re-use the existing bearings.

Compressor Drawing Clearance Maximum

Size mm Inches Allowable
Clearance
204 0.070/0.110 0.0028/0.0043 0.150mm/0.006
255 0.095/0.136 0.0037/0.0054 0.180mm/0.007
321 0.130/0.170 0.0052/0.0068 0.226mm/0.009
365 0.175/0.220 0.0069/0.0087 0.295mm/0.012

Fig. 55 Journal Bearing Clearances

Removing the Input Shaft Seal

After the driven half coupling and key have been removed, extract the cap screws from the shaft end
cover and using the jacking holes provided and using T bar jacking tools, remove the shaft cover
(Fig. 56).

Fig. 56

42
8.4 DISMANTLING 204, 255, 321 & 365 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Removing the Input Shaft Seal (Continued)

Pull out the shaft seal, taking care not to damage the carbon face of the seal. (Fig. 57) Withdraw the
inlet balance piston using T-bar jacking tools in the jacking holes provided. (Fig. 58) Follow this up
by removing the stationary seat from the seal cover.

Fig. 57 Fig. 58

Removing the Vi adjuster-WRVi255, WRVi321 & WRVi365 Compressors.

Remove the retaining clip at the back of the square Vi adjusting screw and push the adjusting screw
into the compressor.
Extract the capscrews fixing the Vi cover and remove the cover.

Removing the Inlet End Cover

Fit an eyebolt at the top of the inlet end cover to the main casing (Fig. 59).

Remove the dowel pins locating the inlet cover to the main casing.

Fig. 59 Fig. 60 Fig. 61

43
8.4 DISMANTLING 204, 255, 321 & 365 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Removing the Inlet End Cover (Continued)

Remove the rest of the set pins and carefully slide the inlet cover over the extended shaft of the male
rotor taking the O ring seal with it (Figs. 60-61).

Removing the Rotors

In preparation for removing the rotors, unlock the thrust bearing lockwasher (Fig. 62) and remove the
bolts from the male and female rotors (Fig. 63).

A construction variation between the above compressors and the WRV163 & WRV204 compressor
is that thrust bearing housings are fitted in the WRVi255, WRVi321 & WRVi365 compressors.

Before removing the rotors, the thrust bearings must be withdrawn. It has been known that the thrust
housings, which have jacking holes provided for removal purposes, have been used as bearing
extractors by jacking out the housings and drawing the bearings off with them. This method of thrust
bearing removal is not recommended. The risk of the thrust housing flange being distorted, due to
the tight fit of the thrust bearing, is a possibility and would have a detrimental effect on the outlet end
clearance. The correct procedure is as follows:

1. Remove the set screws securing the thrust housings to the main casing.
2. Fit three long studs and a jacking plate (See Tool Section 9.3).
3. Using a suitable hydraulic jack and cylinder between the jacking plate and the end of the
rotor shaft , apply pressure to the cylinder with the pump, press each rotor in turn out of the
thrust bearings and the casings (Fig. 64).
4. The rotors will require to be carefully supported as shown (Figs. 65-66) and the weight of the
various sizes of rotors is given in the following table (Fig. 67).

Fig. 62 Fig. 63

44
8.4 DISMANTLING 204, 255, 321 & 365 COMPRESSOR FOR MAJOR OVERHAUL (Continued)

Fig. 64

Fig. 65

Estimated Weights
Rotor
Male Female
Size
lbs Kgs lbs kgs
204/1.10 128 58 98 44
204/1.65 171 78 131 59
255/1.10 267 121 231 106
255/1.65 353 160 298 135
255/2.20 437 198 364 161
321/1.32 527 239 435 197
321/1.65 630 286 515 234
321/1.93 763 346 593 269
365/1.65 990 450 770 350
Fig. 66
365/1.93 1111 505 891 405

Fig. 67. Rotor Weights

The thrust bearing sleeves and the angular contact thrust bearings can now be easily removed. The
balance piston and balance piston sleeves are now accessible and, with the aid of the screwed T
bars, (see Special Tool List, Section 9.3) the pistons and sleeves are removed.

The journal bearings can now be extracted from the Main and Inlet casings using an extractor tool.
See Tool List Section 9.3.

Fit new journal bearings using assembly tool in preparation for re-assembly.

The journal bearings are located by a dowel pin and are retained by circlips.

45
8.5 RE-ASSEMBLY WRV204, WRVi255, WRVi321 & WRVi365 COMPRESSORS AFTER OVERHAUL

When repair or rectification work has been completed, the compressor should be assembled as
follows:

1. Lubricate the bearing bores with lubricating oil and lift in the rotors, ensure the lobes mesh at the
serial numbers on the rotors.
Assemble the inlet casing to the main casing, locate with the dowel pins, and secure with set
pins. (See Torque Specification in Section 9.1)
2. For WRV204 Refer to Section 8.2 Re-assembly WRV163 Compressor after overhaul.
3. For WRVi255, WRVi321 & WRVi365 compressors proceed as follows:
4. Assemble the balance piston sleeves into the outlet end casing, fit the balance pistons followed
by the thrust bearing sleeves.
5. Heat the angular contact thrust bearings using an oil bath or induction heater to a temperature of
approx 100C, and assemble to the rotors.
6. Fit bearing retaining plate and lockwasher and secure (Fig. 63). Torque as per specification
Section 9.1

The angular contact thrust bearings are designed to take axial thrust only. The thrust bearing is not
a tight fit on the OD in the thrust housing. This being the case, it is necessary to clamp the outer ring
of the bearing to prevent it from rotating with the rotor. To do this the thrust plate is to be ground to
give an interference on the outer race of the bearings and the required interference is as shown in
the table below (Fig. 68).

Compressor
Interference fit in outer race
Size

255 mm 0.0015/ 0.038mm/

0.004 0.100mm

321 mm 0.0015/ 0.040mm/

0.0045 0.115mm

365 mm 0.0015/ 0.038mm/

0.004 0.100mm

Fig. 68 Thrust Bearing Nip Fig. 69

At this stage of the assembly, the rotor outlet end clearance must be checked to ensure the
clearance is correct (Fig. 69).

Checking Rotor to Main Casing Outlet End Clearance

For WRV204 Compressors refer to WRV163 procedure Sect 8.3

For WRVi255, WRVi321 & WRVi365 Compressors slacken the set screws securing the thrust
bearing housing to the main casing. Do not remove them.

46
8.5 RE-ASSEMBLY WRVi255, WRVi321 & WRVi365 COMPRESSORS AFTER OVERHAUL
(Continued)
Checking Rotor Outlet End Clearance

Insert the jacking screw into the holes provided on the bearing housing flange and lightly tighten the
jacking screws until resistance is felt.

The action of tightening the jacking screws draws the rotors against the outlet face of the main
casing. Ensure the adjusting pieces are located between the flange of the thrust sleeve and main
casing. (Fig 71)

Set up a dial indicator on a convenient part of the main casing with the indicator spindle touching on
the end of the rotor. Remove the tension from the jacking screws and ease them back a few
threads. Set the dial indicator to zero.

Apply the torque wrench to the set screw securing the thrust bearing housing to the main casing and
tighten the screws to the specified torque value (used in Section 9.1).

NOTE: The movement shown on the indicator dial is the rotor outlet end clearance. Check it
against the table, Fig. 70.

Rotor Outlet End Maximum Allowable

Compressor Size
Clearance Clearance
0.002/0.003 0.004
204 mm
(0.050/0.075mm) (0.100mm)
0.003/0.004 0.005
255 mm
(0.075.0.100mm) (0.125mm)
0.008/0.010 0.011
255/220
(0.200/0.250mm) (0.280mm)
0.012/0.014 0.015
321 mm
(0.300/0.350mm) (0.375mm)
365mm 0.012/0.014 0.015
(0.300/0.350mm) (0.375mm)

Fig. 70 Rotor to Main Casing Outlet End Clearance

Adjustment, if necessary, is carried out by machining of the adjusting washers behind the thrust
bearing sleeve (WRVi255, WRVi321 & WRVi365) (Fig. 71).
WRV204 Compressor rotor outlet end clearance is carried out by grinding the balance pistons
(Fig 72 ) .

Fig. 71 Fig. 72

47
8.5 RE-ASSEMBLY WRV204, WRVi255, WRVi321 & WRVi365 COMPRESSORS AFTER OVERHAUL
(Continued)

Re-assemble the Outlet End Cover and Hydraulic Cylinder

Re-assembly as described per Section 7.5 for WRV204, WRVi255, WRVi321 & WRVi365
compressors.
Then proceed:

Re-assemble the Vi Cover WRVi255, WRVi321 & WRVi365 Compressors.

Pull Vi adjusting screw until the nut is against the inlet cover.
Refit the Vi adjuster cover ensuring new O rings are in place and secure with fixing capscrews.
Refit circlip retaining ring to secure adjusting screw to cover.

NOTE: Reset Vi adjusting screw to original position.

Re-assemble the Input Shaft Seal

Re-assemble the component in the following sequence:

1. Enter the inlet balance piston ensuring it locates on the drive dowel.
2. Lubricate the shaft seal and assemble to the rotor shaft, locate in the outward facing
dowel/driving pin of the inlet balance piston.
3. Refit balance piston sleeve (WRV204 Only).
4. Fit new O ring to stationary seat and fit to seal cover, ensuring seat locates on anti-rotation
dowel.
5. Fit the seal cover with a new O ring and secure with cap screws, tightening in a systematic
fashion to avoid tilting.

To complete the assembly, fit the coupling key and the compressor driven half coupling.

48
SECTION 9

SPECIAL
INSTRUCTIONS

49
9.1 TORQUE SPECIFICATIONS

Fig.73 Torque Specifications for Fasteners on WRV163 compressors.

PART NUMBER TYPE OF FASTENER TORQUE lb ft TORQUE Nm
40mm Locknut
R25055 206 150
Actuator Piston
G26019 UNC x 5/8 Long Set Screw
8 11
Piston Seal Retaining Plate
M12 x 60 Long Capscrew
M0216050 69 95
Cylinder to outlet cover
x 2 Long Set Screw
M0313050 80 110
Inlet and Outlet Casings
Locknut M42
R16154 225 165
Slide Valve
x 1 Long Capscrew
G25062 10 14
Thrust Bearing Clamp Plate
50mm Locknut
G39007 210 284
Thrust Bearing Retaining Locknut
3/8 x 1 Long Capscrew
G25058 35 48
Rotor Cover Plates
M16 x 40mm Long Capscrew
G29012 175 240
Cylinder End Cover to Cylinder
5/8 x 2 Long Setscrew
G21015 160 220
Superfeed Flange

Fig.74 Torque Specifications for Fasteners on WRV204 compressors.

PART NUMBER TYPE OF FASTENER TORQUE lb ft TORQUE Nm
40mm Locknut
R25055 150 206
Actuator Piston
G26019 UNC x 5/8 Long Set Screw
8 11
Piston Seal Retaining Plate
M12 x 60 Long Capscrew
M0216050 69 95
Cylinder to outlet cover
M16 x 60mm Long Set Screw
M0316060 175 240
Inlet and Outlet Casings
36mm Locknut
R20313 125 167
Slide Valve
M16 x 40mm Long Capscrew
G29012 10 14
Thrust Bearing Clamp Plate
M12 x 40mm Long Setscrew
G27001 69 95
Bearing Retaining Plate
M10 x 30 Long Capscrew
G29007 40 55
Rotor Cover Plates
M16 x 40mm Long Capscrew
G29012 175 240
Cylinder End Cover to Cylinder
3/4 x 1-3/4 Long Setscrew
G21047 208 285
Superfeed Flange

50
9.1 TORQUE SPECIFICATIONS (Continued)

Fig. 75 Torque Specifications for Fasteners on WRVi255 compressors.

PART NUMBER TYPE OF FASTENER TORQUE lb ft TORQUE Nm
R25055 40mm Locknut 150 206
Actuator Piston
G26019 UNC x 5/8 Long Set Screw 8 11
Piston Seal Retaining Plate
M0212045 M12 x 45 Long Capscrew 69 95
Cylinder to outlet cover
M0116070 M16 x 70 Long Set Screw 175 240
Inlet and Outlet Casings
M0212035 M12 x 35 Long Capscrew 69 95
Vi Housing & Rotor Cover
VR25126-2 Locknut M42 165 225
Slide Valve
M0116050 M16 x 50 Long Capscrew 175 240
Bearing Retaining Plate
M0116060 M16 x 60 Long Setcrew 175 240
Thrust Housing
G21026 3/8 UNC x 1 Setscrew 35 48
Thrust Plate
M0112025 M12 x 25 Setscrew 69 95
Vi Screw Stop Plate
G21039 5/8UNC x 1-1/2 Long 160 220
Setscrew
Superfeed Flange

Fig. 76 Torque Specifications for Fasteners on WRVi321 compressors.

PART NUMBER TYPE OF FASTENER TORQUE lb ft TORQUE Nm
R32115 1-3/4 Locknut 180 245
Actuator Piston
G21026 3/8UNC x 1 Long Set Screw 35 48
Piston Seal Retaining Plate
M0216060 M16 x 50 Long Capscrew 175 240
Cylinder to outlet cover
M0216050 M16x 70 Long Set Screw 175 240
Inlet and Outlet Casings
M0324080 M24 x 80 Long Capscrew 585 790
End Casings to Main Casings
M0216040 M16 x 40 Long 175 240
Vi Housing to Inlet
VR3149-2 M60 Locknut 270 371
Piston Rod to Slide Valve
G21016 UNC x 1 Long Setcrew 80 110
Bearing Retaining Plate
M0120070 M20 x 70 Long Setscrew 334 460
Thrust Housing
M0120060 M20 x 60 Long Setscrew 334 460
Thrust Plate
M0116040 M16 x 40 Long Setscrew 175 240
Vi Screw Stop Plate
G22006 UNC x 2 Long Set Screw 285 391
Superfeed Flange

51
9.1 TORQUE SPECIFICATIONS (Continued)

Fig. 77 Torque Specifications for Fasteners on WRVi365 compressors.

PART NUMBER TYPE OF FASTENER TORQUE lb.ft TORQUE Nm
VR36148-2 45mm Locknut 180 245
Actuator Piston
G21026 3/8UNC x 1 Long Set 35 48
Screw
Piston Seal Retaining Plate
M0216060 M16 x 60 Long Capscrew 175 240
Cylinder to outlet cover
M0124100 M24 x 100 Long Set Screw 575 790
Inlet and Outlet Casings
M0216045 M16 x 45 Long 175 240
Vi Housing to Inlet
VR36149-2 45mm Locknut 180 245
Piston Rod to Slide Valve
M0110030 M10 x 30 Long Setcrew 22 30
Bearing Retaining Plate
M0216060 M16 x 60 Long Capscrew 175 240
Rotor covers
M0120070 M20 x 70 Long Setscrew 170 230
Thrust Housing
M0120060 M20 x 60 Long Setscrew 334 460
Bearing retaining Plate
M0216045 M16 x 45 Long Setscrew 175 240
Cylinder End cover
G22019 UNC x 2 Long Set 285 391
Screw
Superfeed Flange

52
9.2 PROCEDURE FOR FITTING LOCKWASHERS

This instruction applies to all lockwashers used on Howden Compressors, for the purpose of
retaining, in position, the locknuts locating the bearings, thrust collars, pistons, etc.

A typical example of the items concerned is shown below (Fig.105).

Assembly method:
In all cases where this type of lockwasher is used, the components must be assembled without the
lockwasher and torqued to the prescribed value. The locknut must then be removed, the lockwasher
dipped in oil and placed on the shaft, the locknut replaced and again torqued to the prescribed value.

This assembly process limits the amount of relative movement between the locknut and the
lockwasher under torque, and avoids the possibility of the inner tank being damaged.

53
9.3 SPECIAL TOOLS

Tools can be provided for ease of dismantling/assembly. However, they are not a mandatory
requirement.

WRV163 Compressor Tools Part No.

Locknut Spanner 30mm for Valve Spindle 19274J

Locknut Spanner 40mm for Piston 19187J
Locknut Spanner 50mm for Thrust Bearing 17916J
Piston Withdrawal Gear 163045J
Pull Rod for Slide Valve 163046J
Withdrawal Tool for Output Shaft Balance Piston 163122J
Jacking Screws to Thrust Bearing 163123J
Bearing Extraction Tools for WRV163 163063J
Dummy Thrust Bearing WRV163 163188J
Jacking Bolt 14T UNC 32436JC

WRV204 Compressor Tools Part No.

Locknut Spanner 40mm for Piston Locknut 19187J

Locknut Spanner 36mm 204-5009
Assembly/Withdrawal Tool for Journal Bearings 204-5101
Jacking Plate for Rotor Removal when using 204-5088
Hydraulic Jack

WRVi 255 Compressor Tools Part No.

Locknut Spanner M50 33152J

T-Screws for Extractor purposes 17411J
Assembly/Withdrawal Tool for Crane Seal and 17413J
Labyrinth Seal
Assembly Tool for Journal Bearings 17414J
Assembly/Withdrawal Tool for Balance Piston 17418J
Withdrawal Tool for Balance Piston Sleeves 32747J
Locknut Spanner 40mm for Piston Locknut 19187J
Locknut Spanner 60mm Piston Rod to Slide Valve 33181J
T-Screws for Pulling Piston to Off Load Position 32784J
Rotor Jacking Plate 33180J

9.4 SPECIAL TOOLS (Continued)

54
WRVi 321 & WRVi365 Compressor Tools Part No.

Jacking Plate for Rotor Removal when using a 32919J

Hydraulic Jack
Extractor for Balance Pistons 32920J
Extractor for Inlet Balance Piston Sleeve and 32921J
Mechanical Seal
Locknut Spanner for Piston (WRVi321 Only) 32922J
T-Screws for Extraction purposes 5/8 UNC 32924J
T-Screws for Pulling Piston to Off Load Positions 32993J
Extractor Tool for Balance Piston Sleeves 32949J
Extractor Tool for Piston 32927J
Thrust Bearing Assembly Tool 32928J
Journal Bearing Assembly and Withdrawal Tool 32929J
Jacking Screws for Thrust Housings 32994J
Locknut Spanner for Coupling 32995J
Locknut Spanner M60 32948J

Locknut Spanner for Piston (WRVi365 Only) 360001J

55
SECTION 10

SPARES

56
10.1 WRV WRVi RECOMMENDED SPARES LIST

Spares are available for all WRV compressors in the form of the following kits:

SHAFT SEAL KIT

Shaft seal and cover O Ring

ANNUAL INSPECTION KIT

All O Rings and seals required for an annual inspection.

JOURNAL BEARING KIT

1 Set of Inlet and Outlet Journal Bearings.

THRUST BEARING KIT

1 Set of Thrust Bearings.

NOTE:
An Annual Inspection Kit is required when changing the journal bearing or the thrust bearings.

For further information and details of the above, please contact our Compressor Business Unit
directly.

HOWDEN COMPRESSORS or HOWDEN COMPRESSORS LLC

Compressor Business Unit 1850B North Gravers Road
133 Barfillan Drive Plymouth Meeting
Glasgow PA 19462
G52 1BE USA
UK

Telephone: 0044 (0)141 882 3346 Telephone: 001 610 313 9800
Fax: 0044 (0)141 882 8648 Fax: 001 610 313 9215
E-mail: hcl@aftersales@howden.com E-mail: sales@howdencompressors.com
Website: www.howden.com Website: www.howden.com

57
 RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS: Mk1G/H WRV(H) 163/145 & 180

Replacement Shaft Seal Kit KWS163-1G

PART NUMBER DESCRIPTION QUANTITY
KWS163-1G Input Shaft Seal c/w Cover O Ring 1

Annual Inspection Kit KW163-1

PART NUMBER DESCRIPTION QUANTITY
G31002 Spring Washer 48
G33001 Bonded Seal BSP 3
G33002 Bonded Seal " BSP 1
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4521 Lockwasher 50mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R16044 Lockwasher 30mm (Piston Rod / Slide Valve) 1
R16164 PTFE Ring (Actuator Piston) 1
R20044 Joint for Superfeed 2
R25145 PTFE Ring (Piston rod) 1
R16101 - OK O - Ring Kit containing:
G44001 ORing (Piston Rod) 1
G44005 ORing (Actuator Spindle) 1
G44006 ORing (Cylinder Cover) 1
G44052 ORing (Main / Inlet / Outlet) 2
G44053 ORing (Actuator Piston) 1
G44054 ORing (Rotor Covers) 2
G44055 ORing (Cylinder Spigot) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60114 Retaining Ring (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as
required.

Replacement Thrust Bearing Kit KWT163

PART NUMBER DESCRIPTION QUANTITY
G51081 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ163

PART NUMBER DESCRIPTION QUANTITY
R16063 Outlet End Journal Bearing 2
R16083 Inlet End Journal Bearing 2
G34045 Dowel Pin 4

Note: For Viton or Fluorosilicone O Rings please contact:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648

58
 RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS: Mk6 6A & 6B WRV(H) 204/110, 145, 165 & 193

Replacement Shaft Seal Kit KWS204

PART NUMBER DESCRIPTION QUANTITY
KWS204 Input Shaft Seal c/w Cover O Ring 1

Annual Inspection Kit KW204-6

PART NUMBER DESCRIPTION QUANTITY
R20224 Rotor Locking Plate 2
G26019 Tuflock Screw UNC x LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking wire 1/32 Dia. 2 metres
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Piston Locknut 40mm 1
R20065 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 1
R20101 - OK O Ring Kit containing:
G44001 ORing (Piston Rod) 1
G44005 ORing (Actuator Spindle) 1
G44007 ORing (Actuator Piston) 1
G44021 ORing (Main / Inlet / Outlet) 2
G44071 ORing (Rotor Covers) 2
G44072 ORing (Cylinder Spigot) 1
G44073 ORing (Cylinder Dia.) 1
G44074 ORing (Cylinder Face) 2
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as
required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-5/6

PART NUMBER DESCRIPTION QUANTITY
R20232 Inlet End Journal Bearing 2
R20242 Outlet End Journal Bearing 2
G34060 Dowel Pin 6mm 4
Note: For Viton or Fluorosilicone O Rings please contact:
Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648

59
 RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS: Mk6 & 6A 6B WRVi 255/110, 130, 145, 165, 193

Replacement Shaft Seal Kit KWS255-6

PART NUMBER DESCRIPTION QUANTITY
KWS255-6 Input Shaft Seal c/w Cover O Ring 1
Annual Inspection Kit KW255-6
PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x LG 6
G32009 Straight Tab Washer 8
G32013 Straight Tab Washer 6
VR25500-BK Bonded Seal Kit containing:
G33001 Bonded Seal BSP 6
G33003 Bonded Seal BSP 3
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1- BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Gasket S/Feed 1
Q5163 Lockwasher 40mm (Piston) 1
R25125 PTFE Ring (Actuator Piston) 1
R25135 Adjusting Washer (Thrust Bearings) 6
R25883 Rotor Locking Plate 2
G60009 Circlip (Journal Bearings) 4
G60086 Circlip (Vi Adjuster) 1
M0702016 Spring Washer 16 Dia. 56
R25145 PTFE Ring (Piston Rod / Guide Bracket) 1
VR25101 - OK O Ring Kit containing:
G44001 ORing (Piston Rod) 1
G44002 ORing (Piston) 1
G44005 ORing (Ind. Spindle) 1
G44008 ORing (Casing) 2
G44020 ORing (Cylinder. Spigot) 1
G44070 ORing (Covers) 3
G44075 ORing (Act. Cylinder.) 2
M6000269 ORing (Cylinder. Flange.) 1
M6002962 ORing (Vi Spindle) 2
M6009453 ORing (Cover) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as
required.

Replacement Thrust Bearing Kit KWT255

PART NUMBER DESCRIPTION QUANTITY
G51035 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ255

PART NUMBER DESCRIPTION QUANTITY
R25663 Inlet End Journal Bearing 2
R25643 Outlet End Journal Bearing 2
G36005 Dowel Pin 4

Note: For Viton or Fluorosilicone O Rings please contact:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648

60
 RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS: Mk6 6A WRV 321, ALL L/DS

Replacement Shaft Seal Kit KWS321-6

PART NUMBER DESCRIPTION QUANTITY
KWS321-6 Input Shaft Seal c/w Cover O Ring 1

Annual Inspection Kit KW321-6

PART NUMBER DESCRIPTION QUANTITY
G32009 Straight Tab Washer 6
G32014 Straight Tab Washer 8
G33001 Bonded Seal BSP 2
G33002 Bonded Seal BSP 4
G33003 Bonded Seal 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1- BSP 1
G33006 Bonded Seal 1- BSP 2
G33007 Bonded Seal 2 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip (Female I.E. Journal Bearing) 2
G60071 Circlip (O.E. Journal Bearings) 2
M0702024 Spring Washer M24 64
M0704020 Straight Tab Washer M20 6
M6602040 Circlip (Vi Adjuster) 1
R32015 PTFE Piston Ring (Actuator Piston) 1
R32055 PTFE Piston Rod Ring (Piston Rod / Guide Bracket) 1
R32135 Lockwasher 1- UNC (Actuator Piston) 1
R32175 Adjusting Washer (Thrust Bearings) 6
R32555 Rotor Locking Plate 2
VR32101 - OK WRV 321 O Ring Kit containing:
G44005 ORing (Actuator Spindle) 1
G44030 ORing (Actuator Cylinder Spigot) 1
G44038 ORing (Actuator Piston) 1
G44046 ORing (Seal housing / Rotor Covers) 3
G44048 ORing (Piston Rod / Cylinder Bore) 1
G44049 ORing (Actuator Cylinder / End Cover) 2
G44050 ORing (Balance Piston Sleeves) 2
G44051 ORing (Main Casing / Inlet / Outlet) 2
G44072 ORing (Vi Adjuster Dia) 1
M6003962 ORing (Vi Adjuster Face) 2
M6026935 ORing (Actuator Cylinder Dia) 1
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as
required.

Replacement Thrust Bearing Kit KWT321

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 4
Replacement Journal Bearing Kit KWJ321
PART NUMBER DESCRIPTION QUANTITY
R32063 Inlet End Journal Bearing 2
R32083 Outlet End Journal Bearing 2
G36013 Dowel Pin 4

Note: For Viton or Fluorosilicone O Rings please contact:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648

61
 RECOMMENDED SPARES LIST

MODELS Mk1 WRVi 365, ALL L/DS

Replacement Shaft Seal Kit KWS365

PART NUMBER DESCRIPTION QUANTITY
KWS365 Input Shaft Seal c/w Cover Oring XR12112-3 1

Annual Inspection Kit KW365

PART NUMBER DESCRIPTION QUANTITY
G32020 Tab Washer 8
G32021 Tab Washer 7/16 12
G55074 Joint 4 NB (Superfeed Port) 1
M0701024 Plain Washer 24mm 72
M6601240 Circlip Internal (Journal Bearings) 4
M6602060 Circlip External (Vi Adjuster) 1
Q4521 Lockwasher 50mm (Piston Rod / Actuator Piston) 1
R32175 Adjusting Washer (Thrust Bearings) 8
R32555 Rotor Locking Plate 2
R36401-BK Bonded Seal Kit
G33001 Bonded Seal 3/8 BSP 5
G33002 Bonded Seal BSP 3
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 BSP 3
VR36101-OK O-Ring Kit containing:
G44005 ORing (Actuator Spindle) 1
G44079 ORing (Core Hole Cover, bott) 1
G44050 ORing (Female Rotor Cover) 2
XR12112-3 ORing - (Seal Housing) 4
M6005953 ORing (Adjusting Screw) 2
M6009453 ORing (Core Hole Cover, Side) 1
M6011453 ORing (Vi Cover) 1
M6022625 ORing (Cylinder Spigot) 1
M6031935 ORing (Cylinder Spigot) 1
M6035935 ORing (Actuator Cylinder) 2
M6089168 ORing (Main Casing / Covers) 2
VR36134-3 Turcon Glyd Ring T40 1
VR36135-3 ORing (Glyd Seal) 1
VR36141-3 Turcon Glyd Ring T40 1
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as
required.

Replacement Thrust Bearing Kit KWT365

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 5

Replacement Journal Bearing Kit KWJ365

PART NUMBER DESCRIPTION QUANTITY
M6510020 Spring Pin 4
VR36086-2 Inlet End Journal Bearing 2
VR36088-2 Outlet End Journal Bearing 2

62
Printed in the UK Issue HCL/September 2007
Howden Compressors Limited

63
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk1A-F WRV 163/145 & 180

Replacement Shaft Seal Kit KWS163

PART NUMBER DESCRIPTION QUANTITY
G60205 Input Shaft Seal 1
G44054 ORing 1

Annual Inspection Kit KW163-1

PART NUMBER DESCRIPTION QUANTITY
G31002 Spring Washer 48
G33001 Bonded Seal 3/8 BSP 3
G33002 Bonded Seal " BSP 1
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4521 Lockwasher 50mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R16044 Lockwasher 30mm (Piston Rod / Slide Valve) 1
R16164 PTFE Ring (Actuator Piston) 1
R20044 Joint for Superfeed 2
R25145 PTFE Ring (Piston rod) 1
R16101 - OK O - Ring Kit 1 Kit containing:
G44001 ORing (Piston Rod) 1
G44005 ORing (Actuator Spindle) 1
G44006 ORing (Cylinder Cover) 1
G44052 ORing (Main / Inlet / Outlet) 2
G44053 ORing (Actuator Piston) 1
G44054 ORing (Rotor Covers) 2
G44055 ORing (Cylinder Spigot) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60114 Retaining Ring (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT163

PART NUMBER DESCRIPTION QUANTITY
G51081 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ163

PART NUMBER DESCRIPTION QUANTITY
R16063 Outlet End Journal Bearing 2
R16083 Inlet End Journal Bearing 2
G34045 Dowel Pin 4
Rev:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk1G WRV(H) 163/145 & 180

Replacement Shaft Seal Kit KWS163-1G

PART NUMBER DESCRIPTION QUANTITY
G60235 Input Shaft Seal 1
G44054 ORing 1

Annual Inspection Kit KW163-1

PART NUMBER DESCRIPTION QUANTITY
G31002 Spring Washer 48
G33001 Bonded Seal 3/8 BSP 3
G33002 Bonded Seal " BSP 1
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4521 Lockwasher 50mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R16044 Lockwasher 30mm (Piston Rod / Slide Valve) 1
R16164 PTFE Ring (Actuator Piston) 1
R20044 Joint for Superfeed 2
R25145 PTFE Ring (Piston rod) 1
R16101 - OK O - Ring Kit 1 Kit containing:
G44001 ORing (Piston Rod) 1
G44005 ORing (Actuator Spindle) 1
G44006 ORing (Cylinder Cover) 1
G44052 ORing (Main / Inlet / Outlet) 2
G44053 ORing (Actuator Piston) 1
G44054 ORing (Rotor Covers) 2
G44055 ORing (Cylinder Spigot) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60114 Retaining Ring (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT163

PART NUMBER DESCRIPTION QUANTITY
G51081 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ163

PART NUMBER DESCRIPTION QUANTITY
R16063 Outlet End Journal Bearing 2
R16083 Inlet End Journal Bearing 2
G34045 Dowel Pin 4

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk1A-F WRV 163/145 & 180

Fitted with viton Orings

Replacement Shaft Seal Kit KWS163-V

PART NUMBER DESCRIPTION QUANTITY
G60205-V Input Shaft Seal 1
M6200347 ORing 1

Annual Inspection Kit KW163-1-V

PART NUMBER DESCRIPTION QUANTITY
G31002 Spring Washer 48
G33001 Bonded Seal 3/8 BSP 3
G33002 Bonded Seal " BSP 1
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4521 Lockwasher 50mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R16044 Lockwasher 30mm (Piston Rod / Slide Valve) 1
R16164 PTFE Ring (Actuator Piston) 1
R20044 Joint for Superfeed 2
R25145 PTFE Ring (Piston rod) 1
R16102 - OK O - Ring Kit (Viton) 1 Kit containing:
M6200112 ORing (Piston Rod) 1
M6200226 ORing (Actuator Spindle) 1
M6200241 ORing (Cylinder Cover) 1
M6200242 ORing (Main / Inlet / Outlet) 2
M6200261 ORing (Actuator Piston) 1
M6200347 ORing (Rotor Covers) 2
M6203848 ORing (Cylinder Spigot) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60114 Retaining Ring (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT163

PART NUMBER DESCRIPTION QUANTITY
G51081 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ163

PART NUMBER DESCRIPTION QUANTITY
R16063 Outlet End Journal Bearing 2
R16083 Inlet End Journal Bearing 2
G34045 Dowel Pin 4

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk1G WRV(H) 163/145 & 180

Fitted with viton Orings

Replacement Shaft Seal Kit KWS163-1G-V

PART NUMBER DESCRIPTION QUANTITY
G60235-V Input Shaft Seal 1
M6200347 ORing 1

Annual Inspection Kit KW163-1-V

PART NUMBER DESCRIPTION QUANTITY
G31002 Spring Washer 48
G33001 Bonded Seal 3/8 BSP 3
G33002 Bonded Seal " BSP 1
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4521 Lockwasher 50mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R16044 Lockwasher 30mm (Piston Rod / Slide Valve) 1
R16164 PTFE Ring (Actuator Piston) 1
R20044 Joint for Superfeed 2
R25145 PTFE Ring (Piston rod) 1
R16102 - OK O - Ring Kit (Viton) 1 Kit containing:
M6200112 ORing (Piston Rod) 1
M6200226 ORing (Actuator Spindle) 1
M6200241 ORing (Cylinder Cover) 1
M6200242 ORing (Main / Inlet / Outlet) 2
M6200261 ORing (Actuator Piston) 1
M6200347 ORing (Rotor Covers) 2
M6203848 ORing (Cylinder Spigot) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60114 Retaining Ring (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT163

PART NUMBER DESCRIPTION QUANTITY
G51081 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ163

PART NUMBER DESCRIPTION QUANTITY
R16063 Outlet End Journal Bearing 2
R16083 Inlet End Journal Bearing 2
G34045 Dowel Pin 4

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk2A-H WRV(H) 204/110 & 165
Replacement Shaft Seal Kit KWS204-2/3/4
PART NUMBER DESCRIPTION QUANTITY
G60056 Shaft Seal 1
G44033 ORing 1

Annual Inspection Kit KW204-2

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 6
G32010 Straight Tab Washer 6
G32014 Straight Tab Washer 12
G44001 ORing (Piston Rod) 2
G44005 ORing (Actuator Spindle) 1
G44006 ORing (Cylinder / Cylinder End Cover) 2
G44007 ORing (Actuator Piston) 1
G44010 ORing (Main / Outlet Mk2) 1
G44013 ORing (F/m Balance Piston Sleeve) 1
G44017 ORing (O.E. Journal Bearings old brgs only) 2
G44021 ORing (Main / Inlet) 1
G44031 ORing (Guide Bracket) 1
G44032 ORing (Oil injection Pipe Mk2) 2
G44033 ORing (Rotor Covers) 4
G44034 ORing (Injection Pipe) 1
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60006 Retaining Ring (I.E. Journal Bearings) 2
G60068 Oil Return Pipe Lock Plate 4
Q4522 Lockwasher 45mm (Coupling) 1
Q4683 Lockwasher 65mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Actuator Piston) 1
R20065 PTFE Piston Ring 1
R20155 Adjusting Washer 8
R25145 PTFE Piston Rod Ring 2
R25205 PTFE Connecting Tube Ring 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-2/3/4

PART NUMBER DESCRIPTION QUANTITY
R20103 Inlet End Journal Bearing 2
R20123 Male Outlet End Journal Bearing 1
R20143 Outlet End Journal Bearing 1
G34004 Dowel Pin 5/16 Dia. x 5/8 LG 2
G34007 Dowel Pin 5/16 Dia. x LG 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk3/4-4B WRV(H) 204/110 & 165
Replacement Shaft Seal Kit KWS204-2/3/4
PART NUMBER DESCRIPTION QUANTITY
G60056 Shaft Seal 1
G44033 ORing 1

Annual Inspection Kit KW204-3-4B

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 6
G32010 Straight Tab Washer 6
G32014 Straight Tab Washer 12
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G44001 ORing (Piston Rod) 2
G44005 ORing (Actuator Spindle) 1
G44006 ORing (Cylinder / Cylinder End Cover) 2
G44007 ORing (Actuator Piston) 1
G44013 ORing (F/m Balance Piston Sleeve) 1
G44017 ORing (O.E. Journal Bearings old brgs only) 2
G44021 ORing (Main / Inlet) 2
G44031 ORing (Guide Bracket) 1
G44033 ORing (Rotor Covers) 4
G44034 ORing (Injection Pipe) 1
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60006 Retaining Ring (I.E. Journal Bearings) 2
Q4522 Lockwasher 45mm (Coupling) 1
Q4683 Lockwasher 65mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Actuator Piston) 1
R20044 Joint for Superfeed 2
R20065 PTFE Piston Ring 1
R20085 Lockwasher 50mm 1
R20155 Adjusting Washer 8
R20204 PTFE Sleeve 1
R25145 PTFE Piston Rod Ring 2
R25205 PTFE Connecting Tube Ring 2
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-2/3/4

PART NUMBER DESCRIPTION QUANTITY
R20103 Inlet End Journal Bearing 2
R20123 Male Outlet End Journal Bearing 1
R20143 Outlet End Journal Bearing 1
Rev: 03.00

G34004 Dowel Pin 5/16 Dia. x 5/8 LG 2

G34007 Dowel Pin 5/16 Dia. x LG 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk5-5E WRV(H) 204/110, 145, 165 & 193

Replacement Shaft Seal Kit KWS204-5

PART NUMBER DESCRIPTION QUANTITY
G60179 Shaft Seal 1
G44071 ORing 1

Annual Inspection Kit KW204-5

PART NUMBER DESCRIPTION QUANTITY
R20224 Rotor Locking Plate 2
G26019 Tuflock Screw UNC x 5/8 LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal 3/8 BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G39006 Locknut 45mm (Coupling) 1
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking wire 1/32 Dia. 2 metres
Q4522 Lockwasher 45mm (Coupling) 1
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Locknut 40mm (Actuator Piston) 1
R20065 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 1
R20101 - OK O Ring Kit 1 Kit containing:
G44001 - ORing (Piston Rod) 1
G44005 - ORing (Actuator Spindle) 1
G44007 - ORing (Actuator Piston) 1
G44021 - ORing (Main / Inlet / Outlet) 2
G44071 - ORing (Rotor Covers) 2
G44072 - ORing (Cylinder Spigot) 1
G44073 - ORing (Cylinder Dia.) 1
G44074 - ORing (Cylinder Face) 2
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-5/6

PART NUMBER DESCRIPTION QUANTITY
R20232 Inlet End Journal Bearing 2
R20242 Outlet End Journal Bearing 2
G34060 Dowel Pin 6mm 4

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk 5 WRV(H) 204 ALL L/DS
Replacement Shaft Seal Kit KWS204-5-V

Annual Inspection Kit KW204-5-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal 3/8 BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G39006 Locknut 45mm (Actuator Piston) 1
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
G72002 Locking wire 1/32 Dia. 2 metres
Q4522 Lockwasher 45mm (Coupling) 1
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20065 PTFE Piston Ring 1
R20102 - OK Viton O Ring Kit 1 Kit containing:
M6200112 - ORing (Actuator spindle) 1
M6200226 - ORing (Piston rod) 1
M6200428 - ORing (Actuator Piston) 1
M6203885 - ORing (Main/Inlet/Outlet) 2
M6212453 - ORing (Cylinder / Main) 1
M6213453 - ORing (Rotor Covers) 2
M6216453 - ORing (Cylinder Spigot) 1
M6218453 - ORing (Cylinder) 2
R20224 Rotor Locking Plate 2
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Piston Locknut 40mm 1
R25145 PTFE Piston Rod Ring 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-5/6

PART NUMBER DESCRIPTION QUANTITY
R20232 Inlet End Journal Bearing 2
R20242 Outlet End Journal Bearing 2
G34060 Dowel Pin 6mm 4

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk6 & 6A WRV(H) 204/110, 145, 165 & 193

Replacement Shaft Seal Kit KWS204

PART NUMBER DESCRIPTION QUANTITY
G60236 Shaft Seal 1
G44071 ORing 1

Annual Inspection Kit KW204-6

PART NUMBER DESCRIPTION QUANTITY
R20224 Rotor Locking Plate 2
G26019 Tuflock Screw UNC x 5/8 LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal 3/8 BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G51001 Ball Bearing (Actuator Spindle) 1
G72002 Locking wire 1/32 Dia. 2 metres
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Piston Locknut 40mm 1
R20065 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 1
R20101 - OK O Ring Kit 1 Kit containing:
G44001 - ORing (Piston Rod) 1
G44005 - ORing (Actuator Spindle) 1
G44007 - ORing (Actuator Piston) 1
G44021 - ORing (Main / Inlet / Outlet) 2
G44071 - ORing (Rotor Covers) 2
G44072 - ORing (Cylinder Spigot) 1
G44073 - ORing (Cylinder Dia.) 1
G44074 - ORing (Cylinder Face) 2
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT204

PART NUMBER DESCRIPTION QUANTITY
G51034 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ204-5/6

PART NUMBER DESCRIPTION QUANTITY
R20232 Inlet End Journal Bearing 2
R20242 Outlet End Journal Bearing 2
G34060 Dowel Pin 6mm 4
Rev:
Rev:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk 6 WRV(H) 204, ALL L/DS

Annual Inspection Kit KW204-6-F (Flourosilicone)

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal 3/8 BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
G72002 Locking wire 1/32 Dia. 2 metres
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20065 PTFE Piston Ring 1
R20103 - OK O Ring Kit 1 Kit containing:
M6300112 - ORing (Actuator spindle) 1
M6300226 - ORing (Piston rod) 1
M6300428 - ORing (Actuator Piston) 1
M6303885 - ORing (Main/Inlet/Outlet) 2
M6312453 - ORing (Cylinder / Main) 1
M6313453 - ORing (Rotor Covers) 2
M6316453 - ORing (Cylinder Spigot) 1
M6318453 - ORing (Cylinder) 2
R20224 Rotor Locking Plate 2
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Piston Locknut 40mm 1
R25145 PTFE Piston Rod Ring 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Rev:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk 6 WRV(H) 204, ALL L/DS

Annual Inspection Kit KW204-6-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G31015 Spring Washer M16 56
G33001 Bonded Seal 3/8 BSP 2
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 3
G33008 Bonded Seal BSP 4
G34060 Dowel Pin 6mm Dia. x 10mm LG 4
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60178 Circlip (Journal Bearings) 4
G72002 Locking wire 1/32 Dia. 2 metres
Q5163 Lockwasher 40mm ( Actuator Piston) 1
R20065 PTFE Piston Ring 1
R20102 - OK O Ring Kit 1 Kit containing:
M6200112 - ORing (Actuator spindle) 1
M6200226 - ORing (Piston rod) 1
M6200428 - ORing (Actuator Piston) 1
M6203885 - ORing (Main/Inlet/Outlet) 2
M6212453 - ORing (Cylinder / Main) 1
M6213453 - ORing (Rotor Covers) 2
M6216453 - ORing (Cylinder Spigot) 1
M6218453 - ORing (Cylinder) 2
R20224 Rotor Locking Plate 2
R20313 Locknut (Slide Valve) 1
R20493 Superfeed Joint 1
R25055 Piston Locknut 40mm 1
R25145 PTFE Piston Rod Ring 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk1-4F WRV(H) 255/110, 130, 145, 165, 193 & 220
Replacement Shaft Seal Kit KWS255
PART NUMBER DESCRIPTION QUANTITY
G60206 Shaft Seal 1
G44070 ORing (Was G44013) 1

Annual Inspection Kit KW255-1-4F

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32010 Straight Tab Washer 6
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G44003 ORing (Pre Mk4 models Injection tube) 2
G44022 ORing (Pre Mk4 models Balance Pistons) 2
G44027 ORing (Pre Mk4 models Journal Bearings) 2
not required when new bearings are fitted.
G51001 Ball Bearing (Actuator Spindle) (Actuator Spindle) 1
G72002 Locking Wire 1/32 Dia. 2 metres
Q4274 Lockwasher 60mm (Couplng) 1
Q4506 Lockwasher 85mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R20085 Lockwasher 50mm (Slide Valve- where fitted) 1
R25135 Adjusting Washer 6
R25154 Superfeed Joint 2
R25205 PTFE Ring (Injection Tube Pre Mk4) 2
R20204 PTFE Sleeve (Injection Tube - Mk4) 1
R25125 PTFE Ring (Actuator Piston) 1
R25145 PTFE Ring (Piston Rod) 2
R25101 - OK O Ring Kit 1 Kit containing:
G44001 ORing (piston Rod) 2
G44002 ORing (Actuator Piston) 1
G44005 ORing (Actuator Spindle) 1
G44008 ORing (Main / Inlet / Outlet) 2
G44070 ORing (Rotor covers - Was G44013) 4
G44020 ORing (Piston Rod Guide Bracket) 1
G44034 ORing (Injection Tube) 1
G44075 ORing (Cylinder Was G44004) 2
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip (Journal Bearings) 3

Replacement Thrust Bearing Kit KWT255

PART NUMBER DESCRIPTION QUANTITY
G51035 Angular Contact Bearing 4
Replacement Journal Bearing Kit KWJ255
PART NUMBER DESCRIPTION QUANTITY
R25663 Inlet End Journal Bearing 2
R25643 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk4G WRV(H) 255/110, 130, 145, 165, 193 & 220
Replacement Shaft Seal Kit KWS255
PART NUMBER DESCRIPTION QUANTITY
G60206 Shaft Seal 1
G44070 ORing 1

Annual Inspection Kit KW255-4G

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
Q4274 Lockwasher 60mm (Couplng) 1
Q4506 Lockwasher 85mm (Thrust Bearings) 2
Q5163 Lockwasher 40mm (Piston) 1
R20085 Lockwasher 50mm 1
R25135 Adjusting Washer 6
R20204 PTFE Sleeve 1
R25125 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 2
R25101 - OK O Ring Kit 1 Kit containing:
G44001 ORing (piston Rod) 2
G44002 ORing (Actuator Piston) 1
G44005 ORing (Actuator Spindle) 1
G44008 ORing (Main / Inlet / Outlet) 2
G44070 ORing (Rotor covers - Was G44013) 4
G44020 ORing (Piston Rod Guide Bracket) 1
G44034 ORing (Injection Tube) 1
G44075 ORing (Cylinder Was G44004) 2
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 3
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT255

PART NUMBER DESCRIPTION QUANTITY
G51035 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ255

PART NUMBER DESCRIPTION QUANTITY
R25663 Inlet End Journal Bearing 2
R25643 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
WRV(H) 255, MK4G MODEL, ALL L/DS

Annual Inspection Kit KW255-4G-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 3
Q4274 Lockwasher 60mm 1
Q4506 Lockwasher 85mm 2
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R20204 PTFE Sleeve 1
R25102 - OK O Ring Kit - Viton 1 Kit containing:
M6200112 ORing 1
M6200226 ORing 2
M6200227 ORing 1
M6200258 ORing 4
M6200266 ORing 2
M6203925 ORing 2
M6204375 ORing 1
M6204385 ORing 1
R25125 PTFE Piston Ring 1
R25135 Adjusting Washer 6
R25145 Piston Rod Ring 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

09.02
HOWDEN COMPRESSOR MODEL
Mk5 WRV(H) 255/110, 130, 145, 165, 193 & 220
Replacement Shaft Seal Kit KWS255
PART NUMBER DESCRIPTION QUANTITY
G60206 Shaft Seal 1
G44070 ORing 1

Annual Inspection Kit KW255-5

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R25135 Adjusting Washer 6
R25883 Rotor Locking Plate 2
R20204 PTFE Sleeve 1
R25125 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 2
R25101 - OK O Ring Kit 1 Kit containing:
G44001 ORing (piston Rod) 2
G44002 ORing (Actuator Piston) 1
G44005 ORing (Actuator Spindle) 1
G44008 ORing (Main / Inlet / Outlet) 2
G44070 ORing (Rotor covers - Was G44013) 4
G44020 ORing (Piston Rod Guide Bracket) 1
G44034 ORing (Injection Tube) 1
G44075 ORing (Cylinder Was G44004) 2
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 3
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT255

PART NUMBER DESCRIPTION QUANTITY
G51035 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ255

PART NUMBER DESCRIPTION QUANTITY
R25663 Inlet End Journal Bearing 2
R25643 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
MK1-4F WRV(H) 255, ALL L/DS

Annual Inspection Kit KW255-1-4F-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32010 Straight Tab Washer 6
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 3
G72002 Locking Wire 2
Q4274 Lockwasher 60mm 1
Q4506 Lockwasher 85mm 2
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R20204 PTFE Sleeve 1
R25102 - OK Viton O Ring Kit 1 Kit containing:
M6200112 - ORing 1
M6200226 - ORing 2
M6200227 ORing 1
M6200258 ORing 4
M6200266 ORing 2
M6203925 ORing 2
M6204375 ORing 1
M6204385 ORing 1
R25125 PTFE Piston Ring 1
R25135 Adjusting Washer 6
R25145 PTFE Piston Rod Ring 2
R25154 Superfeed Joint 2
R25205 Connecting Tube Ring (PTFE) 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk5 WRV(H) 255 ALL L/DS
Annual Inspection Kit KW255-5-V (Viton)
PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G31003 Spring Washer 5/8 48
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 3
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R20204 PTFE Sleeve 1
R25102 - OK Viton O Ring Kit 1 Kit containing:
M6200112 - ORing 1
M6200226 - ORing 2
M6200227 ORing 1
M6200258 ORing 4
M6200266 ORing 2
M6203925 ORing 2
M6204375 ORing 1
M6204385 ORing 1
R25125 PTFE Piston Ring 1
R25135 Adjusting Washer 6
R25145 PTFE Piston Rod Ring 2
R25883 Rotor Locking Plate 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk6 WRVi 255 ALL L/DS

Annual Inspection Kit KW255-6-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 4
G60086 Circlip 1
M0702016 Spring Washer M16 56
Q5163 Lockwasher 40mm 1
R25125 Piston Ring (PTFE) 1
R25135 Adjusting Washer 6
R25145 Piston Rod Ring 1
R25883 Rotor Locking Plate 2
VR25102 - OK WRVi 255 Viton O Ring Kit 1 Kit containing:
M6200112 - ORing 1
M6200226 - ORing 1
M6200258 ORing 3
M6200266 ORing 2
M6200269 ORing 1
M6202962 - ORing 2
M6203925 ORing 2
M6204375 ORing 1
M6204385 ORing 1
M6209453 ORing 1
VR25500-BK WRVi255 Bonded Seal Kit 1
G33001 - Bonded Seal 3/8 BSP 4
G33002 - Bonded Seal BSP 2
G33003 - Bonded Seal BSP 3
G33004 - Bonded Seal 1 BSP 2
G33005 - Bonded Seal 1 BSP 2
G33008 - Bonded Seal BSP 4
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk4-4E 5 WRVT 255/110, 130, 145, 165, 193 & 220

Replacement Shaft Seal Kit KWST255

PART NUMBER DESCRIPTION QUANTITY
G60198 Shaft Seal 1
G44070 ORing 1

Annual Inspection Kit KWT255-4-5

PART NUMBER DESCRIPTION QUANTITY
R20224 Rotor Locking Plate 2
G31003 Spring Washer 5/8 48
G32010 Straight Tab Washer 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 1
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G44027 ORing 2
R25101 - OK O Ring Kit 1 Kit containing:
G44001 ORing (piston Rod) 2
G44002 ORing (Actuator Piston) 1
G44005 ORing (Actuator Spindle) 1
G44008 ORing (Main / Inlet / Outlet) 2
G44070 ORing (Rotor covers - Was G44013) 4
G44020 ORing (Piston Rod Guide Bracket) 1
G44034 ORing (Injection Tube) 1
G44075 ORing (Cylinder Was G44004) 2
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 4
Q4274 Lockwasher 60mm 1
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R20204 PTFE Sleeve 1
R25125 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 2
R25154 Superfeed Joint 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWTT255

PART NUMBER DESCRIPTION QUANTITY
G51114 Floating Seal 2
G51115 Tilting Pad 44

Replacement Journal Bearing Kit KWJ255

PART NUMBER DESCRIPTION QUANTITY
R25663 Inlet End Journal Bearing 2
R25643 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk4 5 WRVT 255 ALL L/DS
Annual Inspection Kit KWT255-4-5-V (Viton)
PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 48
G32010 Straight Tab Washer 6
G32014 Straight Tab Washer 4
G33001 Bonded Seal 3/8 BSP 1
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60009 Circlip 4
M6200252 ORing 2
Q4274 Lockwasher 60mm 1
Q5163 Lockwasher 40mm 1
R20085 Lockwasher 50mm 1
R20204 PTFE Sleeve 1
R20224 Rotor Locking Plate 2
R25102 - OK WRV Viton O Ring Kit 1 Kit containing:
M6200112 ORing 1
M6200226 ORing 2
M6200227 ORing 1
M6200258 ORing 4
M6200266 ORing 2
M6203925 ORing 2
M6204375 ORing 1
M6204385 ORing 1
R25125 PTFE Piston Ring 1
R25145 PTFE Piston Rod Ring 2
R25154 Superfeed Joint 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

Rev: 07.02
HOWDEN COMPRESSOR MODEL
Mk6 WRVi 255/110, 130, 145, 165, 193
Replacement Shaft Seal Kit KWS255-6
PART NUMBER DESCRIPTION QUANTITY
G60238 Shaft Seal 1
G44070 ORing Seal Cover 1

Annual Inspection Kit KW255-6

PART NUMBER DESCRIPTION QUANTITY
G26019 Tuflock Screw UNC x 5/8 LG 6
G32009 Straight Tab Washer 3/8 8
G32013 Straight Tab Washer 5/8 6
VR25500-BK Bonded Seal Kit 1 Kit containing:
G33001 Bonded Seal 3/8 BSP 6
G33003 Bonded Seal BSP 3
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 2
G33008 Bonded Seal BSP 4
G51001 Ball Bearing (Actuator Spindle) 1
G55012 Gasket S/Feed 1
Q5163 Lockwasher 40mm 1
R25125 Piston Ring 1
R25135 Adjusting Washer 6
R25883 Rotor Locking Plate 2
G60009 Circlip 4
G60086 Circlip 1
M0702016 Spring Washer 16 Dia. 56
R25145 PTFE Piston Rod Ring 1
VR25101 - OK O Ring Kit 1 Kit containing:
G44001 - ORing Piston Rod 1
G44002 - ORing Piston 1
G44005 ORing Ind. Spindle 1
G44008 ORing Casing 2
G44020 ORing Cylinder. Spigot 1
G44070 ORing Covers 3
G44075 ORing Act. Cylinder. 2
M6000269 ORing Cylinder. Flange. 1
M6002962 ORing Vi Spindle 2
M6009453 ORing Cover 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT255

PART NUMBER DESCRIPTION QUANTITY
G51035 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ255

PART NUMBER DESCRIPTION QUANTITY
Rev: 06.02

R25663 Inlet End Journal Bearing 2

R25643 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk4-4F WRV(H) 321/132, 165, 193 & 220
Replacement Shaft Seal Kit KWS321
PART NUMBER DESCRIPTION QUANTITY
G60207 Shaft Seal 1
G44046 ORing 1

Annual Inspection Kit KW321-4

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32014 Straight Tab Washer 8
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G33007 Bonded Seal 2 BSP 2
G40001 Lockwasher 100mm Thrust Bearings 2
G44006 ORing (Old Bearings) 2
G44047 ORing (Old Bearings) 2
G51001 Ball Bearing (Actuator Spindle) 1
Q4683 Lockwasher 65mm Coupling 1
R32035 PTFE Connecting Tube Ring 2
R32134 Superfeed Joint (132/165) 2
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32255 Lockwasher 60mm 1
R 32015 PTFE Piston Ring 1
R32055 PTFE Piston Rod Ring 2
R32274 PTFE Sleeve 1
R32101-OK O Ring Kit 1 Kit containing:
G44004 O Ring 2
G44005 O Ring 1
G44030 O Ring 1
G44038 O Ring 1
G44041 O Ring 1
G44046 O Ring 4
G44048 O Ring 2
G44049 O Ring 2
G44050 O Ring 2
G44051 O Ring 2
G55101 Superfeed Joint (193/220) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2

Replacement Thrust Bearing Kit KWT321

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ321

PART NUMBER DESCRIPTION QUANTITY
R32063 Inlet End Journal Bearing 2
R32083 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk4 WRV(H) 321 ALL L/DS

Annual Inspection Kit KW321-4-V

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32014 Straight Tab Washer 8
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G33007 Bonded Seal 2 BSP 2
G40001 Lockwasher 100mm 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Superfeed Joint (193/220) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
M6200261 ORing 2
Q4683 Lockwasher 1
R32015 PTFE Piston Ring 1
R32035 PTFE Connecting Tube Ring 2
R32055 PTFE Piston Rod Ring 2
R32102 - OK O Ring Kit 1 Kit containing:
M6200112 ORing 2
M6200229 ORing 1
M6200235 ORing 1
M6200265 ORing 1
M6200267 ORing 1
M6200271 ORing 4
M6200399 ORing 2
M6200445 ORing 2
M6200446 ORing 2
M620452A ORing 2
R32134 Superfeed Joint (132/165) 2
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32255 Lockwasher 60mm 1
R32274 Sleeve (PTFE) 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
Rev: 07 02

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk4-4E WRVT 321/132, 165, 193 & 220
Replacement Shaft Seal Kit KWS321
PART NUMBER DESCRIPTION QUANTITY
G60207 Input Shaft Seal 1
G44046 ORing 1

Annual Inspection Kit KWT321-4

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
Q4683 Lockwasher 65mm 1
R32134 Superfeed Joint (132/165) 2
R32135 Lockwasher 1-3/4 UNC 1
R32255 Lockwasher 60mm 1
R32434 Rotor Locking Plate 2
R32015 Piston Ring 1
R32035 PTFE Connecting Tube Rings 2
R32055 PTFE Piston Rod Ring 2
R32274 PTFE Sleeve 1
R32101 - OK O Ring Kit 1 Kit containing:
G44004 ORing 2
G44005 ORing 1
G44030 ORing 1
G44038 ORing 1
G44041 ORing 1
G44046 ORing 4
G44048 ORing 2
G44049 ORing 2
G44050 ORing 2
G44051 ORing 2
G55101 Superfeed Joint (193/220) 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Journal Bearing Kit KWJ321

PART NUMBER DESCRIPTION QUANTITY
R32063 Inlet End Journal Bearing 2
R32083 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk4 WRVT 321, ALL L/DS

Annual Inspection Kit KWT321-4-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
Q4683 Lockwasher 65mm 1
R32015 PTFE Piston Ring 1
R32035 PTFE Connecting Tube Ring 2
R32055 PTFE Piston Rod Ring 2
R32102 - OK WRV-321 Viton O Ring Kit 1 Kit
R32134 Superfeed Joint (132/165) 2
R32135 Lockwasher 1-3/4 UNC 1
R32255 Lockwasher 60mm 1
R32274 PTFE Sleeve 1
R32434 Rotor Locking Plate 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk5 WRV(H) 321/132, 165, 193 & 220
Replacement Shaft Seal Kit KWS321
PART NUMBER DESCRIPTION QUANTITY
G60207 Shaft Seal 1
G44046 ORing 1

Annual Inspection Kit KW321-5

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32014 Straight Tab Washer 8
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G33007 Bonded Seal 2 BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
R32135 Lockwasher 1-3/4 UNC Piston/Rod 1
R32175 Adjusting Washer 6
R32255 Lockwasher 60mm S/U Piston Rod 1
R32555 Rotor Locking Plate 2
R32015 PTFE Piston Ring 1
R32055 PTFE Piston Rod Ring 2
R32274 PTFE Sleeve 1
R32101 OK O Ring Kit 1 Kit containing:
G44004 ORing 2
G44005 ORing 1
G44030 ORing 1
G44038 ORing 1
G44041 ORing 1
G44046 ORing 4
G44048 ORing 2
G44049 ORing 2
G44050 ORing 2
G44051 ORing 2
G55101 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT321

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ321

PART NUMBER DESCRIPTION QUANTITY
R32063 Inlet End Journal Bearing 2
R32083 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk5 WRV(H) 321, ALL L/DS

Annual Inspection Kit KW321-5-V (Viton)

PART NUMBER DESCRIPTION QUANTITY

G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32014 Straight Tab Washer 8
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33003 Bonded Seal BSP 2
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G33007 Bonded Seal 2 BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Superfeed Joint 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
R32015 PTFE Piston Ring 1
R32055 PTFE Piston Rod Ring 2
R32102 OK Viton O Ring Kit 1 Kit containing:
M6200112 ORing 1
M6200229 ORing 2
M6200235 ORing 1
M6200265 ORing 2
M6200267 ORing 4
M6200271 ORing 2
M6200399 ORing 2
M6200445 ORing 1
M6200446 ORing 1
M620452A ORing 2
R32135 Lockwasher 1-3/4 UNC Piston/Rod 1
R32175 Adjusting Washer 6
R32255 Lockwasher 60mm S/U Piston Rod 1
R32274 PTFE Sleeve 1
R32555 Rotor Locking Plate 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
Rev: 03.00

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk5 WRVT 321, ALL L/DS

Annual Inspection Kit KWT321-5

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
Q4683 Lockwasher 65mm 1
R32015 PTFE Piston Ring 1
R32055 PTFE Piston Rod Ring 2
R32101 - OK WRV-321 Neoprene O Ring Kit 1 Kit
R32135 Lockwasher 1-3/4 UNC 1
R32255 Lockwasher 60mm 1
R32274 PTFE Sleeve 1
R32434 Rotor Locking Plate 2
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Rev:06.02

Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk5 WRVT 321, ALL L/DS

Annual Inspection Kit KWT321-5-V (Viton)

PART NUMBER DESCRIPTION QUANTITY
G31003 Spring Washer 5/8 12
G31011 Spring Washer 7/8 Dia. 64
G32009 Straight Tab Washer 3/8 6
G32013 Straight Tab Washer 5/8 4
G32014 Straight Tab Washer 8
G32020 Straight Tab Washer 6
G33001 Bonded Seal 3/8 BSP 4
G33002 Bonded Seal BSP 4
G33003 Bonded Seal BSP 6
G33004 Bonded Seal 1 BSP 2
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 1
G60071 Circlip 2
R32015 PTFE Piston Ring 1
R32055 Piston Rod Ring (PTFE) 2
R32102 OK WRV 321 Viton O Ring Kit 1 Kit
R32135 Lockwasher 1-3/4 UNC 1
R32255 Lockwasher 60mm 1
R32274 Sleeve (PTFE) 1
R32434 Rotor Locking Plate 2

Suction and Discharge joints are not part of Inspection Kit.

These are available at extra cost as required.

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk6 WRV 321, ALL L/DS

Replacement Shaft Seal Kit KWS321-6

PART NUMBER DESCRIPTION QUANTITY
G60239-N Input Shaft Seal 1
G44046 ORing 1

Annual Inspection Kit KW321-6

PART NUMBER DESCRIPTION QUANTITY
G32009 Straight Tab Washer 3/8 6
G32014 Straight Tab Washer 8
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 4
G33003 Bonded Seal 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 2
G60071 Circlip 2
M0702024 Spring Washer M24 64
M0704020 Straight Tab Washer M20 6
M6602040 Circlip 1
R32015 Piston Ring (PTFE) 1
R32055 PTFE Piston Rod Ring (PTFE) 1
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32555 Rotor Locking Plate 2
VR32101 - OK WRV 321 Neoprene O Ring Kit 1 Kit containing:
G44005 ORing 1
G44030 ORing 1
G44038 ORing 1
G44046 ORing 3
G44048 ORing 1
G44049 ORing 2
G44050 ORing 2
G44051 ORing 2
G44072 ORing 1
M6003962 ORing 2
M6026935 ORing 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
Rev: 06.02

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk6 WRV(H) 321, ALL L/DS

Annual Inspection Kit KW321-6-F

PART NUMBER DESCRIPTION QUANTITY

G32009 Straight Tab Washer 3/8 6
G32014 Straight Tab Washer 8
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 4
G33003 Bonded Seal 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 2
G60071 Circlip 2
M0702024 Spring Washer M24 64
M0704020 Straight Tab Washer M20 6
M6602040 Circlip 1
R32015 Piston Ring (PTFE) 1
R32055 PTFE Piston Rod Ring (PTFE) 1
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32555 Rotor Locking Plate 2
VR32103 OK WRV 321 Fluorosilicone O Ring Kit 1 Kit containing:
M6300112 ORing 1
M6300229 ORing 1
M6300267 ORing 3
M6300271 ORing 2
M6300399 ORing 2
M6300445 ORing 1
M6300446 ORing 1
M6303962 ORing 2
M630452A ORing 2
M6312453 ORing 1
M6326935 ORing 1 Rev. 11.02

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
Mk6 WRVi (H) 321, ALL L/DS
Replacement Shaft Seal Kit (Viton) KWS321-6-V
PART NUMBER DESCRIPTION QUANTITY
G60239-V Input Shaft Seal 1
M620067 ORing 1

Annual Inspection Kit (Viton) KW321-6-V

PART NUMBER DESCRIPTION QUANTITY
G32009 Straight Tab Washer 3/8 6
G32014 Straight Tab Washer 8
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 4
G33003 Bonded Seal 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 2
G60071 Circlip 2
M0702024 Spring Washer M24 64
M0704020 Straight Tab Washer M20 6
M6602040 Circlip 1
R32015 Piston Ring (PTFE) 1
R32055 PTFE Piston Rod Ring (PTFE) 1
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32555 Rotor Locking Plate 2
VR32102 - OK WRV i321 Viton O Ring Kit 1 Kit containing:
M6200112 ORing 1
M6200229 ORing 1
M6200267 ORing 3
M6200271 ORing 2
M6200399 ORing 2
M6200445 ORing 1
M6200446 ORing 1
M6203962 ORing 2
M620452A ORing 2
M6212453 ORing 1
M6226935 ORing 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
Rev:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk6 WRVi 321, ALL L/DS
Replacement Shaft Seal Kit KWS321-6
PART NUMBER DESCRIPTION QUANTITY
G60239-N Input Shaft Seal 1
G44046 ORing 1

Annual Inspection Kit KW321-6

PART NUMBER DESCRIPTION QUANTITY
G32009 Straight Tab Washer 3/8 6
G32014 Straight Tab Washer 8
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 4
G33003 Bonded Seal 4
G33004 Bonded Seal 1 BSP 1
G33005 Bonded Seal 1-1/4 BSP 1
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 2
G51001 Ball Bearing (Actuator Spindle) 1
G55101 Joint 3 NB 1
G60004 Retaining Ring (Actuator spindle Outer) 1
G60005 Retaining Ring (Actuator spindle Inner) 1
G60070 Circlip 2
G60071 Circlip 2
M0702024 Spring Washer M24 64
M0704020 Straight Tab Washer M20 6
M6602040 Circlip 1
R32015 Piston Ring (PTFE) 1
R32055 PTFE Piston Rod Ring (PTFE) 1
R32135 Lockwasher 1-3/4 UNC 1
R32175 Adjusting Washer 6
R32555 Rotor Locking Plate 2
VR32101 - OK WRV 321 Neoprene O Ring Kit 1 Kit containing:
G44005 ORing 1
G44030 ORing 1
G44038 ORing 1
G44046 ORing 3
G44048 ORing 1
G44049 ORing 2
G44050 ORing 2
G44051 ORing 2
G44072 ORing 1
M6003962 ORing 2
M6026935 ORing 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT321

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 4

Replacement Journal Bearing Kit KWJ321

PART NUMBER DESCRIPTION QUANTITY
R32063 Inlet End Journal Bearing 2
R32083 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk1 WRVi 365, ALL L/DS
Replacement Shaft Seal Kit KWS365
PART NUMBER DESCRIPTION QUANTITY
VR36225-3 Input Shaft Seal 1
XR12112-3 ORing 2

Annual Inspection Kit KW365

PART NUMBER DESCRIPTION QUANTITY
G32020 Tab Washer 8
G32021 Tab Washer 7/16 12
G55074 Joint 4 NB 1
M0701024 Plain Washer 24mm 72
M6601240 Circlip Internal 4
M6602060 Circlip External 1
Q25036-1 Lockwasher 50mm 1
R32175 Adjusting Washer 8
R32555 Rotor Locking Plate 2
R36401-BK Bonded Seal Kit
G33001 Bonded Seal 3/8 BSP 5
G33002 Bonded Seal BSP 3
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 BSP 3
VR36101-OK O-Ring Kit (Viton)
G44005 ORing (Actuator Spindle) 1
G44079 ORing (Core Hole Cover, bott) 1
G44050 ORing (Female Rotor Cover) 2
XR12112-3 ORing - (Seal Housing) 4
M6005953 ORing (Adjusting Screw) 2
M6009453 ORing (Core Hole Cover, Side) 1
M6011453 ORing (Vi Cover) 1
M6022625 ORing (Cylinder Spigot) 1
M6031935 ORing (Cylinder Spigot) 1
M6035935 ORing (Actuator Cylinder) 2
M6089168 ORing (Main Casing / Covers) 2
VR36134-3 Turcon Glyd Ring T40 1
VR36135-3 ORing (Glyd Seal) 1
VR36141-3 Turcon Glyd Ring T40 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT365

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 5

Replacement Journal Bearing Kit KWJ365

PART NUMBER DESCRIPTION QUANTITY
M6510020 Spring Pin 4
VR36086-2 Inlet End Journal Bearing 2
VR36088-2 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk1 WRVi 365, ALL L/DS (Viton)
Replacement Shaft Seal Kit KWS365-V
PART NUMBER DESCRIPTION QUANTITY
N0xxxx08040 Input Shaft Seal 1
M6223935 ORing 2

Annual Inspection Kit KW365-V

PART NUMBER DESCRIPTION QUANTITY
G32020 Tab Washer 8
G32021 Tab Washer 7/16 12
G55074 Joint 4 NB 1
M0701024 Plain Washer 24mm 72
M6601240 Circlip Internal 4
M6602060 Circlip External 1
Q25036-1 Lockwasher 50mm 1
R32175 Adjusting Washer 8
R32555 Rotor Locking Plate 2
R36401-BK Bonded Seal Kit
G33001 Bonded Seal 3/8 BSP 5
G33002 Bonded Seal BSP 3
G33003 Bonded Seal BSP 4
G33004 Bonded Seal 1 BSP 2
G33006 Bonded Seal 1-1/2 BSP 2
G33007 Bonded Seal 2 BSP 3
VR36102-OK O-Ring Kit (Viton)
M6200112 ORing (Actuator Spindle) 1
M6200262 ORing (Core Hole Cover, bott) 1
M6200271 ORing (Female Rotor Cover) 2
M6205953 ORing (Adjusting Screw) 2
M6209453 ORing (Core Hole Cover, Side) 1
M6211453 ORing (Vi Cover) 1
M6222625 ORing (Cylinder Spigot) 1
M6231935 ORing (Cylinder Spigot) 4
M6235935 ORing (Actuator Cylinder) 2
M6289168 ORing (Main Casing / Covers) 2
VR36136-3 Turcon Glyd Ring T40 1
VR36135-3 ORing (Glyd Seal) 1
VR36141-3 Turcon Glyd Ring T40 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.

Replacement Thrust Bearing Kit KWT365

PART NUMBER DESCRIPTION QUANTITY
G51063 Angular Contact Bearing 5

Replacement Journal Bearing Kit KWJ365

PART NUMBER DESCRIPTION QUANTITY
M6510020 Spring Pin 4
VR36086-2 Inlet End Journal Bearing 2
VR36088-2 Outlet End Journal Bearing 2

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk2, 2A & 2B XRV 127/165 R1
Replacement shaft seal kit KXDS127
PART NUMBER DESCRIPTION QUANTITY
XR12096-3 Input Shaft Seal 1
G44059 ORing Inlet Cover 1

Annual Inspection Kit KX127-2

PART NUMBER DESCRIPTION QUANTITY
G44059 ORing Inlet Cover 1
XR12059-3 Actuator Piston Seal 1
XR12106-3 ORing Actuator Cyl. Cover 2
XR16102-3 ORing - Piston/Slide Valve 1
XR16515-3 Locknut M30 (S/Lock) 1
XR16522-2 Indicator Pin 1
M0905010 Grub Screw 1

Overhaul Kit KXD127-2

PART NUMBER DESCRIPTION QUANTITY
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 1
G33003 Bonded Seal BSP 1
G33008 Bonded Seal BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60005 Retaining Ring 1
M1701008 Washer 8mm Dia. 1
M1701010 Washer 10mm Dia. 10
M1701012 Washer 12mm Dia. 26
M1701020 Washer 20mm Dia. 4
Q4273 Lockwasher S 1
Q5163 Lockwasher 40mm 2
XR12014-2 Labyrinth Insert 1
XR12032-2 Floating Bush 2
XR12033-2 Bearing Spacer 2
XR12060-3 Disc Spring 2
XR12457-3 Cylindrical Roller Bearing 3
XR12097-3 Cylindrical Roller Bearing 1
XR12101-3 Angular Contact Bearing 4
XR16295-3 Potentiometer (1k OHM) 1
XR12101 - OK O Ring Kit 1 Kit containing:
G44005 ORing Indicator Spindle 1
G44059 - ORing G Box Cover 1
G44076 - ORing G Box/Main 1
XR12106-3 - ORing Covers 6
XR12107-3 - ORing Gas Seal 2
XR16102-3 ORing Piston/Slide Valve 1
XR12109-3 - ORing Man. Vi Spindle 2
XR12112-3 - ORing - Main/Outlet 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
When undertaking a compressor overhaul, all of the above three Kits are required.
Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk2, 2A & 2B XRV 127/165 R3-5

Replacement Shaft Seal Kit KXGS127

PART NUMBER DESCRIPTION QUANTITY
XR12124-3 Input Shaft Seal (Short Seat) 1
XR12105-3 ORing Shaft Seal Hsg. 1
XR12110-3 ORing Shaft Seal Hsg. 1

Annual Inspection Kit KX127-2

PART NUMBER DESCRIPTION QUANTITY
G44059 ORing GBox Cover 1
XR12059-3 Actuator Piston Seal 1
XR12106-3 ORing Act. Cyl Cover 2
XR16102-3 ORing Piston/Slide Valve 1
XR16515-3 Locknut M30 (S/Lock) (up to Mk2) 1
XR16522-2 Indicator Pin 1
M0905010 Grub Screw 1

Overhaul Kit KXG127-2

PART NUMBER DESCRIPTION QUANTITY
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 1
G33003 Bonded Seal BSP 1
G33008 Bonded Seal BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60005 Retaining Ring 1
G60156 Circlip 1
M1701008 Washer 8mm Dia. 1
M1701010 Washer 10mm Dia. 10
M1701012 Washer 12mm Dia. 26
M1701020 Washer 20mm Dia. 4
Q4273 Lockwasher 1
Q5163 Lockwasher 40mm 2
XR12014-2 Labyrinth Insert 1
XR12032-2 Floating Bush 2
XR12033-2 Bearing Spacer 2
XR12060-3 Disc Spring 2
XR12457-3 Cylindrical Roller Bearing 4
XR12101-3 Angular Contact Bearing 4
XR12103-3 Cylindrical Roller Bearing 1
XR12116-3 Angular Contact Thrust Bearing 2
XR16295-3 Potentiometer (1k OHM) 1
XR12102 - OK O Ring Kit 1 Kit containing:
G44005 - ORing Indicator Spindle 1
G44059 - ORing GBox Cover 1
G44076 - ORing GBox/Main 1
XR12105-3 - ORing Shaft Seal Hsg. 1
XR12106-3 - ORing Covers 6
XR12107-3 - ORing Gas Seal 2
XR16102-3 - ORing Piston/Slide Valve 1
XR12109-3 - ORing Man.Vi Spindle 2
XR12110-3 - ORing Shaft Seal Hsg. 1
XR12112-3 - ORing Main/Outlet 1
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.

When undertaking a compressor overhaul, all of the above three Kits are required.
Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODEL
XRV 127 VITON
Replacement Shaft Seal Kit Viton - KXDS127 - XRV127/R1 Compressors, All Models

PART NUMBER DESCRIPTION QUANTITY

M6222953 ORing 1
XR12096-3 Input Shaft Seal 2

Annual Inspection Kit Viton - KX127-2-V - XRV127/R1-5 Compressors, Mk2 Model

PART NUMBER DESCRIPTION QUANTITY
M0905010 Grub Screw 1
M6208453 ORing 2
M6222953 ORing 2
XR12059-3 Actuator Piston Seal 1
XR16522-2 Indicator Pin Solid (4.8) 1
XR16527-2 Lock Nut M30 (Extended) 1

Overhaul Kit Viton - KXD127-2-V - XRV127/R1 Compressors, MK 2 Model

PART NUMBER DESCRIPTION QUANTITY
G33001 Bonded Seal 3/8 BSP 2
G33002 Bonded Seal BSP 1
G33003 Bonded Seal BSP 1
G33008 Bonded Seal BSP 3
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60005 Retaining Ring 1
M1701008 Washer 8mm Dia. 1
M1701010 Washer 10mm Dia. 10
M1701012 Washer 12mm Dia. 26
M1701020 Washer 20mm Dia. 4
Q4273 Lockwasher 1
Q5163 Lockwasher 40mm 2
XR12014-2 Labyrinth Insert 1
XR12032-2 Floating Bush 2
XR12033-2 Bearing Spacer 2
XR12060-3 Disc Spring 2
XR12097-3 Cylindrical Roller Bearing 1
XR12101-3 Angular Contact Bearing 4
XR12103 - OK XRV (R1) Viton O Ring Kit 1
XR12457-3 Cylindrical Roller Bearing 3
XR13295-3 Potentiometer (1K OHM) 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
When undertaking a compressor overhaul, all of the above three Kits are required.
Rev:

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk2, 2A, 2B, 2C & 2D XRV 163/165 & 193
Replacement Shaft Seal Kit KXS163
PART NUMBER DESCRIPTION QUANTITY
G60205 Input Shaft Seal 1
XR16105-3 ORing Seal Housing 1

Annual Inspection Kit KX163-2C

PART NUMBER DESCRIPTION QUANTITY
M0905010 Grub Screw 1
M1701010 Washer 10mm Dia. 4
XR16079-3 Actuator Piston Seal 1
XR16102-3 ORing Piston/Slide Valve 1
XR16105-3 ORing Covers 3
XR16522-2 Indicator Pin 1
XR16515-3 Locknut M30 (S/Lock) (up to Mk2B) 1

Overhaul Kit KX163

PART NUMBER DESCRIPTION QUANTITY
G33002 Bonded Seal BSP 3
G33003 Bonded Seal BSP 4
G33010 Bonded Seal 1/8BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60005 Retaining Ring 1
G60175 Circlip 2
M1701010 Washer 10mm Dia. 27
M1701016 Washer 16mm Dia. 30
M1701020 Washer 20mm Dia. 12
Q4521 Lockwasher 50mm 2
Q4792 Lockwasher 30mm 1
XR16029-2 Outlet End Floating Bush 2
XR16047-2 Labyrinth Insert 1
XR16049-4 Thrust Bearing Assembly 2
XR16072-3 Superfeed Joint 1
XR16080-2 Disc Spring 2
XR16531-3 Cylindrical Roller Bearing 4
XR16295-3 Potentiometer (1k OHM) 1
XR16101 - OK O Ring Kit 1 Kit containing:
G44005 ORing Ind. Spindle 1
G44065 ORing Main/Outlet 2
XR16102-3 ORing Piston/Slide Valve 1
XR16101-3 - ORing Man. Vi Spindle 2
XR16104-3 - ORing Gas Seals 2
XR16105-3 - ORing Covers etc. 9
XR16106-3 - ORing Inlet Bearings 2
XR16460-3 - ORing Vi Cover 1
Suction and Discharge joints are not part of Inspection Kit.
These are available at extra cost as required.
When undertaking a compressor overhaul, all of the above three Kits are required.

Additional Parts: KX163 AUTO Vi

PART NUMBER DESCRIPTION QUANTITY
M1701004 Washer 4mm. 2
M1701005 Washer 5mm. 3
G33010 Bonded Seal 1/8 BSP 2
XR20776-3 ORing 1
Rev: 09.00

XR16280-3 Variseal 4mm. 1

XR16265-3 Glyd Ring 1
XR16266-3 Slyd Ring 1

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
HOWDEN
COMPRESSORS

RECOMMENDED SPARES LIST

HOWDEN COMPRESSOR MODELS
Mk3, 3A, 3B, 3C, 3D & 3E XRV 204/110, 145, 165 & 193
Replacement Shaft Seal Kit KXS204
PART NUMBER DESCRIPTION QUANTITY
G60224 Shaft Seal 1
XR20104-3 ORing - Seal Housing 1

Annual Inspection Kit KX204-3D

PART NUMBER DESCRIPTION QUANTITY
M1701012 Washer 12mm Dia. 4
R25065 Indicator Pin 1
XR20100-3 ORing Slide Valve/Piston 1
XR20104-3 ORing Act. Cylinder Cover 4
XR20875-3 Actuator Piston Seal 1
XR20782-3 Locknut M35 (S/Lock) (up to Mk 3C) 1
M0905010 Grub Screw 1

Overhaul Kit KX204

PART NUMBER DESCRIPTION QUANTITY
G33002 Bonded Seal BSP 3
G33003 Bonded Seal BSP 4
G33008 Bonded Seal BSP 1
G33010 Bonded Seal 1/8BSP 2
G51001 Ball Bearing (Actuator Spindle) 1
G57057 Microswitch 2
G60004 Retaining Ring 1
G60005 Retaining Ring 1
G60017 Circlip 2
M1701012 Washer 12mm Dia. 12
M1701016 Washer 16mm Dia. 34
M1701020 Washer 20mm Dia. 12
Q4683 Lockwasher 65mm 2
Q5163 Lockwasher 40mm 1
XR16295-3 Potentiometer (1k OHM) 1
XR20042-2 Outlet End Floating Bush 2
XR20053-2 Labyrinth Insert 1
XR20237-3 ORing Man. Vi Adjustment 2
XR20060-2 Disc Spring 2
XR20910-3 Cylindrical Roller Bearing 2
XR20101 - OK O Ring Kit 1 Kit containing:
G44005 - ORing Indicator Spindle 1
G44066 - ORing Inlet/Main/Outlet 2
XR16105-3 - ORing Vi Adj. Cover 1
XR20100-3 ORing Slide Valve/Piston 1
XR20102-3 - ORing Gas Seal 2
XR20104-3 - ORing Covers etc. 8
XR20105-3 - ORing Inlet Bearing 2
XR20520-4 Thrust Bearing Assembly 2
XR20823-3 Cylindrical Roller Bearing 2
Suction and Discharge joints are not part of Inspection Kit. These are available at extra cost as required.
When undertaking a compressor overhaul, all of the above three Kits are required.

Additional Parts: KX204 AUTO Vi

PART NUMBER DESCRIPTION QUANTITY
M1701004 Washer 4mm Dia. 2
M1701005 Washer 5mm Dia. 6
G33010 Bonded Seal 1/8 BSP 2
XR20776-3 ORing 1
03 00
Rev:

XR16280-3 Variseal 4mm 1

XR20730-3 Glyd Ring 1

Howden Compressors Limited, Compressor Business Unit, 133 Barfillan Drive, Glasgow, G52 1BE, UK
Telephone: +44 (0)141 882 3346 Fax: +44 (0)141 882 8648
Pump Documentation
Haight Pumps . . .
For Superior Performance

Operating, Maintenance, and

Instruction Manual

HPOM9/02
 Operating Manual for Haight Positive Displacement Rotary Gear Pumps

Pre-Installation

1. Choose a location that is easily accessible for pump servicing. Ensure adequate electrical service
is available.

2. Locate the pump for direct piping. Special attention should be given to the suction piping which
should be as large, or larger, than the pump intake port. For efficient operation, it is essen-
tial the suction side of a gear pump not be restricted. Avoid tees, elbows, valves, and other
flow devices within 12 pipe diameters of the pipe inlet. Provide adequate support for the piping.
The pump should not be used to support piping.

3. Pumps are shipped with the suction port marked - IN; the discharge port marked - OUT. The
suction port on pumps with relief valves is the port nearest to the relief valve adjusting screw.

4. Pumps will operate in either direction. However, the relief valve will only function in one
direction. Relief valve components are symmetrical and can be installed to operate with either
clockwise or counter-clockwise shaft rotation.

5. Have an electrician connect the motor using sound practice. Provide adequate overload
protection. Note: When checking the direction of rotation, the pump must be full of
liquid. Pumps fitted with mechanical seals must not run dry, not even momentarily.
Determine the direction of rotation by watching the motor fan, which must turn clockwise.

6. The motor selected meets the requirements of the specified operating conditions. Changed
conditions, for example, higher viscosity, higher specific gravity, or lower head losses, can over-
load the motor. When changing operating conditions, or whenever there is any doubt, please
contact your local distributor with the full details.

Installation

1. Provide a solid foundation free from excessive vibration.

2. Shim to prevent distortion of the pump mount base. Securely anchor the pump and motor to
the foundation.

3. All pipe connections on the suction side of the pump must be air tight. An air leak on the suc-
tion side of the pump will result in the loss of prime.

4. Provide priming tee on the discharge line of the pump.

5. If the media pumped contains solids, a suction strainer is recommended to exclude solid
particles from the pump. Contact Haight Pump for a recommendation.

6. Support the piping independent of the pump. Excessive strain on the pump casing can interfere
with gear alignment.

7. When the piping is complete, loosen the bracket set screws and allow the pump to align with the
piping. Tighten the bracket set screws and re-check the shaft alignment. Make sure there is no
metal to metal contact of the coupling halves. Do not over tighten the pipe/pump connections,
as damage can result.

8. A vacuum gauge can be installed in the pipe plug on the relief valve nearest the adjustment
screw. A pressure gauge can be installed in the opposite pipe plug.

9. Check the shaft rotation to ensure it is correct. Normal rotation is clockwise as viewed from the
shaft side of the pump. 2
Precautionary Notes

1. Prior to performing any service on the pump or motor:

(a) Disconnect and lockout the power source to the motor (refer to OSHA 1910.147.)
(b) Shut off any liquid heating source.
(c) If the unit operates at elevated temperatures, allow it to cool to room temperature before
performing any service.

2. Drain the pump and piping of excess liquid. Caution: Handle and dispose of liquids in accor-
dance to the manufacturers Material Safety Data Sheets.

Disassembly for Inspection Purposes Only

1. Remove the bolts from the drive plate.

2. Carefully separate the drive cover and housing. Rotate the pump shaft by hand. It should turn
freely. If resistance is present, check for built up residue.

3. Use a soft marker to mark the rotor/pinion location. Remove the rotor from the housing.

4. Inspect the housing, shaft/pinion, rotor, and drive plate for signs of wear or damage. Excessive
wear will decrease pump performance.

5. Inspect the O-rings, gaskets, and bearings for chipping, splitting, or missing sections.

6. Inspection of the pump seal requires complete removal of the pump from the motor and bracket.

Complete Disassembly for Repair or Replacement

1. Complete precautionary steps 1 and 2.

2. Loosen the support bracket screws that secure the pump to the bracket.
(a) Size 1-8 pumps: 3 set screws
(b) Size 10-80 pumps: 4 cap screws

3. Remove the coupling and shaft key. Inspect the shaft end for burrs or other damage.

4. Rotate the pump shaft by hand. It should rotate freely.

5. Remove the bolts from the drive plate.

6. Carefully separate the drive cover and housing.

7. Use a soft marker to mark the rotor/pinion location. Remove the rotor from the housing.

8. Remove the shaft/pinion assembly from the housing.

9. Carefully pry the cover off the housing.

10. Inspect, repair, or replace all damaged parts. Note: If significant damage is evident to the major
pump components, it is best to replace the pump. If possible, determine the cause of the damage
and correct the identified problem.

3
Reassembly

1. Pump reassembly is the reverse of disassembly. However, care should be exercised in three
areas:
(a) It is good practice to replace elastomer sealing devices and gaskets every time the pump is
reassembled. This is mandatory for Teflon O-rings and lip seals. Gently stretch the O-
rings before placing them in the O-ring groove.
(b) Place the rotor into position with your mark facing out.
(c) Use a cross bolt tightening pattern to re-assemble the housing and covers. Periodically
turn the pump shaft. Check for unusual noise. Improper tightening will cause the pump
to bind.

2. The pump will function best if primed first. Return the pump to service and check for
leaking and loose connections. Air leaks on the suction side of the pump will reduce pump
performance.

Relief Valve Components

1. See precautionary notes.

2. To change the relief valve for reverse rotation:

(a) Loosen the locknut on the adjusting screw while holding the adjusting screw
stationary.
(b) Remove the bonnet and bonnet washer.
(c) Remove the adjusting screw, spring, and poppet.
(d) Remove the cap and cap washer.

3. Reassemble in reverse order. Remember the spring and adjusting screw must be on the suction
side of the pump for the relief valve to operate.

Special Seal Components

1. Standard 1 through 40 D/DR pumps use a lip seal as the main shaft seal, and two wiper seals
function to keep the bearings clean. These seals are available in Buna-N or Viton synthetic
materials.

2. Packed pumps use 4 or 5 element V-cup Teflon shaft seals. Shaft seals are also available in
Graphite rope, Graphfoil, and virgin Teflon. A gland is included to provide tension for the
packing.

3. Crane Type 9 and Type 21 mechanical seals are available. Contact Haight Pump for special
drawings for pumps with mechanical seals.

Maintenance Parts or Factory Repair

1. When ordering parts, locate the pump serial number stamped on the machined face of the cover
or body of the pump housing.

2. Haight Pump maintains a repair service shop that will rebuild, test, and return pumps promptly.

3. Remove pipes, coupling, and mounting bracket before returning the pump to the factory.

4. Contact Haight Pump for a Return Authorization number before sending the pump to the factory.

4
General Information

The following is general information about Haight rotary gear pumps. Due to the variety of options
and configurations available, it is not possible to provide detailed information in this manual. Detailed
drawings and bill of materials will be provided upon request.

Never operate a pump with the discharge line closed or plugged. Severe damage to the pump
and/or system will result.

Haight Pump does not accept responsibility or liability for damage or injury resulting from
improper application and/or operation of the pump and/or system.

Direction of Rotation. Haight pumps are designed to operate in either direction by simply changing the
shaft rotation. Pumps supplied with relief valves are the exception to this rule. Failure to reverse the
relief valve components will render the relief valve inoperable. The procedure for reversing the flow
direction in the relief valve is covered in the Assembly and Disassembly instructions.

Pump Alignment. Bedplate mounted pumps and motor combinations are aligned and tested at the
factory. Vibration during shipment and/or poor bedplate mounting conditions can cause premature
failure or unacceptable noise and vibration.

Simple alignment checks can be performed by placing a straight edge on the top and side of the cou-
pling. Improper alignment is indicated by a separation between the coupling and straight edge. Ad-
just the motor and pump location until any separation disappears in both planes.

Bedplate Mounting. Install nuts on the foundation bolts to provide location adjustment. Loosely place
the bedplate on the foundation bolts. Adjust the bedplate height and location to meet the inlet and
outlet piping. Ensure the bedplate is level and true. Fasten in place with lock washers or lock nuts.
Check coupling alignment.

Piping. Improper suction piping is the leading cause of poor pump performance, including cavitation,
noisy operation, inadequate performance, and premature pump failure. Particular care should be
taken to avoid long, restricted pipe runs, the use of elbows, tees, valves, or other flow devices within
twelve (12) pipe diameters of the pump inlet. Inlet piping should be at least equal to the pump inlet
size.

The discharge piping arrangement is somewhat less critical than the inlet side, however, good en-
gineering practice, as defined by the Hydraulic Institute, should be followed.

Pumps are not designed to be used as piping system support devices. Piping systems should have
adequate, independent hangers to provide support. Again, the Hydraulic Institute offers guidelines for
proper pipe support design.

Seals. Haight Pump offers three standard type seals, each with specific operating characteristics.

Lip seals: Available in Buna-N, Viton, Teflon, Silicone, and Kalraz seals. Lip seals are inexpen-
sive, but have certain limitations, which include:
Expected operating life of 2,000 -3,000 hours
Should not be used with system pressures over 75 psig
Should not be used in vacuum applications over 3" Hg

5
General Information: Seals (contd)

Packing gland: Available in Graphfoil, or Teflon, and other materials upon request. Packing
glands are useful at high temperatures and pressures, resist shock and vibration, and can be
adjusted to accommodate wear. However, packing glands must weep to function properly and
require adjustment during the start-up operation.

During start-up, or after repacking, run the pump to pressurize the stuffing box. Steady
weepage should occur in less than ten (10) minutes. If steady weepage has not begun within
ten (10) minutes, stop the pump and allow it to cool. Overheating the gland will damage the
packing gland and shaft. Do not loosen the gland adjustment screws. Repeat this process
until steady weepage is established.

Adjust the packing gland screws 1/6th of a turn in a cross bolt tightening pattern. Allow to
run ten (10) minutes. Continue this process until the weepage rate is approximately one (1)
drop per minute. Periodic inspection and adjustment will be required. Do not over tighten the
packing gland as damage to the gland and shaft will result.

Bearings and Rotor/Pinion Shaft

DU Bearings. Recommended for applications over 100 PSI and for thin fluids.

Teflon Rotor. Do not use Teflon rotors in applications exceeding 100 PSI, and 200 F. The pump is
provided with open tolerances. Increased slip will reduce efficiency with fluids below 200 SSU.

Delrin Rotor. Do not use above 120 F and 80 PSI. Delrin rotors provide better abrasion resistance
than Teflon rotors. The pump is provided with open tolerances. Increased slip will reduce efficiency
with fluids below 200 SSU.

Stainless Steel Rotor and Pinion. Manufactured with open tolerances as standard. Increased slip will
reduce efficiency with fluids below 200 SSU.

Note: For applications above 175 PSI, vent both shaft bearings to the suction side of pump.

Spares and Repairs

Haight Pump operates a repair service for all pumps for which records exist. To ensure the correct
parts are supplied, the pump serial number is required. The serial number is stamped into the metal
of the pump body or cover, in a prominent position on the top area of the pump.

We advise customers whose pumps are custom fabricated to have spare pumps or parts on hand.
Custom fabricated pumps and parts generally have long delivery times for replacement.

Pumps That Perform. Pumps That Fit.

6
Troubleshooting

Problem Probable Cause

No liquid delivered. Pump not primed

Suction lift too high; check with a gauge at the pump suction
Wrong direction of rotation
Pump not rotating (failure of drive from prime mover)

Not enough liquid delivered. Air leaks in suction line or through stuffing box
Speed too low
Suction lift too high, or not enough suction head (for hot liquids)
Foot valve too small or obstructed
Foot valve or end of suction pipe not immersed deeply enough
Piping improperly installed, permitting air or gas to pocket in
pump
Mechanical defects:
Pump damaged
Pump badly worn
Packing defective
Relief valve not sealing or jammed by foreign matter

Pump works for awhile, Leaky suction lines

then loses suction. Suction lift too high
Air or gases in liquid
Plugged lines or filter

Pump takes too much power. Speed too high

Liquid heavier or more viscous than design condition
Suction or discharge line obstructed
Mechanical defects:
Shaft bent
Rotating element binds
Stuffing boxes too tight
Misalignment due to improper connection of pipe lines or driver
Check pressure is being measured at the pump and not some
distance away from the pump, thus ignoring pressure losses in
piping, valves, etc.
Poor piping conditions

Noisy pump. Speed too high

Suction lift or viscosity too high (piping diameter too small)
Wrong direction of rotation (recesses in the pump covers to
prevent hydraulic noise operate only in one direction)
Badly supported pipe or bedplates causing resonant vibration
Relief valve chattering
Pressure too low; an increase in pressure can prevent gear noise
in low pressure applications
Cavitation due to inlet or outlet conditions

Gland leakage. Packing hard and shaft scored

Pressure on pump too high or pressure relief passage blocked
Shaft run out excessive
When re-packing a gland, all the old packing must be removed; it
is not good enough to just add extra rings as the original packing
becomes compressed

7
 3E & 5E STANDARD "Hot Oil" PUMP REPLACEMENT PARTS

Item Number Description Style Part Number Qty Required

1 E style casing 3E & 5E ED53F5 1
2 3E Cover 3E ED330F 1
5E Cover 5E ED530F 1
5 Cover Bolts 3E & 5E E90HC.7 4
6 Bearing 3E & 5E E11F 2
7 Cover o-ring 3E & 5E E28V1 1
8 Lip Seal 3E & 5E E18V 1
10 Rotor 3E D326F1 1
10 Rotor 5E D526F1 1
11 Pinion 3E & 5E N/A 1
13 Screw 3E & 5E E46C 2
16 Shaft - Tang 3E & 5E N/A 1
16A Tang Shaft-Pinion Assy 3E ED3C13BC 1
16A Tang Shaft-Pinion Assy. 5E ED5C13BC 1
17 Keyed Shaft 3E & 5E N/A 1
17A Keyed Shaft-Pinion Assy. 3E D3C13C 1
17A Keyed Shaft-Pinion Assy. 5E D5C13C 1

Viton is a registered trademark of DuPont Dow Elastomers

8
 6G & 8G Hot Oil Gerotor Pump
Replacement Parts

Item Number Description Style Part Number Qty Required

1 G style casing 6G EG63F7A 1
8G DG83F7A 1
2 6G cover 6G & 8G EG830F 1
5 Cover bolts 6G & 8G E90HC.7 4
6 Bearing 6G & 8G E11F 2
7 Cover o-ring 6G & 8G SE2151V76 1
8 Lip Seal 6G & 8G E18V 2
10 Gerotor Set 6G HJ169A 1
8G HJ89A 1
12 Spacer 6G & 8G HJ80A 1
13 Key 6G & 8G F18C50 2
16 Shaft-Tang 6G F18C50 1
8G ED524BC 1
16A Shaft/Spacer/Key Assy 6G ED514BC 1
16A Tang Shaft-Pinion Assy. 8G ED5C13BC 1
17 Keyed Shaft 8G N/A 1
17A Keyed Shaft-Pinion Assy. 8G D5C13C 1

Viton is a registered trademark of DuPont Dow Elastomers

9
 1U through 5U Haight Pump w/o Relief Valve
1U through 5U Haight Pump with Relief Valve

Item Qty Item Qty

Number Description Required Number Description Required
15 Lip Seal 1
1 Screw-cover 4 -Buna
-Viton
2 Cover 1 -Neoprene
3 Shaft bearing 1 15A Mechanical T-21 Seal 1
-Iron -Buna
-Bronze -Viton
-Carbon Graphite -Pinned Viton
-DU-Iron Sleeve -Neoprene
4 Wiper Seal 1 16 Gland 1
-Buna 17 O-ring 2
-Viton (cover plate, relief valve)
-Neoprene -Buna
5 O-Ring Cover 1 -Viton
-Buna -Neoprene
-Viton 18 Cover Plate 1
-Neoprene 19 Cover Plate Screw 4
-Teflon 20 Lock Nut 1
6 Rotor*-C.I. Standard 1 21 Adjusting Screw 1
7 Shaft & Pinion Assembly 1 22 Gasket 1
7A Tanged Shaft & Pinion Assy. 1 -Metallic
7B Outboard Bearing Shaft 1 -Buna
(not shown) -Viton
8 Shaft 1 23 Bonnet 1
9 Pinion 1 24 Gasket 2
10 Key 1 -Buna
11 Shaft Bearing 1 -Neoprene
-Iron -Viton
-Bronze 25 Spring 1
-Carbon Graphite 26 Poppet 1
-Du-Iron Sleeve 27 Relief Valve Cap 1
12 Set Screw 1 28 Valve Housing 1
13 Case 1/2" ports 1 29 Pipe Plug 2
14 O-ring Gland 1 30 Relief Valve Screw 4
-Buna
-Viton * Designate Rotor Material
-Neoprene -Cast Iron-Standard
-Teflon -Delrin
-Teflon
-Ni-Resist
Viton is a registered trademark of DuPont Dow Elastomers
10
 6U & 8U Haight Pump w/o Relief Valve
6U & 8U Haight Pump with Relief Valve

Item Qty Item Qty

Number Description Required Number Description Required
1 Screw-cover 4 13A Mechanical T-21 Seal 1
2 Cover 1 -Buna
3 Shaft bearing 2 -Viton
-Iron -Pinned Viton
-Bronze -Neoprene
-Carbon Graphite 14 Gland 1
-DU-Iron Sleeve 15 O-ring (cover plate, relief valve) 2
4 Wiper Seal 1 -Buna
-Buna -Viton
-Viton -Neoprene
-Neoprene 16 Cover Plate 1
5 O-Ring Cover 1 17 Cover Plate Screw 4
-Buna 18 Lock Nut 1
-Viton 19 Adjusting Screw 1
-Neoprene 20 Gasket 1
-Teflon -Metallic
6 Gerotor & Shaft Assemby 1 -Buna
6A Gerotor & Tang Shaft Assembly 1 -Viton
7 Gerotor Set 1 21 Bonnet 1
8 Shaft 1 22 Gasket 1
9 Key 1 -Buna
10 Set Screw 1 -Neoprene
11 Case 1/2" ports 1 -Viton
12 O-ring Gland 1 23 Spring 1
-Buna 24 Poppet 1
-Viton 25 Relief Valve Cap 1
-Neoprene 26 Valve Housing 1
-Teflon 27 Pipe Plug 2
13 Lip Seal 1 28 Relief Valve Screw 4
-Buna
-Viton
-Neoprene
Viton is a registered trademark of DuPont Dow Elastomers 11
 10U through 40U Haight Pump w/o Relief Valve
10U through 40U Haight Pump with Relief Valve

Item Qty. Item Qty.

Number Description Required Number Description Required
1 Screw on O-ring gland 1 11 Shaft 1
2 O-Ring 1 12 Key 1
-Buna 13 Rotor*-C.I. Standard 1
-Viton 14 Case 1
-Neoprene -1" ports
-Kalrez -1-1/4" ports
-Teflon -1-1/2" ports
3 Thurst Washer Kit 1 15 Lip Seal 1
Nut -Buna
Washer -Viton
Washer -Neoprene
Washer 15A Mechanical Seal 1
Bearing -Buna
Washer -Viton
4 Screw 8 -Neoprene
5 Cover 1 15B Packing Seal 1
6 & 6A Bearing 2 -Graphoil
-Bronze -Teflon
-Iron 16 Set Screw 1
-Graphite 17 Gland 1
-DU 18 Set Screw 1
7 Wiper Seal 2 19 Roll Pin 1
-Buna 20 O-Ring 1
-Neoprene -Buna
-Viton -Viton
8 O-Ring 1 -Neoprene
-Buna 21 O-Ring 2
-Viton -Buna
-Neoprene -Viton
-Kalrez -Neoprene
-Teflon -Teflon
9 Shaft & Pinion Assy-std. 1 22 Screw 4
9 Shaft & Pinion Assy-OBB 1 23 Cover Plate 1
10 Pinion 1 24 Valve Body 1

12
 44D through 80D Double Pump

Item Number Description Qty Required Item Number Description Qty Required
1 .375 x .875 UNC HSCS 12 12A Mating Rotor 1
2 .188 x .75 Sq. key 1 - 44gpm
4 Shaft Bearing .877 x 1.5 x 1.128 3 - 54gpm
- Iron - 60gpm
- Bronze - 70gpm
- Carbon Graphite - 80gpm
5 Eyebolt 1 13 Drive Plate 1
6 Cover Gasket 2 - 44gpm
- Neoprene - 54gpm
- Buna N - 60gpm
- Viton - 70gpm
7 44-80 Dual Casing 1 - 80gpm
8 Shaft & Pinion Assembly 1 13A Cover 1
- 44gpm - 44gpm
- 54gpm - 54gpm
- 60gpm - 60gpm
- 70gpm - 70gpm
- 80gpm - 80gpm
9 Standard Pinion-Only 1 14 Roll Pin .156x1.13 2
- 44gpm 15 Seal Kit (See Pg. 20) 1
- 54gpm 16 Washer .625x1.12x.094 2
- 60gpm 17 Thrust Bearing (Keyed end) 1
- 70gpm 18 Thrust Bearing 1
- 80 gpm 23 Locking Nut 1
9A Keyed Pinion 1 25 O-ring-gland cap 2
- 44gpm Neoprene
- 54gpm Buna N
- 60gpm Viton
- 70gpm Teflon
- 80 gpm 26 Gland Cap-shaft 1
10 Shaft 1 27 Gland Cap 1
11 Square Key - .188x 1.0 1 28 Mechanical shaft seal 1
12 Rotor 1 29 Washer .53x1.12x.023 spherical 1
- 44gpm 30 Washer .656x1.66x.094 1
- 54gpm
- 60gpm
- 70gpm
- 80gpm

Viton is a registered trademark of DuPont Dow Elastomers

13
Product Service Log

Model Number: _______________________ Serial Number: ____________________________

Date Purchased: ______________________ Date Entered Service: _____________________

Location: _____________________________ Tag #: ____________________________________

Application Data: Motor:

Liquid: _________________________ Horsepower: _________________________

Flow: ___________________________ Enclosure: ___________________________

Pressure: _______________________ Speed _______________________________

Elastomers: ____________________

Service History:

Date of Service Type of Service

_____________________ __________________________________________________________

_____________________ __________________________________________________________
_____________________ __________________________________________________________

_____________________ __________________________________________________________

_____________________ __________________________________________________________
_____________________ __________________________________________________________

_____________________ __________________________________________________________

_____________________ __________________________________________________________
_____________________ __________________________________________________________

_____________________ __________________________________________________________

_____________________ __________________________________________________________
_____________________ __________________________________________________________

_____________________ __________________________________________________________

_____________________ __________________________________________________________

14
 SECTION TSM 340 SECTION TSM 340
TECHNICAL SERVICE PAGE 12 OF 12
TECHNICAL SERVICE PAGE 1 OF 12
MANUAL MANUAL
ISSUE F ISSUE F

INSTALLATION, START UP, TROUBLESHOOTING, INSTALLATION, START UP, TROUBLESHOOTING,

pREVENTIVE MAINTENANCE, DOS & DONTS pREVENTIVE MAINTENANCE, DOS & DONTS
SERIES SG-04, SG-05 & SG-07 spur gear PUMPS SERIES SG-04, SG-05 & SG-07 spur gear PUMPS

CONTENTS
S D
Installation......................................................... 1

Mounting............................................................ 2

Start Up............................................................. 3

Troubleshooting................................................. 6

Miscellaneous.................................................... 7 S D
Dos and Donts ................................................ 8

Warranty............................................................ 6
figure 1

INSTALLATION
General
The following items must be considered prior to pump installation:

1. Location - locate the pump as close as possible to the liquid supply. If possible locate the
pump below the liquid supply. Viking pumps are self-priming; but the better the suction
conditions, the better the pump will perform.

2. Accessibility the pump must be accessible for inspection, maintenance and repair.

3. Suction/Discharge - SG Series pumps are designed for clockwise rotation as standard

(viewed from end of shaft). Refer to Figure 1.

4. Pressure Relief Valve - the SG Series is a positive displacement pump and requires some
form of over pressure protection. Without pressure protection, if the discharge line is
blocked or becomes closed, pressure will build up until the motor stalls, drive equipment
fails, a pump part breaks, or the piping and/or other equipment in the system bursts.
To prevent the possibility of any one or more of the above from occurring, the use of a
pressure relief valve is recommended.

5. Storage - drain the pump and apply a light coat of non-detergent SAE 30 weight oil to all
internal pump parts. Apply grease to the pump shaft extension. Viking suggests rotating
the pump shaft by hand one complete revolution every 30 days to circulate the oil.

5/2007 Viking Pump Inc.

All rights reserved

VIKING PUMP, INC. A Unit of IDEX Corporation Cedar Falls, IA 50613 USA VIKING PUMP, INC. A Unit of IDEX Corporation Cedar Falls, IA 50613 USA
MOUNTING
1. Surfaces to which the pump mounts must be clean and flat.

2. Use SAE Grade 5 or better capscrews to mount pump.

3. The 4 mounting capscrews for the SG-04 and SG-05 pumps must have a minimum of
inch thread engagement, and must be torqued evenly to 12-15 ft-lbs.

4. The 2 mounting capscrews for the SG-07 pumps must have a minimum of inch
thread engagement, and be evenly torqued to 50-55 ft-lbs.

5. Standard SG Series pumps are designed to be used with jaw type couplings that do not
induce axial thrust on the pump shaft. If an improper type of coupling is used, internal
damage may result.

6. Do not strike or press the pump drive coupling to install. Internal pump damage will
result. If the coupling does not slide onto the shaft, inspect the coupling, shaft and
key for nicks or burrs and remove.

7. If the pump is to be belt or gear driven, the overhung load option must be specified.

8. Once the pump has been mounted and the coupling installed, it is recommended to
put lube oil into the suction port and turn the pump by hand to make sure it turns freely.

Alignment

Check alignment after mounting.

1. If the unit has a flexible coupling, remove any coupling guards or covers and check
alignment of coupling halves. A straight edge (piece of key stock will work) across the
coupling must rest evenly on both rims at the top, bottom and sides. See Figure 3.

2. Make a final check on alignment after the piping is hooked up.

USE STRAIGHT EDGE. THESE
SURFACES MUST
BE PARALLEL

CHECK WIDTH BETWEEN THESE SURFACES WITH INSIDE CALIPERS OR FEELER

GAUGE TO BE CERTAIN THE FACES ARE EQUAL DISTANCE APART AND PARALLEL.

Piping/Hose figure 3

The cause of many pumping problems can be traced to the suction piping. It should always be
as large in diameter and as short in length as possible.

Before starting the layout and installation of your piping system, consider the following
points:
1. Never use piping smaller than the pump port connections. Piping larger in diameter than
the port connection is sometimes required to reduce friction losses.

SECTION TSM 340 ISSUE F PAGE  OF 12 SECTION

SECTION TSM
TSM 340
340 ISSUE
ISSUE FE PAGE
PAGE 11 OF 12
3. DO obtain, read and keep all maintenance instructions furnished with pump. 2. Be sure the inside of the pipe is clean before installing.

3. When approaching an obstacle to the suction line, go around instead of over it. Going
over an obstacle can create an air pocket. Where practical, slope the piping so no air or
liquid pockets will be formed. Air pockets in the suction line make it hard for the pump to
prime.

4. A strainer on the suction side of the pump should always be considered in any pumping
system. The strainer will keep foreign matter from entering the pump. The strainer mesh
or perforation size should be large enough so that it does not cause excessive pressure
drop, but fine enough to protect the pump. Use of a strainer is particularly important at
start up to help clean the system of weld beads, pipe scale and other foreign objects.

5. A pressure relief valve is required in the discharge line. See Pressure Relief Valves,
General page 1 item 4.

6. The pump must not be used to support the piping. Hangers, supports, stands, etc. must
carry the weight of the pipes.
WARRANTY
7. When fastening piping to the pump do not impose any strain on the pump casing.
Viking warrants all products manufactured by it to be free Springing or drawing the piping up to the pump will cause distortion, possible
from defects in workmanship or material for a period of one misalignment and probable rapid wear of the pump. Do not use the pump to correct errors
(1) year from date of startup, provided that in no event shall in piping layout or assembly.
this warranty extend more than eighteen (18) months from
the date of shipment from Viking. If, during said warranty 8. All joints of piping system must be tight; liquid thread sealant will help assure leak free
period, any products sold by Viking prove to be defective threaded joints. Loose joints result in liquid leaks or suction side leaks. Air leaks make
in workmanship or material under normal use and service, the pump noisy and reduce flow. CAUTION: Be careful not to over tighten fittings as this
and if such products are returned to Vikings factory at can cause cracked joints. Do not use Teflon tape. Reduced friction makes over tightening
very easy and will result in cracked ports. Leaks in the suction line can permit air to be
Cedar Falls, Iowa, transportation charges prepaid, and drawn in, and will cause a noisy pump and reduction in capacity.
if the products are found by Viking to be defective in
workmanship or material, they will be replaced or repaired 9. Drive alignment must be checked after piping is hooked up.
free of charge, FOB. Cedar Falls, Iowa.
Viking assumes no liability for consequential damages 10. Provide a pressure relief device in any part of a pump and piping system that can be
of any kind and the purchaser by acceptance of delivery valved off and, thus, completely isolated. A rise in temperature will cause a liquid to
assumes all liability for the consequences of the use or expand. If there is no provision for pressure relief in the closed off section, there is a
misuse of Viking products by the purchaser, his employees chance that the pump or piping will rupture.
or others. Viking will assume no field expense for service
or parts unless authorized by it in advance. Danger !
Equipment and accessories purchased by Viking from
outside sources which are incorporated into any Viking
product are warranted only to the extent of and by the Before starting pump, be sure all drive equipment guards are in place.
original manufacturers warranty or guarantee, if any. Failure to properly mount guards may result in serious injury or death.

THIS IS VIKINGS SOLE WARRANTY AND IS IN

LIEU OF ALL OTHER WARRANTIES, EXPRESSED
START UP
OR IMPLIED, WHICH ARE HEREBY EXCLUDED,
INCLUDING IN PARTICULAR ALL WARRANTIES OF Before pushing start button, check the following:
MERCHANTABILITY OR FITNESS FOR A PARTICULAR
1. Are vacuum and pressure gauges (liquid filled) mounted on or near the pump? Gauges
PURPOSE. No officer or employee of IDEX Corporation or
are the quickest and most accurate way of finding out what is happening in the pump.
Viking Pump, Inc.. is authorized to alter this warranty.
2. Is the pump is correctly aligned with the drive equipment?

3. Make sure there is no pipe strain on the pump ports.

4. Rotate the pump shaft by hand to be sure it turns freely.

SECTION
SECTION TSM
TSM 340
340 ISSUE
ISSUE FF PAGE
PAGE  10
OF OF
12 12 SECTION TSM
SECTION TSM 340
340 ISSUE
ISSUE E F PAGE
PAGE 3 OF 12
OF 12
 Pump takes too much power (stalls motor):
1. The pump sequence valve set too high.

2. Liquid is more viscous than the is unit sized to handle.

3. The system pressure relief valve set too high.

4. The pump is misaligned.

DOS AND DONTS

Dos and Donts for installation, operation and maintenance of Viking pumps to assure safe, long,
trouble free operation.

Installation:
1. DO install the pump as close to supply tank as possible.

2. DO leave working space around the pumping unit.

typical sg-04/sg-05
3. DO use large, short and straight suction port.
exploded view
4. DO install a strainer in the suction line.

5. DO a double check of alignment after unit is mounted and piping is hooked up.

6. DO provide pressure relief valve for discharge side of pump.

7. DO check for proper rotation.

8. DO use a return line filter.

9. DO use an industrial grade hydraulic oil.

10. DO use piping, hose and fittings rated for maximum system pressure.

Operation
1. DONT run the pump at speeds faster than 3600 RPM.

2. DONT allow the pump to develop pressure higher than those shown in catalog at that
size.

3. DONT operate pumps at temperatures above or below limits shown in catalog for
model.
typical sg-07
4. DONT operate unit without all guards in place.
exploded view
5. DONT operate pump without pressure relief valve in discharge piping; be sure valve is
mounted and set correctly.

6. DONT stick fingers in ports of pump!!! Fingers may be pinched between gears.

7. DONT work on the pump unless driver has been locked out so it cannot be started
ITEM DESCRIPTION ITEM DESCRIPTION while work is being done on the pump.

1. Bracket, lipseal & bearing section 5. Relief valve kit Maintenance:

Match ground casing & (2) gears, driver &
2. 6. Lipseal 1. DO record pump model number and serial number and file for further use.
driven shafts
3. Separation plate & bearing assy. 7. O-ring 2. DO have spare parts, pump or stand by units available, particularly if pump is
4. Head and alignment sleeve assy. 8. Assembly capscrews essential part of key operation process.

SECTION TSM 340 ISSUE F PAGE  OF 12 SECTION

SECTION TSM
TSM 340
340 ISSUE
ISSUE E F PAGE
PAGE 9 OF 12
Miscellaneous
5. Before connecting to the motor, jog it to be sure it is running in the correct direction.
Pump does not pump: Refer to General on page 1.
1. The pump has lost its prime from air leak or low level in tank. 6. Is the pressure relief valve installed properly?
2. The suction lift is too high. 7. Make sure suction piping is properly connected and sealed, and valves are open.
3. Rotating in the wrong direction. 8. Make sure the discharge piping is properly connected and sealed, valves are open,
and there is a place for the liquid to go.
4. The motor does not come up to speed.
9. Make sure all guards are in place.
5. The strainer is clogged.
10. The above checklist is a general guideline to be used prior to starting the pump. Since
6. The bypass valve is open, pressure relief valve set too low or pressure relief valve poppet Viking Pump cannot foresee every application for our product and possible system
stuck open. design, the final responsibility is with the user. The pump must be utilized within the
catalog specifications and the pump system must be designed to provide safe working
7. The pump is worn out. conditions.
The start button may now be pushed.
8. Any changes in liquid, system or operation that would help explain the trouble, e.g. new
liquid, additional lines or process changes. The pump should begin to deliver liquid within 15 seconds! If not, push the stop button. Do not
run the pump without liquid flow longer than 30 seconds or the pump may be ruined.
Pump starts, then looses its prime:
Review Startup steps 1 through 10. Consider what the suction and discharge gauges may
1. The supply tank is empty. indicate. If everything appears in order, re-prime pump. Refer to Mounting, page 2, item 8.
2. The liquid is vaporizing in the suction line.
Push the start button. If nothing is flowing within 30 seconds, stop the pump. The pump is not
3. There is an air leak or air pockets in the suction line. a compressor, it will not build up much air pressure. It may be necessary to vent discharge line
until liquid begins to flow.
4. The pump is worn out. If pump still does not deliver, consider one or more of the following:

Pump is noisy: 1. The suction line has air leaks.

1. The pump is cavitating (liquid vaporizing in suction line) or being starved (heavy liquid 2. The end of the suction pipe is not submerged deeply enough in the liquid.
cannot get to pump fast enough). Increase the suction pipe size and/or reduce the length,
or decrease the pump speed. If the pump is above the liquid, raise the liquid level closer 3. The suction lift is too great or the suction piping is too small.
to the center line of the inlet port. If the liquid is above the pump, increase the head of the 4. Liquid is vaporizing in the suction line before it gets to the pump.
liquid.

2. Check alignment. If after consideration of these points, the pump still does not deliver liquid, review all points
given under START UP and read through the TROUBLESHOOTING guide and try again. If
3. Anchor the base or piping to eliminate vibration. pump still will not deliver liquid, contact your Viking Pump supplier.

Pump not delivering up to capacity:

1. The pump is starving or cavitating see Pump is noisy, item 1.
2. The strainer partially clogged.

3. Air leak somewhere in the suction line.

4. Running too slow. Is the motor the correct speed and wired up correctly?

5. Pressure relief valve is set too low, stuck open or has damaged poppet seat.

6. The bypass line around the pump partially opened.

7. The pump is worn out.

SECTION TSM
SECTION TSM 340340 ISSUE
ISSUE F F PAGE
PAGE 8 OF
 OF 12 12 SECTION
SECTIONTSM 340
TSM 340 ISSUE
ISSUE FE PAGE
PAGE 5 OF 12
OF 12
TROUBLESHOOTING Fluttery, jumping or erratic reading would indicate:

A Viking pump that is properly installed and maintained will give long satisfactory 1. The liquid is vaporizing.
performance.
2. Liquid is coming in to the pump in slugs, possibly an air leak or insufficient liquid
If trouble does develop, one of the first steps toward finding the difficulty is to install a vacuum above the end of the suction pipe.
gauge in the suction line and a pressure gauge in the discharge line. Readings on these
gauges often give a clue on where to start looking for trouble. 3. Vibration from cavitation, misalignment, or damaged parts.

Pressure Gauge - Discharge Port

DANGER !
High reading would indicate:
Before opening any Viking pump liquid chamber (pumping chamber, 1. High viscosity and small diameter and/or lengthy discharge line.
reservoir, relief valve adjusting cap fitting etc.) be sure:
2. The strainer or filter is plugged.
1. That any pressure in chamber has been completely vented through
3. The pressure relief valve is set too high.
the suction or discharge lines or other appropriate openings or
connections. 4. Valve in the discharge line partially closed.

2. That the driving means (motor, turbine, engine, etc.) has been 5. Line partially plugged from build up on inside of pump, solidified product or foreign
locked out or made non-operational so that it cannot be started object.
while work is being done on the pump. 6. Liquid in the pipe not up to temperature.

3. That you know what liquid the pump has been handling and the Low reading would indicate:
precautions necessary to safely handle the liquid. Obtain a material 1. Pressure relief valve set too low.
safety data sheet (MSDS) for the liquid to be sure these precautions
are understood. 2. Pressure relief valve poppet not seating properly.

3. Pump mounting capscrews into torqued to specifications (GP-04 and GP-05

Failure to follow the above listed precautionary measures may result in
Series 12-15 ft.-lbs.).
serious injury or death.
4. Pump assembly bolts not torqued into specifications (GP-07 Series 50-55 ft.-
lbs.).

Vacuum Gauge - Suction Port 5. The bypass around pump partially open.

High vacuum reading would indicate: 6. Pump is damaged or worn.

1. The suction line is blocked, valve closed, a strainer is plugged or a pinched suction
line. 7. The pump has too much internal clearance.

2. The suction line is too small.

Fluttery, jumping or erratic reading would indicate:
3. The liquid is too viscous to flow through the piping.
1. Cavitation.
4. The lift required is too high.
2. Liquid is coming to the pump in slugs.
Low reading would indicate:
3. Air leak in the suction line.
1. There may be an air leak in the suction line.
4. Vibrating from misalignment or mechanical problems.
2. The end of the pipe is not in the liquid.

3. The pump is worn.

4. The pump is dry and should be primed.

SECTION TSM 340

340 ISSUE
ISSUE FF PAGE
PAGE  6OFOF1212 SECTION
SECTION TSM
TSM 340
340 ISSUE
ISSUE EF PAGE
PAGE 7 OF
OF 12
12
Strainer Information
 Bulletin T479c
September, 2000

Specifications, Applications,
Service Instructions & Parts

ST
STRAINERS
(FILTERS)

" thru 6"

(13 mm thru 150 mm)
for refrigerants
2" Strainer: ST200
INTRODUCTION KEY FEATURES
These rugged, refrigerant strainers (filters) are ISO 9002
designed to remove foreign materials, like dirt and
weld slag, from refrigeration systems. Strainers help
prevent damage to valves and other components,
DUCTILE IRON CLOSE-COUPLES
reducing costly service and downtime. Strainers are OR STEEL BODY TO VALVES
usually close-coupled to solenoid valves, pressure
regulators and other flanged valves.
ORDERING INFORMATION
FOR FLANGE STYLE AND SIZES
CAT NO. VALVE CONNECTIONS AVAILABLE
SIZE FPT, SW, WN ODS
inch (mm)
STD ALSO STD
(13)
ST050 5/ 32 5 8
/
(4)
(20) 1, 1 7/ 8

ST100 1 (25) 1 , 1 1 1/ 8 GENEROUS

FLOW AREA
1 (32) 1 , 1 1 3/ 8 STAINLESS
1 (40) 1 2 1 5/ 8 STEEL
ST200 SCREEN
2 (50) 2 1 2 1/ 8 EASY IN-LINE
ST250 2 (65) 2 3 2 5/ 8 SERVICEABILITY
ST300 3 (80) 3 3 1/ 8
ST400 4 (100) 4 4 1/ 8
STW500 5 (125) 5 WN
STW600 6 (150) 6 WN MATERIAL SPECIFICATIONS
Integral butt weld end only Body: " through 4": Ductile iron, ASTM A536,
(nodular iron GGG-40), 65,000 psi tensile
OPTIONS
5" and 6": Cast steel, ASTM A352
Strainer Basket: heavy duty, available for ST100.
Bottom Cover: ": Steel, ASTM 108
Perforated Metal Strainer: necessary for suction
" through 1": Ductile iron, ASTM A536
side port applications (1" through 3"); contact factory.
1" through 6": Steel, ASTM A36
Cloth Bags: available up to 4" for system start-up.
Drain Plug: Standard on " through 1" (" NPT),
Filter System: An extra-fine filter system with double
1" through 4" (" NPT),
the cleansing capacity of standard strainers is
5" & 6" (" NPT)
available. See bulletin T782 for more information.
Screen: Stainless steel, 60 mesh (233 micron rating)
TO ORDER: Specify catalog number and if strainer ST050 has 100 mesh (150 micron rating)
will be close-coupled to valve or installed as a separate Gaskets: Nonasbestos, graphite composite
unit. If it will be a separate unit, also specify flange Safe Working Pressure: 400 psig (27 bar)
connection style and size. Operating Temperature: 60F to +240F (50 to +115C)
 INSTALLATION DIMENSIONS CAUTION
inches (mm) Hansen strainers are for refrigeration systems only.
Read these instructions and related safety precautions
L1 completely before selecting, using, or servicing these
strainers. Only knowledgeable, trained refrigeration
mechanics should install, operate, or service these
strainers. Stated temperature and pressure limits
H2 should not be exceeded. The bottom cover should
not be removed from strainers unless the system
has been evacuated to zero pressure. See also Safety
Precautions in the current List Price Bulletin and
the Safety Precautions Sheet supplied with the
H1 product. Escaping refrigerant can cause injury,
particularly to the eyes and lungs.

WARRANTY
Hansen strainers and valves are guaranteed against
L3 R defective materials or workmanship for one year
F.O.B. our plant. No consequential damages or field
labor is included.
Screen Area
CAT NO. H1 H2 L1 L3 R W
in (c m )

ST050
3.32 0.68 2.03 1.38 3.00 2.03 5.40 REPLACEMENT SCREEN KITS
(84) (17) (52) (35) (76) (52) (35)
D E S C R IP T IO N QTY PART NO.
5.15 1.56 3.75 4.59 3.00 4.59 63.00
ST100
(130) (40) (95) (117) (76) (117) (407) Screen Kit for ST050 Consists of: 7 8 -1 0 0 1
5.34 2.79 9.88 4.25 4.00 4.58 84.50 Screen Assembly 1 78-0005
ST200
(136) (71) (251) (108) (102) (116) (545) Bottom Cap Gasket 1 78-0016
Screen Kit for ST100
ST250
6.10 3.62 9.88 5.38 4.50 5.62 134.50 7 8 -1 0 0 3
(155) (92) (251) (137) (114) (143) (868) (standard) Consists of:
Screen Assembly 1 78-0028
6.56 4.06 12.25 5.38 4.75 6.50 134.50
ST300 Bottom Cover Gasket 1 78-0026
(167) (103) (311) (137) (121) (165) (868)
Screen Kit for ST100
7.38 4.73 14.12 6.75 5.75 8.06 219.00 7 8 -1 0 1 3
ST400
(187) (120) (359) (171) (146) (205) (1413) (optional, heavy duty) Consists of:
Screen Assembly 1 78-0135
14.34 6.40 20.40 12.75 8.00 12.75 536.50
STW500
(364) (163) (518) (324) (203) (324) (3462)
Bottom Cover Gasket 1 78-0026
Screen Kit for ST200 Consists of: 7 8 -1 0 0 5
14.34 6.40 20.40 12.75 8.00 12.75 536.50
STW600 Screen Assembly 1 78-0052
(364) (163) (518) (324) (203) (324) (3462)
Bottom Cover Gasket 1 75-0196
W = Maximum width of strainer body
R = Clearance for screen assembly removal Screen Kit for ST250 Consists of: 7 8 -1 0 0 6
Screen Assembly 1 78-0040
SERVICE AND MAINTENANCE Bottom Cover Gasket 1 75-0128
Repeated inspection of strainers during system Screen Kit for ST300 Consists of: 7 8 -1 0 0 7
start-up or repairs is essential for optimum benefit. Screen Assembly 1 78-0054
Before opening a strainer or any other component, Bottom Cover Gasket 1 75-0128
be sure it is isolated from the system, and all Screen Kit for ST400 Consists of: 7 8 -1 0 0 8
refrigerant is removed (pumped out to zero pressure). Screen Assembly 1 78-0057
The " through 6" strainers have a drain plug in the Bottom Cover Gasket 1 75-0234
bottom cover for connecting a drain valve and hose Screen Kit for STW500 & STW600 7 8 -1 0 0 9
for proper and safe removal of any trapped liquid Screen Assembly 1 78-0071
refrigerant. Bottom Cover O-Ring, Inner 1 75-0605
Screen Removal and Cleaning: Be careful to Bottom Cover O-Ring, Outer 1 75-0606
avoid any refrigerant which may still be in the strainer.
For the " strainer, slowly remove the hex bottom
cap, then remove the screen assembly. For " through
6" strainers, loosen the bottom cover bolts and bottom
cover, check for refrigerant presence, and then remove HANSEN TECHNOLOGIES
the bolts, cover, and screen assembly. Clean the CORPORATION
screen assembly with a good solvent, blow dry, and 6827 High Grove Boulevard
inspect. If the screen is damaged or sediment cannot Burr Ridge, Illinois 60521 USA
be removed from the screen, replace the screen Telephone: 630-325-1565
assembly. Carefully align the screen assembly in Toll-free: 800-426-7368
the center of the strainer body and replace the bottom FAX: 630-325-1572
cover. Pressure test for leaks before returning to E-mail: info@hantech.com
service. Web site: www.hantech.com
2000 Hansen Technologies Corporation Printed in U.S.A.
2
Refrigerant Strainer Bulletin 00-12
Type RSW
Type RSW
Size: 125mm - 200mm (5" - 8")
For Ammonia, R-22, R134a, R404a, R-507
and other common Refrigerants

Features
Stainless Steel (60 Mesh) Screen
Drain Connection for Safe Cleaning
Ample Screen Area
Low Pressure Drop
Desigh Pressure: 27.6 bar (400 psig)

March 2003
STRAINER Installation, Service and Parts Information
BODY
Service Pointers
It is very important that the strainer is frequently inspected for
dirt and cleaned during system start-up and until no further dirt
is found.

Before beginning to loosen cover screws, be sure that the

SPRING strainer has been pumped out and any entrapped refrigerant
SCREEN liquid is properly removed. Then remove Screen Assembly #2
ASSEMBLY by removing Strainer Cover #3. The screen assembly should
COVER be washed with a good solvent and blown dry. The inside of
the Strainer Body #1 should also be cleaned.

3/8" FPT DRAIN After the strainer has been thoroughly inspected and cleaned,
CONNECTION insert the screen assembly into the strainer body, making
sure that it is properly centered to avoid crushing (and that the
Fig. 1 Spring #6 is properly located). Lightly oil and place gasket on
the valve body and fasten the strainer cover in place. Cover
Description bolts must be tightened evenly to the torque values shown.
These rugged valve bodies are made of ASTM A352, Grade LCB
cast steel and they butt weld directly into the pipe line, with Additional Service Pointers
connections suitable for either metric or U. S. pipe sizes. Refrigerant Ruptured Screen Assembly: (a) Screen is clogged causing
Strainers with stainless steel screen are designed especially for excessive pressure drop to rupture the screen - check and
the protection of R/S Control Valves from foreign materials clean more frequently. (b) Fluid velocity too great. Use
present in refrigeration systems. The fine stainless screen mesh oversized strainer, or a restricting hand valve to reduce fluid
will collect particles as small as six thousands of an inch in flow.
diameter. Generous available screen area allows maximum dirt Collapsed Screen Assembly: (a) Possibly caused by reverse
capacity at minimum pressure drop. flow through the strainer (avoid reverse flow and never open a
hand valve downstream of a strainer before a valve upstream
Purpose has been opened first). (b) Screen Assembly crushed during
The RSF Refrigerant Strainer collect foreign materials and dirt installation.
in a refrigerant system at minimal pressure drop in order to Dirt Passing Through Strainer: (a) Ruptured or collapsed
minimize damage to or prevent malfunction of control valves. screen assembly. (b) Spring #6 is broken or missing. (c) Fine
This, of course, is extremely important upon start-up of a new dirt, less than several thousandths of an inch in size requires
refrigeration system where dirt, scale, and weld particles may more frequent cleaning of the strainer or possible temporary
be present in the system and are disturbed and circulated insertion of R/S Filter Bag where applicable.
when pressure testing or upon system start-up. Also when an
existing system is revised, any settled dirt or foreign matter Safe Operation (See also Bulletin RSBCV)
may be disturbed and circulated throughout the system. It is People doing any work on a refrigeration system must be
not safe to omit strainers upstream of the control valves qualified and completely familiar with the system and the
unless there is a certainty that the system will always be Refrigerating Specialties Division valves involved, or all other
clean. precautions will be meaningless. This includes reading and
understanding pertinent Refrigerating Specialties Division

Refrigerating Specialties Division 1 I S O 9 0 0 1-2 0 0 0 C E R T I F I E D

310625
product bulletins and Safety Bulletin RSB prior to installation
or servicing work.

Where cold refrigerant liquid lines are used, it is necessary

that certain precautions be taken to avoid damage that could
result from liquid expansion. Temperature increase in a
piping section full of solid liquid will cause high pressure, due
to the expanding liquid that can possibly rupture a gasket, pipe
7
or valve. All hand valves isolating such sections should be
marked, warning against accidental closing, and must not be
closed until the liquid is removed. Check valves must never
be installed upstream of solenoid valves or regulators with
electric shut-off, nor should hand valve upstream of solenoid
valves or downstream of check valves be closed until the
liquid has been removed. It is advisable to properly install 4
relief devices in any section where liquid expansion could take 2
place.
Avoid all piping or control arrangements that might produce
thermal or pressure shock. For the protection of people and
6
products, all refrigerant must be removed from the section to
be worked on before a valve, strainer, or other device is 3
opened or removed.
8
Installation (see also Bulletin RSBHV) 5
Strainer must be installed in a horizontal line with the cover on
the bottom. Allow sufficient space below the Strainer Cover #3
(see page 1), to permit the Screen Assembly #2 to be SPARE PARTS
removed for cleaning. If the strainer is insulated make sure Item Description Qty 5" 6" 8"
the insulation can be easily removed to allow access to the 2 Screen Assembly 1
strainer cover. Installation must be done according to all 3 Cover 1
applicable Safety Codes and Standards, and by personnel 4 Gasket 1 303005 301703 303002
qualified to install refrigeration systems. Refrigerating 5 Bolt 8
Specialties Division control valves and strainers must be 6 Spring 1
installed according to the specific valves instructions, this
2, 4, 6 Screen Kit 201561 201562 201563
bulletin, and generally known safe practices.
ince most maintenance problems caused by dirt occur at the start-up
7 Nut 8
of a system, it is advisable to delay insulating the control valves and 4, 5, 7 Bolt Kit 201555 201556 201557
strainers until the system has operated for several days. During that 8 Plug Package 12 202553 202553 202553
time the strainers should be checked for dirt and cleaned as
necessary. During installation of strainer remove pipe plug #5 (see
page 1) from cover and install a refrigerant drain valve
LENGTH HEIGHT WIDTH
Warranty 5" 381mm 15" 406 mm 16" 267 mm 10.5"
All Refrigerating Specialties products are warranted against
6" 483 mm 19" 483 mm 19" 318 mm 12.5"
defects in workmanship and materials for a period of one (1)
year from date of shipment from originating factory. This 8" 622 mm 24.5" 635 mm 25" 381 mm 15"
warranty is in force only when products are properly installed,
field assembled, maintained, and operated in use and service
as specifically stated in Refrigerating Specialties catalogs or
bulletins for normal refrigeration applications, unless
otherwise approved in writing by Refrigerating Specialties
Division. Defective products or parts of returned to the factory
with transportation charges prepaid and found to be defective
by factory inspection will be replaced or repaired at Refrigerating
Specialties option, free of charge F.O.B. factory. Warranty does not
cover products that have been altered or repaired in the field,
damaged in transit as a result of accidents, misuse, or abuse.
Products disabled by dirt or other foreign substances will not be
considered defective.
The express warranty above constitutes the only warranty of 8.5
particular purpose. In no event is Refrigerating Specialties responsible
for any consequential damages of any nature whatsoever. No
employee, agent, dealer or other person is authorized neither to give
any warranties on behalf of Refrigerating Specialties nor to assume
for Refrigerating Specialties any other liability in connection with any
of it products.

Refrigerating Specialties Division 2

Valve Documentation
Check Valves
(C Series)

Catalog 4130-C
August 2005
C Series Check Valves Catalog 4130-C

Introduction
Parker C Series Check Valves are designed for uni-directional ow control of uids and gases in
industries such as chemical processing, oil and gas production and transmission, pharmaceutical, pulp
and paper, power and utilities.
Features Specications
Resilient, custom molded, blow-out resistant seat design Pressure Rating:**
Back stopped poppet minimizes spring stress 316 SS 1/8" to 3/4": ....................6000 psig (414 bar) CWP
1": ..................................5000 psig (345 bar) CWP
100% factory tested for both crack and reseat All sizes with PTFE Seats: .............4000 psig (276 bar) CWP
Brass 1/8": to 1": .........................3000 psig (207 bar) CWP
Cracking pressures include: 1/3, 1, 5, 10, 25, 50, 75, and
100 psi. Temperature Rating:
Fluorocarbon Rubber....... -15F to +400F (-26C to +204C)
Port connections include male and female NPT, CPI, Nitrile ............................... -30F to +275F (-34C to +135C)
A-LOK, UltraSeal, VacuSeal, BSP, SAE and Seal-Lok
Ethylene Propylene Rubber
Heat code traceability ......................................... -70F to +275F (-57C to +135C)
Neoprene Rubber ............ -45F to +250F (-43C to +121C)
Materials of Construction PTFE ............................... -65F to +400F (-54C to +204C)
Highly Fluorinated Fluorocarbon Rubber
Item # Part Stainless Steel Valve Brass Valve
........................................... -15F to +200F (-26C to +93C)
1 Cap ASTM A 276, ASTM B 16
TYPE 316 Alloy C36000
Orice:......................... .078" to .656" (2.0 mm to 16.7 mm)
2 Seat* Fluorocarbon Rubber*
Cv: ........................................................................ .18 to 6.56
3 Poppet ASTM A 479, ASTM B 16 1 3 4
2
TYPE 316 Alloy C36000 5

4 Spring 316 Stainless Steel

5 Body ASTM A 276, ASTM B 16
TYPE 316 Alloy C36000
* Optional seat materials are available. See How to Order section.
Lubrication: Silicone Paste.
Note: PTFE seated valves employ an additional PTFE coated
316 SS gasket between the seat and the body and are
distinguishable from elastomeric seated valves by the gap INLET OUTLET
designed between the body and cap. Port 1 Port 2

**See Pressure Rating note on page 4. Model Shown: 4V-C4L-5-SS

Flow Calculations with 1000 psig (69 bar) Inlet Pressure

Pressure Water Air
Valve Maximum Drop P @ 60F (16C) @ 60F (16C)
Series Cv psig bar gpm m3/hr scfm m3/hr
10 0.7 1.0 0.2 30.8 52.1
C2 0.31 50 3.4 2.2 0.5 67.2 112.8
100 6.9 3.1 0.7 92.0 155.3
10 0.7 2.4 0.5 74.6 126.1
C4 0.75 50 3.4 5.3 1.2 162.7 273.0
100 6.9 7.5 1.7 222.8 376.2
10 0.7 7.1 1.6 225.3 380.9
C6 2.26 50 3.4 16.0 3.6 495.2 831.0
100 6.9 22.6 5.1 685.1 1157.2
10 0.7 11.2 2.5 352.0 595.0
C8 3.53 50 3.4 25.0 5.6 774.3 1299.4
100 6.9 35.3 8.0 1072.4 1811.6
10 0.7 19.0 4.3 596.6 1008.3
C12 6.01 50 3.4 42.5 9.6 1287.5 2160.4
100 6.9 60.1 13.7 1738.5 2934.5
10 0.7 20.7 4.7 648.9 1096.6
C16 6.56 50 3.4 46.4 10.5 1379.4 2314.7
100 6.9 65.6 14.9 1824.4 3077.6

2 Parker Hannin Corporation

Instrumentation Products Division
Jacksonville, Alabama
www.parker.com/ipdus
Catalog 4130-C
C Series Check Valves

Available End Connections

A -Two ferrule A-LOK M -ANSI/ASME B1.20.1 TA -Tube adapter L -SAE J1453, Fitting
compression port External pipe threads connection O-ring face seal External
thread with O-ring groove
designed to seal with an
elastomer against a sleeve

Z -Single ferrule CPITM Q -UltraSeal face F5 -SAE J1926/2, Part 2:

compression port seal port Heavy-duty (S Series) KF -British Standard BS 21
stud ends (ISO 7-1), Internal pipe threads

F -ANSI/ASME B1.20.1 V -VacuSeal face G5 -SAE J1926/1, Part 1:

Internal pipe threads seal port Threaded port with O-ring KM -British Standard BS 21
seal in truncated housing (ISO 7-1), External pipe threads

Kit Information
To order repair kits for the C Series Check Valves simply
ll in the designators from the chart below.
Size Crack Pressure Seat Material
C2 1/3 V - Fluorocarbon
C4 1 Rubber
C6 5 BN - Nitrile
C8 10 EPR - Ethylene
C12 25 Propylene
C16 50 Rubber
75 NE - Neoprene
100 Rubber
T - PTFE
KZ - Highly
Fluorinated
Fluorocarbon Check Valve Kits Contain:
Seat
Examples: KIT-C8-10-V Spring
KIT-C16-100-BN Instructions

WARNING
FAILURE, IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL
INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users
having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due
to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the nal selection of the
products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specications, designs, availability and pricing, are subject to change by Parker Hannin Corporation and its
subsidiaries at any time without notice.

Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed
by the provisions stated in the Offer of Sale located in Catalog 4110-U Needle Valves (U Series).

Copyright 2004, 2005, Parker Hannin Corporation. All Rights Reserved.

7 Parker Hannin Corporation

Instrumentation Products Division
Jacksonville, Alabama
www.parker.com/ipdus
 Drawn By: JDA Date: 6-14-04
5555 S. Packard Ave.
Redrawn By: Approved By: RPK
3214 R0
Cudahy, WI 53110

DANFOSS REGULATING/MIXING VALVES

NOTE:
PORT A IS FOR THE OUTLET
PORT B IS FOR THE HOT INLET
PORT C IS FOR THE COLD INLET

VILTER BODY OIL FLOW NOMINAL NO OF

DANFOSS
PART HOUSING (GPM) PIPE THERMOSTATIC VALVE TYPE
CODE NO.
NO. TYPE 2 PSID 7PSID DIAMETER ELEMENTS
3214A H1 20 40 1 SW 1 ORV 25 SOC H1 49qC/120qF 148H3229
3214B H2 42 71 1-1/2 SW 1 ORV 40 SOC H2 49qC/120qF 148H3232
3214C H2 44 83 2 SW 1 ORV 50 SOC H2 49qC/120qF 148H3235
3214D H3 80 150 2-1/2 BW 2 ORV 65 A H3 49qC/120qF 148H3237

SPARE/REPLACEMENT NOTES:
THERMOSTAT 49qC/120qF AND GASKET + GUIDE RING -FLAMMABLE HYDROCARBONS ARE NOT
VILTER RECOMMENDED.
SPARE PARTS FOR CODE NO. -CAN BE MOUNTED IN ANY DIRECTION
PART NO.
ORV 25 AND ORV 40 H1 148H3243 3214X -DESIGNED FOR MAX WORKING PRESSURE 580 PSIG
ORV 40 AND ORV 50 H2 148H3244 3214Y -STAINLESS STEEL NICKEL PLATED THERMOSTATIC
ORV 65 AND ORV 80 H3 148H3245 3214Z ELEMENT

Revisions
MAKING MODERN LIVING POSSIBLE

ICM Motor Operated Valve with ICAD Actuator

Magnetic Stainless steel

coupling shield

ICAD Actuator

ICM Top cover / Spindle

Function module

Regulating
cone
Valve seat

Open position

ICV Valve body

Open position
REFRIGERATION AND
AIR CONDITIONING DKRCI.PV.HT0.A1.02 / 520H0566, 06-2005
Refrigeration and Air Conditioning Controls

Refrigeration Note
Sales Info

ICM valves used in CO2 applications

Introduction ICM used in CO2 low temperature liquid lines

Since release of the ICM in September 2004, we
have experienced some technical problems in the
above mentioned CO2 applications.
Even though the problems only have occured
with ICM used in CO2 liquid lines with phase
change (ICM with type -A cone*), Danfoss has
decided to offer a special ICM dedicated for use
in all CO2 applications in general.
The dedicated ICM CO2 solution is designed
to regulate CO2 expansion process in liquid
lines with or without phase change or control
pressure/temperature in dry and wet suction
lines and hot gas lines.
The ICM CO2 solution is only available as ICM
function modules. I.e not complete ICM CO2
valves.
The ICM designations with type -A and type -B
remain the same as for the standard function
modules**.

Product class and stat. no Proudct class Stat. no.

530 01042

Code numbers Description Code No.

ICM 20-A CO2 Module 027H1183
ICM 20-B CO2 Module 027H1184
ICM 20-C CO2 Module 027H1185
ICM 25-A CO2 Module 027H2183
ICM 25-B CO2 Module 027H2184
ICM 32-A CO2 Module 027H3183
ICM 32-B CO2 Module 027H3184
ICM 40-A CO2 Module 027H4183
ICM 40-B CO2 Module 027H4184
ICM 50-A CO2 Module 027H5183
ICM 50-B CO2 Module 027H5184
ICM 65-B CO2 Module 027H6184

Delivery Danfoss can receive orders from week 5, 2007.

The lead time is 2 weeks

For further information please contact:

Kurt M. Sand
Global Product Manager
Phone: +45 8738 9625
E-mail: KMS.DKACD@Danfoss.com

* For ICM 20, both types, -A,-B and -C cones.

** ICM 25-65
-A: Liquid lines with phase change / expansion
-B: Control of pressure or temperature in dry and wet suction lines and hot gas lines.

ICM 20
-A, -B, -C : Liquid lines with phase change / expansion and control of pressure or temperature in dry and wet suction lines
and hot gas lines.

Danfoss A/S (AC-DSL/MWA), 02 - 2007 DKRCI.PM.HT0.A1.02 / 520H1969 

 October 2003 / BULLETIN 10-11

Thermostatic
Expansion Valves
Installation, Field Service, and Assembly

See Bulletin 20-10 for application and selection information on

Table of Contents refrigerant distributors.

Installation While not always convenient or possible, valve Types BI, F, FB, and
O are easier to service if mounted in a vertical and upright position.
Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
If mounted in a horizontal position, the internal parts must be
Solder Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
carefully reassembled to prevent damage to them. Also, some consid-
Bulb Location and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
eration should be taken in mounting larger sized expansion valves.
External Equalizer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
They must be adequately supported since system vibration and the
Driers, Strainers, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 4
weight of the valve may cause valve connections to fracture.
Test Pressures and Dehydration Temperatures . . . . . . . . . . . . . . . 4
Expansion Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
If a hand valve is located on the outlet side of the TEV it should have
How to Determine Superheat Correctly . . . . . . . . . . . . . . . . . . . . 5
a full sized port. No restrictions should appear between the TEV and
How to Change the Superheat Setting . . . . . . . . . . . . . . . . . . . . . 5
the evaporator, except a refrigerant distributor if one is used.

Field Servicing Sporlan TEVs having Selective Charges C, Z, L, or X may be

Complaint: installed and operated in most locations. The amount of thermostatic
A - Valve does not feed enough refrigerant . . . . . . . . . . . . . . . . . 6 charge and the bulb size are such that the bulb retains control despite
B - Valve feeds too much refrigerant . . . . . . . . . . . . . . . . . . . . . . 8 a colder valve body or diaphragm case. The exception is when the
C - Valve feeds too much refrigerant at start-up only . . . . . . . . . 8 element is subjected to sub-zero temperatures for extended periods of
D - Valve doesn't feed properly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 time during an off-cycle. In this case, start-up may be prolonged until
E - System hunts or cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 the bulb and element are warmed sufficiently to open the valve.
F - System won't perform properly . . . . . . . . . . . . . . . . . . . . . . 10
To minimize the possibility of charge migration, the Sporlan MOP
type charges (CP series, ZP series, and VGA) should be installed so
Field Assembly Instructions . . . . . . . 10
the diaphragm case is warmer than the bulb. Special non-condensable
charges without MOP and double diaphragm hydraulic elements with
MOP are available for system manufacturers to overcome this
Installation potential problem.

For peak performance, it is important to select a Sporlan Occasionally, TEVs are located in corrosive atmospheric conditions
Thermostatic Expansion Valve (TEV) with correct capacity, selective that can damage the valve and/or the element assembly. Due to this
charge, external or internal equalizer, etc. See Bulletins 10-9 and 10-10 possibility, the valve must be protected with appropriate materials to
for complete application information. Equally important is the proper prevent premature failure. Consult specialists in protective coatings.
installation, which can determine the success or failure of the entire
system.
Precautions:
When the evaporator and TEV are located above the
Valve Location receiver, there is a static pressure loss in the liquid line. This is due
TEVs may be mounted in any position, but they should be installed to the weight of the column of liquid refrigerant, and this weight may
as close to the evaporator as possible. If a refrigerant distributor is be interpreted in terms of pressure loss in pounds per square inch as
used with the expansion valve, best performance is obtained if the shown in Table 3, Bulletin 10-9. If the vertical lift is great enough,
distributor is mounted directly to the valve outlet. If the distributor vapor or flash gas will form in the liquid line causing a serious
cannot be mounted directly to the valve outlet, the distance between reduction in the capacity of the TEV.
the valve outlet and distributor should not exceed 24 inches or refrig-
erant distribution problems may occur. Also, the tube connecting the When an appreciable vertical lift is unavoidable, precautions should
valve outlet and distributor can be sized smaller to maintain refrig- be taken to prevent the accompanying pressure loss from producing
erant velocity and better distribution. Elbows located between the liquid line vapor. This can be accomplished by providing enough
expansion valve and distributor will hinder proper distribution and subcooling to the liquid refrigerant, either in the condenser or after
therefore, are not recommended. the liquid leaves the receiver. Subcooling is determined by
subtracting the actual liquid temperature from the condensing
Best distribution is usually obtained if the expansion valve feeds temperature (corresponding to the condensing pressure). A
vertically up or down into the distributor. System manufacturers, subcooling calculation example is provided in the "subcooling"
however, have successfully applied distributors in other orientations. section of Bulletin 10-9.

Copyright 2003 by Sporlan Valve Company, Washington, Missouri

Bulletin 10-11, October 2003 Supersedes Bulletin 10-11, September 1996 and all prior publications.
Page 2 / BULLETIN 10-11
Liquid subcooling is provided by the following
methods:
1. In the condenser
2. Suction liquid heat exchanger
3. Special devices

Method 1 will provide sufficient subcooling for the simple short-

coupled system that has only moderate liquid line pressure drop.

Method 2 will usually not provide more than 20F subcooling on

air conditioning systems operating at normal head pressures. The
amount of subcooling will depend on the design and size of the heat
exchanger and on the operating suction and discharge pressures. Figure 2

Method 3 may be used to provide considerable subcooling Solder Techniques

required for systems with excessive vertical lift. The following
It is not necessary to disassemble solder type valves when soldering
special devices are the most commonly used methods:
to the connecting lines. Any of the commonly used types of solders,
Water coils in heat exchange relationship with the liquid line. e.g., 95-5, Sil-Fos, Easy-Flo, Phos-Copper, Stay Brite 8 or equiva-
Separate refrigeration system. lents may be used for copper to copper connections. When soldering
a brass refrigerant distributor to the valve, appropriate solders for
Special heat exchanger which uses a portion of the refrigerant to
these connections, such as 95-5, Easy-Flo, Stay Brite 8 or equivalents
cool the main body of liquid. See Figure 1.
must be used. It is important however, regardless of the solder used,
to direct the flame away from the valve body and avoid excessive
heat on the diaphragm, Figure 2. As an extra precaution, a wet cloth
may be wrapped around the body and element during the soldering
operation.
Main Liquid Line

This precaution will prevent overheating the valve body which could
damage the superheat spring and result in flood back problems. In
addition, the Type O, EBF/SBF, and EBS valve contain synthetic
parts which can be damaged due to overheating, resulting in poor
valve performance.
Receiver

Bulb Location and Installation

Insulation The location and installation of the bulb is extremely important to the
proper performance of the system and care should be taken with its
final location.

Main Suction Line Accepted principles of good suction line piping should be followed
to provide a bulb location that will give the best possible valve
To Compressor control. When system manufacturers have piping recommendations
that differ from the general industry recommendations and Sporlans
Figure 1 suggestions shown in this section, those recommendations should be
used. When specific recommendations are not available, the sugges-
Ordinarily the conventional suction-liquid heat exchanger is installed tions below should be used.
near the evaporator, where the suction vapor is the coldest, to re-
condense any vapor in the liquid line. When the primary purpose of The bulb should be attached to a horizontal suction line at the
the heat exchanger is to prevent the formation of flash gas particu- evaporator outlet (See Figures 3, 4, and 5) If the bulb cannot be
larly on systems that have a long liquid line or excessive vertical lift located in that manner, it may be located on a descending vertical
install the heat exchanger near the receiver before the vertical line only (as shown in Figure 5 for pumpdown control). The bulb
lift occurs. (This also applies to the special devices described in should never be located in a trap or downstream of a trap in the
Method 3). Because vapor in the liquid line considerably increases suction line. Liquid refrigerant or mixture of liquid refrigerant and oil
friction losses, the total pressure drop available across the expansion boiling out of the trap will falsely influence the temperature of the
device on these types of systems is reduced. Also, the suction line and bulb and result in poor valve control.
liquid line should be carefully insulated to minimize heat gain if
subcooled below ambient temperature. On suction lines 7/8 OD and larger, the surface temperature may
vary slightly around the circumference of the line. On these lines, it
Important is generally recommended that the bulb be installed at 4 or 8 oclock
Preventing the formation of vapor in liquid lines having high pressure on the side of the horizontal line, and parallel with respect to the
losses does not eliminate the requirement that an adequate pressure direction of flow. On smaller lines the bulb may be mounted at any
drop must be available across the TEV. The capacity tables show point around the circumference, however locating the bulb on the
valve capacities at pressure drops lower than normal. For TEV bottom of the line is not recommended as an oil-refrigerant mixture
application data and capacities at pressure drops below those listed, is generally present at that point. Certain conditions peculiar to a
consult Sporlan Valve Company. particular system may require a different bulb location than normally
 BULLETIN 10-11 / Page 3

insures individual control for each valve without the influence of

refrigerant and oil flow from other evaporators.
Compressor
ABOVE For recommended suction line piping when the compressor is located
below the evaporator see Figure 5. The vertical riser extending to the
Evaporator height of the evaporator prevents refrigerant from draining by gravity
into the compressor during the off-cycle. When a pumpdown control
is used the suction line may turn immediately down without a trap.

On commercial and low temperature applications requiring

Sporlan Selective Charges C, Z, or X the bulb should be clamped on
the suction line at a point where the bulb temperature will be the same
as the evaporator temperature during the off-cycle. This will insure
tight closing of the valve when the compressor stops. If bulb insula-
Liquid and oil drains tion is used on lines operating below 32F, use non-water absorbing
away from bulb... insulation to prevent water from freezing around the bulb.

On brine tanks and water coolers, the bulb should be below the liquid
Short as possible to minimize amount of oil. surface where it will be at the same temperature as the evaporator
during the off-cycle. When locating the bulb in a brine tank, paint it
and the capillary tubing with pitch or other corrosion resistant paint.
Figure 3
recommended. In these cases the proper bulb location may be If, for practical reasons, the bulb must be located where its tempera-
determined by trial. ture will be higher than the evaporator during the off-cycle, a
solenoid valve must be used ahead of the TEV.
For satisfactory expansion valve control, good thermal contact
between the bulb and suction line is essential. The bulb should be
securely fastened with two bulb straps, supplied with each expansion Compressor BELOW
valve, to a clean straight section of the suction line.
Evaporator
Recommended suction line piping usually includes a horizontal line
leaving the evaporator to which the TEV bulb is attached. This line is Without
pitched slightly downward, and when a vertical riser follows, a short Pumpdown
trap is placed immediately ahead of the vertical line, see Figure 3.
The trap will collect any liquid refrigerant or oil passing through the
suction line and prevent it from influencing the bulb temperature.

On multiple evaporator installations the piping should be

arranged so that the flow from any valve cannot affect the bulb of
another. Approved piping practices including the proper use of traps

Multiple Evaporators
Pumpdown
Above and Below Main Suction Line Control

Figure 5

On air conditioning applications having TEVs equipped with

VCP100 or VGA elements, the bulb may be located inside or outside
Flow from upper valve cannot the cooled space or duct. The valve body should not be located in the
affect bulb. . . . line free draining. air stream leaving the evaporator. Avoid locating the bulb in the
return air stream unless it is well insulated.

Inverted trap to External Equalizer Connection

avoid oil draining For a complete explanation of when an externally equalized valve
into idle evaporator. should be used, refer to "equalization method," Bulletin 10-9. Valves
supplied with an external equalizer will not operate unless this
connection is made.

Free draining. The equalizer connection should be made at a point that will most
accurately reflect the pressure existing in the suction line at the bulb
location. See Figure 6. Generally, the connection is immediately
downstream of the bulb. However, equipment manufacturers
Figure 4 sometimes locate them in return bends or suction headers that are
Page 4 / BULLETIN 10-11

Test Pressures and Dehydration

External Equalizer Temperatures
Connection Inert dry gases such as nitrogen, helium or CO2 are often
used for leak detection.

CAUTION: Inert gases must be added to the system

carefully through a pressure regulator. Unregulated gas
pressure can seriously damage the system and endanger
human life. Never use oxygen or explosive gases.

Excessive test pressures can shorten the life of the TEV diaphragm.
Table 1 lists the maximum pressure that can safely be applied with
the expansion valve connected to the evaporator. These maximum
pressures are well above the minimum field leak test pressures for
low sides, listed by the ANSI/ASHRAE Standard 15-2001 or latest
revision.
It must be connected - NEVER CAPPED!
Must be free of crimps, solder, etc. The external equalizer line should be disconnected if there is any
possibility of exceeding the recommended maximum pressures
listed below.
Figure 6
If elevated temperatures are used to assist in dehydrating the system,
compatible with their specific design requirements. The difference
the TEV should not be exposed to temperatures exceeding those
between the pressure at the equalizer connection and the suction
shown in Table 2.
pressure at the bulb location should not exceed reasonable pressure
drop values. The values shown in Table 1 of Bulletin 10-9 can be Table 2 refers to the maximum dehydration temperatures when the
used as a guide in determining the value. bulb and valve body are subjected to the same temperature. On L, C,
Z, and X charges, 250F maximum valve body temperature is
If any evaporator pressure or temperature control valves are located permissible if the bulb temperature does not exceed those
in the suction line at or near the evaporator outlet, the equalizer must shown in the table.
be connected on the evaporator side of these valves.

Driers, Strainers, and Accessories Table 1

Most Sporlan TEVs are equipped with built-in screens of varying Maximum Low Side Test Pressures
mesh sizes depending on the valve size and type. These strainers are
effective only in removing particles of scale, solder, etc. which could Valve Type psig
obstruct the closure of the pin and seat. (B)I, X, NI, F, FB, (E)BF/SBF, RI, G, EG, C, S, EBS, Small O 450
D, P, H, Large O 425
A, M, V, W 400

Table 2
Maximum Dehydration Temperatures Degrees F
Figure 7 Thermostatic Charge
Refrigerant
L C Z X VGA P Type, ZP Series
Moisture and smaller particles of foreign materials are equally
harmful to the system and must be removed for peak system perfor- 12, 134a 190 190 250 ---
mance. Field experience has proven that, without a doubt, most 22 160 160 185 210 250 250
expansion valve failures are due to the presence of dirt, sludge, and
404A, 502, 507 150 150 170 ---
moisture in the system. Furthermore, the performance and life of
other system components are also seriously affected by these foreign 717 (Ammonia) 150 190 235 --- --- ---
materials. The Sporlan Catch-All Filter-Drier removes dirt,
moisture, acids, and sludge, and insures the circulation of clean, dry
refrigerant through the system at all times.
Expansion Valve Adjustment
For all refrigeration and air conditioning applications we recommend Each Sporlan TEV is thoroughly tested and set at the factory before
that a Sporlan Catch-All Filter-Drier be installed in the liquid line shipment. This factory superheat setting will be correct and no
ahead of the TEV. See Bulletin 40-10 for complete Catch-All Filter- further adjustment is required for the majority of applications.
Drier specifications. However, there are many factors which can affect the performance of
a TEV. These factors are independently variable and all of them
Further system protection is easily and inexpensively provided with cannot be compensated for in the design of a valve. When the
the installation of a Sporlan See-All. The See-All is a combination application or operating conditions require a different valve setting
liquid and moisture indicator that visually indicates if there is a due to one or more of the factors listed below, the valve may be
shortage of refrigerant in the liquid line, or if the moisture content of adjusted to obtain the required operating superheat. Therefore, an
the refrigerant is at a dangerous level. See Bulletin 70-10 for adjusting stem is provided on all standard valves. The valve should
complete See-All specifications. be set with the system as near as possible to design conditions.
 BULLETIN 10-11 / Page 5

Factors which affect valve performance and may make it necessary the estimated pressure drop will equal the approximate
to adjust the valve are: suction line pressure at the bulb.
1. Low temperature difference (TDs) between the refrigerant and 3. Convert the pressure obtained in 2a or 2b above to saturated
the air evaporator temperature by using a temperature-pressure chart.
2. TEV bulb location 4. Subtract the two temperatures obtained in 1 and 3 the differ-
3. Balance between compressor and evaporator ence is superheat.

4. Ratio of load to TEV capacity Figure 8 illustrates a typical example of superheat measurement on
5. Condenser capacity an air conditioning system using Refrigerant 22. The temperature of
6. Operation of several fixtures on multiple installation the suction line at the bulb location is read at 52F. The suction
pressure at the compressor is 66 psig and the estimated suction line
7. Seasonal variation in head pressure caused by extreme changes in pressure drop is 2 psi 66 psig + 2 psig = 68 psig at the bulb, which
ambient air temperature. is equivalent to a 40F saturation temperature. (Use dew point
temperature for refrigerant blends.) 40F subtracted from 52F =
Note: Valve Types F, (E)BF/SBF, Q, A, M, V, K, and W have non- 12F superheat.
rising adjusting stems and a change in adjustment does not change
the stem position. Note: Refrigerated case manufacturers frequently use a tempera-
ture difference method to approximate superheat. This procedure
When setting valves on multi-evaporator refrigeration systems with consists of measuring the temperature of a location on the evaporator
pressure or temperature sensitive evaporator control valves, the which is representative of saturated vapor temperature; and, then
following procedure is recommended: subtracting that temperature from the outlet evaporator temperature
1. Evaporator Pressure Regulating Valve (ORI Type): the ORI valve which is measured at the bulb location.
is set first at the minimum load condition. Then, if necessary, the
expansion valve is adjusted to the desired superheat setting while While this method of reading superheat is acceptable on those
under the normal operating load condition. manufacturers cases where the pressure drop through the evaporator
is low, Sporlan does not recommend the temperature difference
2. Temperature Sensitive Evaporator Regulating Valves (CDS
method for other types of systems.
Type): The CDS valve is forced into a fully open position first.
Then the expansion valve is adjusted to the desired superheat
setting at full load condition. Finally, the controller for the CDS
is set to the desired temperature. Contact Sporlan Valve
Company, or the case manufacturer, for additional details on What's Your
setting the CDS controller. Superheat?
When the adjustment is completed on the TEV, always tighten the
adjusting stem packing nut and replace the seal cap tightly.
Temperature
Many expansion valves are made non-adjustable for use on here reads
Original Equipment Manufacturers units, particularly those valves 52
used on residential air conditioning and heat pump systems. These
valves are set at a superheat predetermined by the manufacturers OBTAIN SUCTION PRESSURE 40
laboratory tests and cannot be adjusted in the field. 68 PSIG (at bulb) 12
SUPERHEAT
Some non-adjustable models are modifications of standard
adjustable type valves. This is done by using a solid bottom cap
instead of one equipped with an adjusting stem and seal cap. These
valves can be identified by an N preceding the standard valve designa-
tion. Adjustable bottom cap assemblies are available for converting
most non-adjustable valves to the adjustable type. However, this is Figure 8
rarely required. If symptoms indicate that a valve adjustment is
needed, carefully check the other possible causes of incorrect
superheat, pages 6 through 10, before attempting an adjustment. How to Change the Superheat
Setting
How to Determine Superheat Note: There are some valve bodies (G, EG, C, S, EBS
and EMC) that have a packing nut around the adjust-
Correctly ment stem. It may be necessary to loosen the packing
1. Measure the temperature of the suction line at the bulb location. nut slightly to turn the adjusting stem. Do not forget
2. Obtain the suction pressure that exists in the suction line at the to retighten the nut after the superheat is set.
bulb location by either of the following methods:
a. If the valve is externally equalized, a gauge in the external To reduce the superheat, turn the adjusting stem counter-
equalizer line will indicate the desired pressure directly and clockwise. To increase the superheat, turn the adjusting stem
accurately. clockwise. When adjusting the valve, make no more than one turn
b. Read the gauge pressure at the suction valve of the of the stem at a time and observe the change in superheat closely to
compressor. To the pressure add the estimated pressure drop prevent over-shooting the desired setting. As much as 30 minutes
through the suction line between bulb location and may be required for the new balance to take place after an adjust-
compressor suction valve. The sum of the gauge reading and ment is made.
Page 6 / BULLETIN 10-11
If in doubt about the correct superheat setting for a particular system, The primary cause of difficulty with either the BP or RPB feature is
consult the equipment manufacturer. As a general rule, the proper dirt and other foreign materials that restrict or plug them. And if the
superheat setting will depend on the amount of temperature differ- system purpose intended for either feature is not being satisfied, the
ence (TD) between refrigerant temperature and the temperature of the valve probably needs cleaning or replacing.
air or other substance being cooled. Where high TDs exist, such as
on air conditioning applications, the superheat setting can be made as As stated in Bulletin 10-9, the RPB type valve is not to be applied on
high as 15F without noticeable loss in evaporator capacity. Where systems using high starting torque compressors or hard-start
low TDs exist, such as in low temperature blower coil applications, electrical components, on outdoor coils of heat pumps, or on any
a superheat setting of 10F or below is usually recommended for refrigeration system, and it should not be used to replace BP type
maximum evaporator capacity. It is these applications that the TEV valves that are applied on those types of systems. On systems other
will more than likely need to be adjusted. than those described above, the RPB type valve can replace the BP
type valve when necessary. Usually it is advisable to replace a valve
For the correct valve setting on factory built equipment, manufac- with one of the same specification unless advised differently. Consult
turers recommendations should be followed. Some manufacturers with the system manufacturer for assistance.
specify the superheat directly; others may recommend valve adjust-
ment to a given suction pressure at certain operating conditions, or
until a certain frost line is observed. Such recommendations, however
they are stated, represent the results of extensive laboratory testing to
Complaint "A"
determine the best possible operation. Valve does not feed enough refrigerant.
SYMPTOMS:
Load temperature (air or water leaving

Field Servicing evaporator) too high.

Superheat too high.

Suction pressure lower than normal with

The TEV is erroneously considered by some to be a mysterious and compressor unloaders locked out or hot gas
complex device. As a result, many valves are needlessly replaced bypass shut off.*
when the cause of the system malfunction is not immediately
recognized.
THE CAUSE MAY BE:
Actually the TEV performs only one very simple function it keeps 1. Moisture Water or a mixture of water and oil frozen in the
the evaporator supplied with enough refrigerant to satisfy valve port or working parts of the valve will prevent proper
all load conditions. It is not a temperature control, suction operation. This is a common source of trouble on expansion
pressure control, a control to vary the compressors running time, or valves. Since the valve is the first cold spot in the system,
a humidity control. moisture will freeze and block the valve open, closed, or any
position in between. If the valve is frozen in the intermediate
How effective the valve performs is easily determined by measuring position so that flow is restricted, the superheat will be high.
the superheat as outlined in Figure 8. Observing the frost on the
suction line, or considering only the suction pressure may be Remedy Install a Sporlan Catch-All Filter-Drier in the
misleading. Checking the superheat is the first step in a liquid line for removal of moisture from the refrigerant and oil.
See Bulletin 40-10.
simple and systematic analysis of TEV performance.
To determine a safe level of moisture in the system, install a
If not enough refrigerant is being fed to the evaporator Sporlan SeeAll Moisture and Liquid Indicator. See Bulletin
the superheat will be high. 70-10.
If too much refrigerant is being fed to the evaporator Excessive moisture has a damaging effect on all
the superheat will be low. system components regardless of the evaporating
temperature. Moisture must be removed for trouble-
Although these symptoms may be attributed to improper TEV
free performance.
control, more frequently the origin of the trouble lies elsewhere.
2. Dirt or foreign material Contaminants such as copper
Note: TEVs with permanent bleed ports (BP) or Rapid Pressure
oxide scale, metal chips, oil breakdown sludge, etc. will restrict
Balancer (RPB) construction are applied on many air conditioning
the flow of refrigerant when it collects in strainers or other liquid
and refrigeration systems by original equipment manufacturers. Each
line accessories. This produces a shortage of refrigerant at the
application is tested and approved by the manufacturer. The primary
TEV port. Conventional strainers frequently allow the material
function of these devices is to equalize high-to-low side pressures
to pass through the screen and obstruct the flow at the valve
during the off cycle on systems equipped with low starting torque
port. If a SeeAll is installed downstream of the restriction,
compressors.
bubbles will be visible. This should not be confused, however,
with a refrigerant shortage or excessive liquid line pressure loss
However, some BP type valves are applied to allow small amounts of
which are also indicated by bubbles in the SeeAll.
liquid refrigerant to pass for compressor motor cooling. The specific
function of the feature on a given unit must be determined from the Remedy Locate and remove the foreign material creating
system manufacturer. Once that is determined, it is easier to the restriction. Install a Sporlan Catch-All Filter-Drier to
troubleshoot the system. provide effective filtration of the refrigerant. See Bulletin 40-10.

* When system has some form of capacity reduction cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
 BULLETIN 10-11 / Page 7

3. Wax Certain systems are contaminated with small amounts 7. Insufficient pressure drop across valve One of the
of wax which will precipitate at low temperatures in systems factors that influence expansion valve capacity is the pressure
with Refrigerants 22 or 502. Since the TEV represents the first drop that exists between the inlet and outlet. Anything
cold point in the refrigeration cycle, wax is most likely to form contributing to a reduction in this pressure drop will reduce valve
at the valve port. capacity. Abnormally low condensing pressures, excessive liquid
It is sometimes difficult to observe the wax in a valve because it line pressure losses (even with adequate subcooling), undersized
may exist in solid form only at very low temperatures. By the distributor nozzle or distributor tubes may also be responsible for
time the valve has been taken apart, the temperature has a very low net pressure drop across the valve port.
increased enough to cause the wax to melt and thus become Remedy Remove source of pressure loss, or install valve
difficult to detect. When wax is suspected, it can usually be with adequate capacity at the reduced pressure drop. If inlet
detected on the pin and seat by packing the valve in dry ice pressure to valve is low due to low condensing pressure, raise
while disassembling. pressure.
Remedy Clean the valve with solvent before reassembling If the refrigerant distributor nozzle is undersized replace with
the valve. The Sporlan HH style Catch-All Filter-Driers have a correct size. See Bulletin 20-10.
special activated charcoal desiccant that is designed to remove
wax in the liquid line before it causes trouble. Therefore, to 8. Dead thermostatic element or wrong thermo-
prevent wax problems, use these HH style driers (e.g., C-415- static charge If the element has partially or completely
S-HH) on all low temperature systems using Refrigerants 22 or lost its thermostatic charge, the valve will be unable to feed
502. sufficient refrigerant or will remain closed. A wrong charge may
cause insufficient feed also.
4. Refrigerant shortage SeeAll or sight glass in the Remedy Replace the element if it is dead. If charge is
liquid line will show bubbles when the system is short of refrig- incorrect, replace with proper selective charge. See Bulletin 10-9.
erant charge. Before adding more refrigerant however, be sure
the bubbles are not produced by other causes (See Paragraphs 9. Charge migration (CP series, ZP series, and VGA
A-2 and A-5). charges only) In order for valves with these charges to
A lack of refrigerant charge may also be detected by a hissing maintain control at the bulb, the bulb must be kept at a lower
sound at the TEV. Some systems not equipped with a liquid line temperature than the element (diaphragm case). If the thermo-
sight glass will have test cocks or other devices for checking the static charge does migrate to the element because of a lower
refrigerant level in the receiver. element temperature, the valve will throttle.
Remedy Add enough refrigerant to obtain desired result. Detection Warm the element with a cloth saturated with
hot water. If this produces more refrigerant feed and reduces the
5. Gas in the liquid line As explained in Paragraphs A-2 superheat to normal, charge migration is responsible for the
and A-4, liquid line vapor can be produced by a partially starved evaporator.
plugged strainer or drier and by a shortage of refrigerant charge. Causes
In addition, gas in the liquid line can be caused by air or other Insufficient pressure drop between the valve outlet and bulb
non-condensable gases in the system or by excessive pressure location, possibly due to an oversized distributor nozzle or no
losses in the liquid line as a result of: nozzle at all.
Long or undersized line. Excessive pushrod leakage, which allows the leaking refrig-

Liquid line vertical lift. erant to cool the diaphragm case before passing into the
Remedy Verify the correct liquid line size for the equiva- equalizer line. This is a rare occurrence and should be
carefully checked before arriving at this conclusion.
lent length and system tonnage. Consult liquid line sizing data
Cold location of TEV, or condensate drippage on the
published in many manufacturers catalogs and in textbooks. If
diaphragm case.
undersized, repipe with the correct size.
Remedies
Determine amount of vertical lift, and obtain the resulting
Install distributor nozzle correctly sized in accordance with
pressure loss from Table 3, Bulletin 10-9. Using the subcooling
calculation example provided in the "subcooling" section of nozzle sizing procedure given in Sporlan Bulletin 20-10.
On valves with packed pushrod construction, remove element
Bulletin 10-9, find required subcooling necessary to prevent
gasification with the existing pressure losses. Provide the and tighten the pushrod packing nuts.
Relocate the TEV away from cold outlet air, or condensate
necessary subcooling by using one of the methods described on
Page 1. drippage.

6. Misapplication of internally equalized valve or 10. Undersized valve

incorrect location of external equalizer If the Remedy Install valve sized in accordance with procedure
pressure drop through the evaporator exceeds the predetermined given in Bulletin 10-9, or Bulletin 10-10.
values shown in Table 1, Bulletin 10-9, an externally equalized
valve must be used. When an externally equalized valve is used, 11. High Superheat adjustment
the equalizer connection should be made at a point in the suction Remedy Turn the adjusting stem counter clockwise until
line that will reflect the pressure existing in the line at the bulb the correct superheat is indicated.
location.
Remedy Replace internally equalized valve with one 12. Feed-back from another valve Review instructions
having an external equalizer. for Bulb Location and Installation, Page 2.
If external equalizer is installed incorrectly, change to correct Remedy Check the bulb temperature and calculate the
location. See Page 3. superheat. If superheat is normal but too little refrigerant is
Page 8 / BULLETIN 10-11

flowing through the evaporator, check the piping for possible Disassemble the valve to be certain that dirt or foreign material
refrigerant flow from another evaporator affecting the bulb. Re- is not responsible (see B-2). If the pin and seat are worn or
pipe if necessary. See Figure 4. damaged and an internal parts kit is available, replace the parts.
When parts are not available, the valve must be replaced.
13. High pressure drop through evaporator
Remedy Check the pressure at the evaporator inlet and 4. Oversized valve Check valve ratings considering all the
outlet with gauges. If pressure difference is greater than the factors which affect its capacity. See Page 16, Bulletin 10-9, or
values shown in Table 1, Bulletin 10-9, use an externally Page 3, Bulletin 10-10.
equalized valve. Remedy Install correctly sized valve.

14. Restricted, plugged, or capped external equalizer 5. Incorrect bulb installation The bulb should be securely
If the pressure under the diaphragm builds up due to pushrod fastened to a straight, clean, section of the suction line using two
leakage and cannot escape through the external equalizer line, bulb straps for good thermal contact. Also, the temperature of the
the valve will remain closed. bulb should not be influenced by ambient temperature an
Remedy Check the external equalizer line to be sure it is external heat source such as a steam pipe or heating coil.
open or not capped. Remedy Install bulb correctly. See Bulb Location and
Installation, Page 2.

Complaint "B" 6. Low superheat adjustment

Valve feeds too much refrigerant. Remedy Turn the adjusting stem clockwise until the correct
SYMPTOMS: superheat is indicated. See Page 4.
Liquid returns to compressor.

Superheat is low. 7. Incorrect thermostatic charge

Suction pressure is normal or higher than
Remedy Select and install the correct selective charge. See
normal. Bulletin 10-9.

8. Incorrectly located external equalizer

THE CAUSE MAY BE:
1. Moisture Water or a mixture of water and oil frozen in the Remedy Relocate external equalizer or the connection
valve port or working parts of the valve will prevent proper between evaporator and any other temperature or pressure
operation. This is the most common source of trouble on TEVs. sensitive evaporator control valve near bulb location. See Page
Since the valve is the first cold spot in the system, moisture will 3 for recommendations.
freeze and block the valve open, closed, or any position in
between. If the valve is held in the open position by ice, liquid 9. Inefficient compressor If the compressor is inefficient
flood-back will occur. or for some other reason lacks capacity, the suction pressure will
Remedy Install a Sporlan Catch-All Filter-Drier in the operate higher than normal. This may or may not be accompa-
liquid line for removal of moisture from the refrigerant and oil. nied by low superheats.
See Bulletin 40-10. Remedy Consult with compressor manufacturer.
For additional protection, install a Sporlan SeeAll Moisture and
Liquid Indicator for a positive indication of when a safe
moisture level is reached. See Bulletin 70-10. Complaint "C"
Valve feeds too much refrigerant at start-up only.
2. Dirt or foreign material Contaminants such as copper
oxide scale, metal chips, oil breakdown sludge, etc. may pass SYMPTOMS:
through ordinary strainers and lodge at the TEV port and prevent Liquid returns to compressor.

the valve from closing. No superheat.

Suction pressure higher than normal.

Remedy Disassemble the valve and remove all foreign
material from the internal parts. Install a Sporlan Catch-All
Filter-Drier in the liquid line. The Catch-All filters out the
THE CAUSE MAY BE:
smallest particles of foreign material that might interfere with
1. Refrigerant drainage Drainage of refrigerant from the
the operation of any system component.
evaporator (during the off-cycle) when installed at a higher level
than the compressor.
3. Expansion valve seat leak When the valve port does
not seat tightly, refrigerant will pass through during the off-cycle Remedy Install a trap-riser to top of evaporator or use
and fill the evaporator with refrigerant. If the seat leak is severe, pump-down control. See Figure 5.
the valve will feed too much refrigerant during the operating
cycle as well. (Not applicable to valves with permanent bleed 2. Compressor or suction line in cold location
ports or RPB feature.) During the period when the system is not in operation, liquid
Remedy If the valve seat is leaking, a gurgling or hissing refrigerant will condense at the coldest point in the system. Liquid
sound can usually be heard during the off-cycle. Also, a sight will condense in the compressor or suction line, if they are located
glass or SeeAll in the liquid line may indicate continued refrig- in an ambient temperature below that of the evaporator during the
erant flow for a long period after the compressor has stopped. off-cycle. Upon re-starting, this liquid will slug the compressor.
Make certain however, that the bubbles are not the result of Remedy Keep compressor or suction line warm during the
back-flow through a vertical liquid line. off-cycle. Some compressors are equipped with crankcase heaters
 BULLETIN 10-11 / Page 9

for this purpose. Another corrective measure is to install a suction 3. Low load Low evaporator load may be caused by insuffi-
line solenoid valve that is de-energized during the off-cycle. cient air over the coil as a result of an undersized blower, dirty
air filters, or an obstruction in the air stream. In addition, frost
3. Restricted or plugged external equalizer A formation on the coil or low entering air temperatures will
momentary flood can occur when the load increases suddenly, reduce the evaporator load.
such as at start-up because the higher suction pressure cannot
Remedy Correct the condition responsible.
reach the underside of the diaphragm and help close the valve.
If the pressure under the diaphragm increases due to any
4. Flow from one coil affecting TEV bulb of another
pressure leakage around the pushrods, the valve will eventually
(Multiple evaporator systems only) The tempera-
throttle.
ture of the bulb may be falsely influenced by flow from another
Remedy Remove the restriction or plugged portion of the evaporator usually because of incorrect piping.
external equalizer.
Remedy Correct the piping. See Figure 4, Page 3.
4. Liquid line solenoid valve seat leak or interrupted
5. Improper compressor-evaporator balance If the
pumpdown Liquid refrigerant can continue to feed the
compressor is too large for the load and evaporator capacity, the
TEV and/or remain in evaporator upon shut-down causing
low suction pressure which results will cause poor system
flood-back to the compressor upon start-up.
performance.
Remedy Disassemble and clean solenoid valve and/or
Remedy Consult with the manufacturer or consulting
replace damaged internal parts if seat leakage is the problem. If
engineer, or the ASHRAE Handbook on component balancing.
the pumpdown cycle isnt completed before the compressor
cycles off, or the thermostat calls for cooling and reopens the If necessary, change or correct the improperly sized component.
liquid line solenoid before the evaporator has been properly Hot gas bypass may be used to balance properly.
evacuated, check the low pressure cut-off setting or the
electrical controls for possible causes. 6. Evaporator oil-logged Poor heat transfer occurs and
unpredictable performance takes place. If erratic performance is
observed over a period of time, and other causes are omitted
from consideration, review the amount of oil in the system.
Complaint "D" Turbulent compressor oil level with little or no return to the
Valve doesn't feed properly. compressor sump indicates oil problems.
SYMPTOMS: Remedy Remove excessive oil from evaporator and
Poor system performance. connecting piping. Many times the evaporator temperature will
Superheat normal or lower than normal. be too low for the oil to be removed. Therefore, the system must
Suction pressure lower than normal with be allowed to warm sufficiently to get cold oil to drain. Analyze
compressor unloaders locked out or hot gas system components for possible causes of oil problem before
bypass shut off.* restarting the system. Consult with the compressor manufacturer
for specific details on their compressor.

THE CAUSE MAY BE:

1. Unequal circuit loading (Multi-circuit evaporators Complaint "E"
and parallel evaporators connected to a single
System hunts or cycles.
refrigerant distributor) When each circuit is not
subjected to the same heat load, the lightly loaded circuits will SYMPTOMS:
allow unevaporated refrigerant or low temperature vapor to Suction pressure fluctuates*

enter the suction line and throttle the valve. This will cause Superheat fluctuates.

normally loaded circuits to be deprived of their share of Valve does not feed enough, and then too much

refrigerant. The net result is a loss of refrigerated evaporator refrigerant.

surface.
Remedy Make necessary modifications which will allow
each evaporator circuit to receive the same percentage of the THE CAUSE MAY BE:
total load. See Bulletin 20-10 for application information on 1. System characteristics Certain design characteristics of
multi-circuit evaporators using a refrigerant distributor. the system may have an effect on the systems tendency to hunt
or cycle. As an example, after the valve admits refrigerant to the
2. Poor refrigerant distribution (Multi-circuit evapora- evaporator inlet, there is a time delay before the bulb senses the
tors and parallel evaporators connected to a single effect at the evaporator outlet. This time delay is dependent on
refrigerant distributor) If the refrigerant distribution is evaporator length, tube size, and load. Generally, there is more
faulty, the circuits receiving the largest portion of refrigerant likelihood for hunting to occur when this time interval is long.
will have the controlling influence on the TEV. The result is the Other influencing factors are circuit arrangement, load per
same as in paragraph 1 above. circuit, and temperature difference.
Remedy Correct refrigerant distribution. See Bulletin 20-10 Remedy When hunting is moderate particularly with no
for complete information on Refrigerant Distributors. floodback, the effect on the system is insignificant and correc-

* When system has some form of capacity reduction cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
Page 10 / BULLETIN 10-11
tions are not necessary. If hunting is severe with floodback to 5. System is hunting or cycling. See Section E on Page 9.
the compressor, check the possible remedies shown in
paragraphs below. 6. The TEV has been physically abused in an effort
to make the valve work properly. This is usually the
2. Valve size An over-sized valve usually aggravates hunting. result of a mistaken analysis. It is frequently assumed that if a
Carefully check the valve rating considering all the factors valve does not feed properly, it is stuck (either opened or
affecting its capacity. See Bulletin 10-9, or Bulletin 10-10. closed). Beating the valve body with a hammer will only distort
Remedy Replace valve with one correctly sized. On the body and make it impossible for the valve to work once the
multiple circuit evaporators using a refrigerant distributor, the real cause is determined.
capacity of the valve can be reduced, within certain limits, by If a valve sticks, it is usually due to moisture freezing in the
installing a smaller distributor nozzle. See Bulletin 20-10. port, dirt and other foreign material restricting or plugging the
internal parts, wax forming on the internal parts at low temper-
3. Bulb location If the bulb is located in a suction line trap, atures, or the valve has been physically abused so it cannot
its temperature will be affected by liquid oil and refrigerant function.
alternately collecting and evaporating at this point. This Remedy Inspect the valve and its internal parts, including
condition frequently results in severe hunting. the inlet strainer. If plugged or restricted in any way, clean the
Remedy As a temporary measure relocate the bulb away parts thoroughly, oil the parts with a good grade of refrigerant
from the trap, and any turbulent areas created by elbows, tees, oil, and reassemble the parts. Complete details on this subject
etc. Also remove the bulb from the air stream or insulate. Re- are found on Pages 10 through 12.
pipe if necessary. Sometimes another position around the If the valve is beyond normal cleaning processes, or if it is
circumference of the suction line will minimize hunting. Follow physically damaged in any way, replace the valve with its proper
the Bulb Location and Installation instructions given on Page 2 replacement model.
for the best TEV control.

4. Refrigerant and load distribution In addition to the

effects of poor distribution explained in paragraphs D-1 and D- Field Assembly
2, hunting also frequently results. This is caused by liquid
refrigerant from the overfed circuits occasionally reaching the Instructions
bulb of the valve.
Remedy Correct the faulty distribution. Sporlan valves my be opened easily for inspection.

5. Superheat adjustment All Sporlan TEVs are preset at

the factory to give the best performance on the average system. Thermostatic
A valve should not be adjusted unnecessarily, but occasionally Element
another setting may prove to be better.
Remedy Turn the adjusting stem clockwise a turn at a time.
If the hunting stops or is reduced, turn the adjusting stem Pushrods
counter clockwise a turn at a time to obtain the lowest superheat
with stable operation.

6. Moisture As ice forms in a TEV from excessive moisture, Inlet

a very erratic hunt may result. Outlet
Remedy Remove the moisture with the installation of a
Sporlan Catch-All Filter-Drier. A safe moisture level can be
determined by installing a Sporlan SeeAll. Body

Seat
Complaint "F"
Pin Carrier
System won't perform properly.
SYMPTOM:
Cannot get valve to react or regulate at all. Spring

Spring Guide
THE CAUSE MAY BE: Bottom Cap
1. No refrigerant being fed to evaporator. See Section Assembly
A on Pages 6 & 7.

2. Too much refrigerant being fed to evaporator. See Adjusting Stem

Section B on Page 8. Seal Cap
3. Too much refrigerant being fed to evaporator at
start-up only. See Section C on Page 8.

4. Refrigerant control is erratic. See Section D on Page 9. Figure 9

 BULLETIN 10-11 / Page 11

Note: These Field Assembly Instructions apply in part to all Sporlan exerting too much pressure in tightening the element or in
TEVs. See Figure 9 for an exploded view of those models that can clamping the body in the vise. Also, do not use a wrench on the
be completely disassembled. When a TEV is to be disassembled for outer welded edge of the element.
inspection and cleaning, or for replacement of the thermostatic
element or the internal parts, the following information should be 4. Inspect parts, element, and body for any foreign materials or
reviewed for assistance. physical damage.

Types F dated approximately C84 or earlier and Types I, BI, NI, RI, 5. On valves with replaceable elements and/or internal parts,
FB manufactured prior to 1994 do not have replaceable elements nor replace any items that appear damaged.
internal parts kits, but can be disassembled for inspection and
cleaning. Type F dated D84 or later, Type S valves dated B69 or later, 6. Clean all parts with solvent, preferably by applying and then
Type C valves dated C70 or later, and ALL Type G, X, (E)BF/SBF blowing off with clean dry compressed air.
and EBS valves employ packless pushrod construction and internal
parts are NOT available for use with them. However, their elements
can be replaced and they can be disassembled for inspection and
cleaning. Due to the single pushrod construction of the Type RIGHT WRONG
(E)BF/SBF and EBS valves, only the bottom cap assembly, pin
guide, and superheat spring may be removed for inspection and
cleaning.

Early production of the Type F valve with the replaceable element

requires a 15/16" thin jaw, open end type element wrench such as a
Bonney 1230. Subsequent production of the Type F valve and all
Types (E)BF/SBF, I, BI, NI, RI, and FB valves require a 1" thin jaw,
open end type element wrench such as the one available from
Sporlan wholesalers. An open end wrench is necessary because of
Figure 10
limited space between the body and element of these valves.
Precautions must be taken in removing the KT-43 element (F) so the
element, body, or connections are not damaged by the wrenches. 7. To reassemble valves with replaceable seats, screw seat into
body with a fairly light pressure since it does not require a heavy
While standard open end or adjustable wrenches fit the other element pressure to make this small knife-edge joint.
sizes, the thin jaw type wrenches are also available for the other Caution: Be sure hexagon corners of seat do not protrude into
element sizes: Bonney 1236 (1-1/8") for KT-53 elements, Bonney pushrod holes (see Figure 10).
1240 (1-1/4") for KT-83 elements, Bonney 1248 for KT-33 elements,
For valves that do not have replaceable elements or for Type O
and Bonney 1252 for KT-63 and 7 elements.
valves, place the pushrod(s) into the body now.
Replaceable elements and internal parts kits are available for current 8. Next, slip the pin and carrier (which have been pressed
valves with packed pushrod construction: together at the factory) into the body and tap the pin into the
Types P, H, M, D, and A. seat to form a true seating surface. It is generally advisable,
before tapping these parts together, to check the concentricity
Replaceable elements for Types O, V, W, and U are also available. of both the pin and seat by engaging the parts by pressing them
However, special field assembly instructions are included with their lightly together with one finger and noting that there is no
internal parts kits. tendency to stick together. This should be repeated several
times after rotating the pin carrier a quarter of a turn. In
Assembling Instructions assembling valves with port sizes of 1/4" and larger which use
The following steps are necessary in properly disassembling, the flat disc instead of the tapered pin, DO NOT TAP THE
inspecting, cleaning, and reassembling a TEV whether the valve is in DISC AGAINST THE SEAT.
or out of the refrigerant piping.
9. Now place the spring guide stamping (when used), and spring,
1. Before disassembling the valve, be sure the refrigerant pressure in the pin carrier, place the lower spring guide on the opposite
end of the spring and screw the bottom cap in place. (Replace
in the system has been reduced to a safe level (0 psig).
the pin guide, spring, and bottom cap assembly together on Type
(E)BF/SBF and EBS valves.) After screwing bottom cap
2. Remove the seal cap and turn the adjustment stem counter-
assembly in place, carefully tighten, preferable with two 10"
clockwise to relieve the spring force. Count and record the
wrenches, to seal the metal-to-metal knife edge joint. The
number of turns so adjustment can be returned to its original
sealing surfaces should be free of any foreign material or nicks
position.
that might prevent a leak-tight joint.
3. Using appropriate wrenches or a vise to properly support the
10. On valves with replaceable elements (except Types O,
valve body, remove the element (if a replaceable type), the
(E)BF/SBF and EBS), place the pushrods into the body and
bottom cap assembly, and the internal parts. (Only remove the
open the valve several times by pressing down on the pins with
bottom cap, pin guide, and superheat spring on Type (E)BF/SBF
a flat metal surface. This will help seat the pin properly.
and EBS valves. DO NOT remove the single pushrod from
these valves.)
11. Check the height of the pushrod(s) above the element sealing
Caution: Regardless of whether the valve is in the system or surface with the pushrod gauge (see Figure 11). The gauge is
in a vise, care must be taken to prevent distorting the body by supplied with internal parts kits or can be obtained at no charge
Page 12 / BULLETIN 10-11
upon request. (Since the internal parts of the Type (E)BF/SBF
Table 3 and EBS valves cannot be replaced, it is not necessary to check
Valve TypeQ Gauge the pushrod height of these valves.)
Current Obsolete Number The appropriate gauge numbers for the various TEVs are given
AA(E), LMC-AA(E) --- 1 in Table 3.
DA(E), LMC-DA(E) --- 2
Caution: If the element-to-body joint utilizes a gasket, the
PFE or HFE-11/2, 3, 4, 5, 8, 12 PFE or HFE-6, 71/2, 10, 11
PVE or HVE-21/2, 51/2, 7, 11, PVE or HVE-2, 5, 8, 10, 12,
gasket must be removed before checking pushrod height.
16, 20 15, 17, 18 If the pushrod(s) are too long, they must be carefully ground off
PDE or HDE-5, 8, 14 PDE or HDE-6, 71/2, 9, 12, 13 to the proper length. Clean the pushrod(s) of all dirt and
PRE or HRE-11/2, 4, 61/2, 9, 12 PRE or HRE-6, 71/2, 11, 13 3 grindings and place them into the body.
UFE-12, 17
UVE-22, 30
---
UDE-15, 21
URE-16, 22
OFE-23, 32, 40 UFE-23 Check Height
OVE-40, 55, 70 UVE-40
ODE-28, 40, 50 UDE-28
3A of Pushrod(s)
Pushrod(s) should just
ORE-30, 35, 45 URE-30 clear here. with Gauge
All F ModelsW except
FF(E)-1/8, FV(E)-1/4, --- 4 Gauge
FD(E)-1/8, FR(E)-1/8
All G Models except
GF(E)-1/8, GV(E)-1/4, All small K models
GR(E)-1/8 5 Pushrod(s)
All X Models ---
MFE-5, 71/2, 11, 13, 15, 20 MFE-12, 17
Valve
MVE-8, 12, 18, 21, 26, 34 MVE-30
MDE-6, 9, 13, 15, 18, 25 MDE-14, 20 Figure 11
6
MRE-9, 15, 20, 25
KFE or VFE-45, KVE or VVE-70 ---
12. Element Replacement If the element is damaged or has
KDE or VDE-55, KRE or VRE-50
MFE-25 MFE-22
lost its thermostatic charge, replace it with the same type.
MVE-42 MVE-40 To properly replace the element without damaging the element
MDE-30 MDE-26 or the valve body on valves which utilize a gasketed joint, be
MRE-30 --- sure only one gasket is used before assembling the element. In
6A
KFE or VFE-35, 55 VFE-50 assembling gasketed elements held in place by two cap screws,
KVE or VVE-52, 100 VVE-90 be sure to pull up the cap screws evenly.
KDE or VDE-40, 65 VDE-42, 60
KRE or VRE-38, 70 --- On valves which utilize the threaded type of element with metal-
WFE-80, 110 WFE-75, 100 to-metal knife edge joints, always use an appropriate wrench
WVE-135, 180 --- (10") on the wrench flats. DO NOT use a wrench on the outer
7
WDE-95, 130 WDE-90, 120 welded edge of the element. The sealing surfaces should be free
WRE-100, 130 --- of any foreign materials or nicks that might prevent a leak-tight
CF(E) or SF(E)-1/4, 1/2, 1, 11/2, joint. A few drops of refrigerant oil on the element threads will
2, 21/2, 3
facilitate easy assembling and removal.
CV(E) or SV(E)-1/2, 1, 11/2,
2, 3, 4, 5 R and T Models
8 13. Return the superheat spring adjustment to its original position.
CD(E) or SD(E)-1/4, 1/2, 1, 11/2, with 83 elements
2, 21/2, 3, 31/2 Replace the seal cap tightly.
CR(E) or SR(E)-1/4, 1/2, 1, 11/2,
2, 3, 4
CFE-5, SFE-5, 6
CVE-8, SVE-8, 10
CDE-6, SDE-6, 7
CRE-6, SRE-6, 7
--- 8A
OFE-6, 9, 12 Q Type F (internally and externally equalized) valves dated D84 or later,
OVE-10, 15, 20 Type S valves dated B69 or later, Type C valves dated C70 or later, and
ODE-7, 11, 14 all Type G (externally equalized only) and X valves have packless
ORE-6, 9, 12 pushrod construction and internal parts kits are not available for use
OFE-16, OVE-30 with them.
ODE-20, ORE-21E --- 8B W Applies only to Type F valves with a replaceable element.
E Formerly used the KT-33-8 element and gauge number 33-8 (redesig-
nated 8B). The KT-33-8 element has been replaced by the KT-83.

Printed in U.S. of A. 1003

 Bulletin C401d
March, 2002

HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications,
Service Instructions & Parts

HCK4 IN-LINE
CHECK VALVES
5
/ 8" thru 4" PORT
(16 thru 100 mm)

Flanged
3
/ 8" thru 4"
FPT, SW, WN, ODS
for refrigerants

HCK4-4 Check Valve

INTRODUCTION KEY FEATURES

The HCK4 series of dependable, compact, rugged
in-line check valves (disc type non-return valves) is
ideally suited for refrigerant flow control applications.
Valves open wide for flow in the arrow direction on
the valve body. Valves close quickly and
reliably when flow reversals occur.

Plated bodies and stainless steel seat discs and

springs enable them to withstand expected
industrial refrigeration conditions. Furthermore, these
check valves can be mounted in any position, close-
coupled to other valves, and use same flanges as
Parker R/S, Frick, and Henry.

ADVANTAGES
These compact check valves offer reliable operation
regardless of position. Corrosion resistant stainless
steel seat disc. Metal-to-metal seats facilitate durable,
tight closing of valves.

APPLICATIONS
These in-line check valves are designed to provide
refrigerant flow control to hot gas lines, liquid lines, ADDITIONAL FEATURES
compressor discharge lines, suction lines, and hot Mounts in any position
gas heated drain pans. Less than 1 PSID wide opening pressure
Can be close-coupled
These valves are not recommended for use with Low bubble leakage tolerance
pulsating loads such as low speed compressor For Ammonia, R22, R134a, and other approved
discharge and screw compressor side port refrigerants
applications. For applications such as these, use Dimensionally replaces R/S CK4A-2, -3, -4, -8, & -1
Hansen HCK1 piston type check valves. U.L. Listed
MATERIAL SPECIFICATIONS INSTALLATION
Body: Valve may be located in any position. Arrow on
5 / 8 " thru 1": Steel, ASTM A108, zinc chromate valve body should match direction of flow. Secure
plated valve with gaskets between flanges and tighten
1" thru 4": Ductile iron, ASTM A536, zinc bolts evenly. Do not use this valve or any component
chromate plated to align pipes or tighten gap between flanges.
Seat Disc: Stainless steel
Seat Cartridge: Do not install on inlet side of solenoid valves or
5 / 8 " thru 1": Stainless steel, ASTM A582 control valves with electric shut-off or shut-off valves
1" thru 4": Steel, ASTM A108, zinc chromate unless a relief valve is used from therein between
plated piping. Do not install on inlet side of outlet pressure
Spring: Stainless steel regulators where liquid may become trapped.
Safe Working Pressure: 400 PSIG (27 bar) Instead, check valves should be located on outlet
Operating Temperature: -60F to 240F (-50 to 115C) side of these valves. Check valves can be close-
coupled to other matching solenoid valves, pressure
regulators, or strainers by using a Male Adapter
Ring and longer bolts supplied when so specified
on order.

INSTALLATION DIMENSIONS

D = Socket Weld Depth

J = Weld Neck
K = ODS Solder

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1035
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1035 
1035 
1035 
1035 
1035 
1035 
1035 
1035
2.50" 3.25" 3.25" 3.25" 5.06" 5.06" 6.06" 6.06" 6.39"
A
(64 mm) (83 mm) (83 mm) (83 mm) (129 mm) (129 mm) (154 mm) (154 mm) (162 mm)
3.19" 4.50" 4.50" 4.50" 4.56" 4.56" 6.00" 6.00" 7.13"
B
(81 mm) (114 mm) (114 mm) (114 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
3.50" 4.50" 4.50" 4.50" 6.38" 6.38" 7.50" 7.50" 8.00"
C
(89 mm) (114 mm) (114 mm) (114 mm) (162 mm) (162 mm) (191 mm) (191 mm) (203 mm)
0.38" 0.50" 0.50" 0.50" 0.75" 0.75" 1.00" 1.00" 1.00"
D
(10 mm) (13 mm) (13 mm) (13 mm) (19 mm) (19 mm) (25 mm) (25 mm) (25 mm)
1.03" 1.22" 1.22" 1.22" 2.56" 2.56" 2.92" 2.92" 3.50"
E=
(26 mm) (31 mm) (31 mm) (31 mm) (65 mm) (65 mm) (74 mm) (74 mm) (89 mm)
1.50" 2.37" 2.37" 2.37" 3.62" 3.62" 4.84" 4.84" 6.06"
F
(38 mm) (60 mm) (60 mm) (60 mm) (92 mm) (92 mm) (123 mm) (123 mm) (154 mm)
1.56" 2.50" 2.50" 2.50" 4.56" 4.56" 6.00" 6.00" 7.13"
G
(40 mm) (64 mm) (64 mm) (64 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
2.19" 3.12" 3.12" 3.12" 3.06" 3.06" 4.00" 4.12" 5.00"
H
(56 mm) (79 mm) (79 mm) (79 mm) (78 mm) (78 mm) (102 mm) (105 mm) (127 mm)
3.26" 4" 4" 4" 6.06" 6.06" 7.06" 7.06" 9.89"
J
(83 mm) (102 mm) (102 mm) (102 mm) (154 mm) (154 mm) (179 mm) (179 mm) (251 mm)
0.33" 0.49" 0.59" 0.62" 0.71" 0.87" 0.96" 1.08" 1.40"
K
(8 mm) (12 mm) (15 mm) (16 mm) (18 mm) (22 mm) (24 mm) (27 mm) (36 mm)
Valve Cv (Kv) 5.8 (5) 8.2 (7) 11.7 (10) 14.0 (12) 39 (33) 50 (43) 74 (63) 93 (80) 210 (180)
Pipe Size ", " " 1" 1" 1" 2" 2" 3" 4"

*Dimensionally replaces R/S check valve models CK4A-2, -3, -4, -8, and -1. = "E" dimension is check valve body outside
edge to outside edge. Flange groove depth: nominal 0.12" each of two; gasket thickness: nominal 0.06" each of two.

2
 PARTS LIST
HCK4-2 (2-BOLT) HCK4-2 (2-BOLT)
*5&. %&4$3*15*0/ 25: 1"35
/0
7BMWF
"TTFNCMZ
,JU
Above Kit Consists of:
1 Seat Disc 1 72-0069
2 Closing Spring 1 72-0070
3 Seat Cartridge 1 72-0068
4 Seat Cartridge O-ring 1 72-0071
5 Flange Gasket 2 70-0065
6 Body, HCK4-2 1 72-0067

7 Bolt ( 7/ 16" - 14 x 3.25") 2 70-0225

8 Nut (7/ 16 " - 14) 2 70-0055
9 Flange (FPT, SW, WN, ODS) 2 FACTORY

Socket weld shown. FPT, weld neck, ODS: available.

HCK4-3, -4, -5 (2-BOLT)
*5&. %&4$3*15*0/ 25: 1"35
/0
7BMWF
"TTFNCMZ
,JU
Above Kit Consists of:
HCK4-3, -4, -5 (2-BOLT)
1 Seat Disc 1 72-0006
2 Closing Spring 1 70-0204
3 Seat Cartridge 1 72-0002
4 Seat Cartridge O-ring 1 72-0003
5 Flange Gasket 2 70-0132
6a Body, HCK4-3 1 72-0004
6b Body, HCK4-4 1 72-0008
6c Body, HCK4-5 1 72-0001

7 Bolt ( 5/ 8" -11 x 4") 2 72-0005

8 Nut ( 5/ 8" -11) 2 70-0136
9 Flange (FPT, SW, WN, ODS) 2 FACTORY

HCK4-7, -8, -9, -0, -1 (4-BOLT)

*5&. %&4$3*15*0/ 25: 1"35
/0
1a Seat Disc 1", 2" 1 72-0016
1b Seat Disc 2", 3" 1 72-0034
1c Seat Disc 4" 1 72-0053 Socket weld shown. FPT, weld neck, ODS: available.
2a Closing Spring 1", 2" 1 72-0021
2b Closing Spring 2", 3" 1 72-0032
2c Closing Spring 4" 1 72-0048
3a Seat Cartridge 1", 2" 1 72-0020 HCK4-7, -8, -9, -0, -1 (4-BOLT)
3b Seat Cartridge 2" 1 72-0029
3c Seat Cartridge 3" 1 72-0028
3d Seat Cartridge 4" 1 72-0047
4a Seat Cartridge O-ring 1", 2" 1 72-0017
4b Seat Cartridge O-ring 2", 3" 1 72-0027
4c Seat Cartridge O-ring 4" 1 72-0049
5a Flange Gasket 1", 2" 2 75-0138
5b Flange Gasket 2" 2 75-0125
5c Flange Gasket 3" 2 75-0137
5d Flange Gasket 4" 2 75-0253
6a Body, HCK4-7 1 72-0042
6b Body, HCK4-8 1 72-0019
6c Body, HCK4-9 1 72-0025
6d Body, HCK4-0 1 72-0026
6e Body, HCK4-1 1 72-0046
7a Bolt, HCK4-7, -8 (5/8" - 11 x 6") 4 70-0268
7b Bolt, HCK4-9, -0 (" - 10 x 7") 4 72-0033
7c Bolt, HCK4-1 ( 7/ 8" - 9 x 7.5") 4 72-0051
8a Nut, HCK4-7, -8 ( 5/ 8" - 11) 4 70-0136
8b Nut, HCK4-9, -0 (" - 10) 4 75-0210
8c Nut, HCK4-1 (7/ 8" - 9) 4 75-0280
9 Flange (FPT, SW, WN, ODS) 2 FACTORY Socket weld shown. Weld neck, ODS: available.
3
OPERATION WARRANTY
HCK4 check valves are normally closed valves. As Hansen valves are guaranteed against defective
inlet pressure increases, it overcomes the closing materials or workmanship for one year F.O.B. our
spring force. As the seat disc is pushed back and plant. No consequential damages or field labor is
away from the seat cartridge, flow through the valve included.
occurs. The valve will remain open until the inlet
pressure drops below the closing spring force or
there is a flow reversal, at which time the seat disc ORDERING INFORMATION,
will close against the seat cartridge, preventing HCK4 CHECK VALVES
reverse flow. '-"/(&
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SIZING 45% "-40 45%

Check valves are normally selected on the basis of HCK4-2* 5 8
/" (16) " 3 8
/ ", " 5 8
/ "
line size. However, for gas flow applications at low HCK4-3* " (20) " 1", 1" 7 8
/ "
load conditions, a minimum of 1 psid across the
HCK4-4* 1" (25) 1" ", 1" 1 1/ 8"
valve is essential. This will maintain valve at full
open position. Valve Cv (Kv) is listed in the HCK4-5 1" (32) 1" ", 1" 1 3/ 8"
installation dimension table on page 2. Factory valve HCK4-7 1" (40) 1" 2" 1 5/ 8"
sizing assistance is available. HCK4-8* 2" (50) 2" 1" 2 1/ 8"
HCK4-9 2" (65) 2" 3" 2 5/ 8"
HCK4-0 3" (80) 3" -- 3 1/ 8"
SERVICE AND MAINTENANCE HCK4-1* 4" (100) 4" -- 4 1/ 8"
These valves are a reliable part of a refrigeration
system. However, if valve does not appear to be * Replaces R/S CK4A-2, CK4A-3, CK4A-4, CK4A-8, & CK4A-1.
HCK4-2 close-couples to HS6 & HS8 Solenoid Valves.
operating satisfactorily, isolate it from the refrigeration
HCK4-3, -4, & -5 close-couples to HS7 Solenoid Valve.
system. Remove all refrigerant from associated piping FPT available only 3/ 8" to 1".
and valves. Follow the guidelines in the caution
section. Loosen each flange nut on the check valve. TO ORDER: Specify valve type, connection style and
Break each flange gasket seal. Carefully loosen size, and close-coupling information if needed.
flange bolts one at a time, being cautious to avoid
any refrigerant which still may be present. Remove
check valve from flanges and inspect. Lapped seating TYPICAL SPECIFICATIONS
surfaces should be smooth and free of pits or
"Refrigeration in-line check valves shall have steel
scratches.
or ductile iron bodies, stainless steel seat discs,
To confirm valve operation, move seat disc with stainless steel closing springs, and be suitable for
eraser end of pencil. Movement should be free from a safe working pressure of 400 PSIG, as manufactured
friction. If not, disassemble and visually inspect for by Hansen Technologies Corporation type HCK4 or
dirt in valve or burrs on seat disc. Clean or replace approved equal."
parts as necessary. Valve discs and seats can be
restored by lapping on a flat plate. Typical close-coupling to solenoid valve.

Reassemble valve and insert between flanges.

Replace and tighten bolts and nuts evenly. Carefully
check for leaks before returning to service.

CAUTION
Hansen check valves are only for refrigeration
systems. These instructions and related safety
precautions must be completely read and understood
before selecting, using, or servicing these valves.
Only knowledgeable, trained refrigeration mechanics
should install, operate, or service these valves. Stated
temperature and pressure limits should not be
exceeded. Valves should not be removed unless
system has been evacuated to zero pressure. See ISO 9002
Hansen Technologies Corp.
also Safety Precautions in current List Price Bulletin Burr Ridge, IL Cert. # 000472
Orlando, FL Cert. # 001523
and Safety Precautions Sheet supplied with product.
Escaping refrigerant might cause personal injury, HANSEN TECHNOLOGIES
particularly to the eyes and lungs. CORPORATION
6827 High Grove Boulevard
Burr Ridge, Illinois 60527 U.S.A.
Telephone: (708) 325-1565 FAX: (708) 325-1572
Toll-free: 1-800-426-7368
1995 Hansen Technologies Corporation Printed in U.S.A.
 Lubrication Instructions
For Ball Bearing Motors

Lubrication
This motor is supplied with pre-lubrication ball bearings. No lubrication required before start up.

Relubrication Intervals
The following intervals are suggested as a guide:

SUGGESTED RELUBRICATION INTERVALS

HOURS OF SERVICE PER YEAR H.P. RANGE RELUBE INTERVAL
5,000 Sub Fractional to 7 1/2 5 Years
10 to 40 3 Years
50-200 1 Year
Continuous Normal Applications Sub Fractional to 7 1/2 2 Years
10 to 40 1 Year
50 to 200 9 Months
Season Service Motor All 1 Year
Idle 6 Months or More (Beginning of Season)
Continuous High Ambients Sub Fractional to 40 6 Months
Dirty or Moist Locations 50 to 200 3 Months
High Vibrations
Where Shaft End is Hot (Pumps-Fans)
Lubrication
Use high quality ball bearing lubricant. Use consistency of lubricant suitable for class of insulation stamped on
nameplate as follows:

LUBRICATION CONSISTENCY
INSULATION CONSISTENCY TYPE TYPICAL FRAME
CLASS LUBRICATION TYPE

B&F Shell Dolium R Sub Fractional

Medium Polyurea and/or to 447T
F&H Chevron SR1 2 All

Procedure
If motor is equipped with Alemite fitting, clean tip of fitting and apply grease gun. Use 1 to 2 full strokes on
motors in NEMA 215T frame and smaller. Use 2 to 3 strokes on NEMA 254T thru NEMA 365 T frame. Use 3
to 4 strokes on NEMA 404T frames and larger. On motors having drain plugs, remove drain plug and operate
motor for 20 minutes before replacing drain plug.

On motors equipped with slotted head grease screw, remove screw and apply grease tube to hole. Insert 2 to
3 inch length of grease string into each hole on motors in NEMA 215T frame and smaller. Insert 3 to 5 inch
length on larger motors. For motors having drain plug and operate motor for 20 minutes before replacing drain
plug.

CAUTION: Keep lubricant clean. Lubricate motors at standstill. remove and replace drain plugs at standstill. Do
not mix petroleum lubricant and silicone lubricant in motor bearings.

300-088.02
 Installation Maintenance Instructions
AC Induction Motors

Installation
After unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections,
check for proper grounding of motor and application. All electrical contacts and connections must be properly
insulated and enclosed. Couplings, belts, chains or other mounted devices must be in proper alignment, balance
and secure to insure safe motor operation.

Electrical Wiring
Prior to connecting to the power line, check nameplate for proper voltage and rotation connection. This motor
should be installed in compliance with the National Electrical Code and any other applicable codes. Voltage at
motor not to exceed + or -10% of nameplate. Authorized person should make all electrical connections.

Mounting
This motor should be securely mounted to the application. Sufficient ventilation area should be provided to
insure proper operation.

RECOMMENDED COPPER WIRE & TRANSFORMER SIZE

SINGLE PHASE MOTORS - 230 VOLTS

TRANSFORMER DISTANCE - MOTOR TO TRANSF. IN FT.
H.P. KVA 100 150 200 300 500
1 1/2 3 10 8 8 6 4
2 3 10 8 8 6 4
3 5 8 8 6 4 2
5 7 1/2 6 4 4 2 0
7 1/2 10 6 4 3 1 0

THREE PHASE MOTORS - 230 & 460 VOLTS

TRANSFORMER DISTANCE - MOTOR TO TRANSF. IN FT.
H.P. VOLTS KVA 100 150 200 300 500
1 1/2 230 3 12 12 12 12 10
1 1/2 460 3 12 12 12 12 12
2 230 3 12 12 12 10 8
2 460 3 12 12 12 12 12
3 230 5 12 10 10 8 6
3 460 5 12 12 12 12 10
5 230 7 10 8 8 6 4
5 460 1/2 12 12 12 10 8
7 1/2 230 7 1/2 8 6 6 4 2
7 1/2 460 10 12 12 12 10 8
10 230 10 6 4 4 4 1
10 460 15 12 12 12 10 8
15 230 15 4 4 4 2 0
15 460 20 12 10 10 8 6
20 230 20 4 2 2 1 000
20 460 10 8 8 6 4
25 230 2 2 2 0 000
25 460 Consult 8 8 6 6 4
30 230 Local 2 1 1 00 0000
30 460 Power 8 6 6 4 2
40 230 Company 1 0 00 0000 300
40 460 6 6 4 2 0
50 230 1 0 00 0000 300
50 460 4 4 2 2 0
60 230 1 00 000 250 500
60 460 4 2 2 0 00
75 230 0 000 0000 300 500
75 460 4 2 0 00 000
 Motor Trouble-Shooting Chart
Caution:
1. Disconnect power to the motor before performing service or maintenance.
2. Discharge all capacitors before servicing motor.
3. Always keep hands and clothing away from moving parts.
4. Be sure required safety guards are in place before starting equipment.

Problem: Like Causes: What To Do:

Motor fails to start upon Motor is miswired. Verify motor is wired correctly.
initial installation.
Motor damaged and rotor is striking stator. May be able to reassemble; otherwise, motor should be replaced.
Fan guard bent and contacting fan. Replace fan guard.

Motor has been running, then Fuse or circuit breaker tripped. Replace fuse or reset the breaker.
fails to start. Stator is shorted or went to ground. Motor Disassemble motor and inspect windings and internal connections.
will make a humming noise and the circuit A blown stator will show a burn mark. Motor must be replaced or
breaker or fuse will trip. the stator rewound.
Motor overloaded or load jammed. Inspect to see that the load is free. Verify amp draw of motor
versus nameplate rating.
Capacitor (on single phase motor) may have First discharge capacitor. To check capacitor, set volt-ohm meter to
failed. RX100 scale and touch its probes to capacitor terminals. If capacitor
is OK, needle will jump to zero ohms, and drift back to high. Steady
zero ohms indicates a short circuit; steady high ohms indicates
an open circuit.
Starting switch has failed. Disassemble motor and inspect both the centrifugal and stationary
switches. The weights of the centrifugal switch should move in and
out freely. Make sure that the switch is not loose on the shaft.
Inspect contacts and connections on the stationary switch.
Replace switch if the contacts are burned or pitted.

Motor runs but dies down. Voltage drop. If voltage is less than 10% of the motors rating contact power
company or check if some other equipment is taking power away
from the motor.
Load increased. Verify the load has not changed. Verify equipment hasnt got tighter. If
fan application verify the air flow hasnt changed.

Motor takes too long to accelerate. Defective capacitor Test capacitor per previous instructions.
Faulty stationary switch. Inspect switch contacts and connections. Verify that switch reeds
have some spring in them.
Bad bearings. Noisy or rough feeling bearings should be replaced.
Voltage too low. Make sure that the voltage is within 10% of the motors name-
plate rating. If not, contact power company or check if some other
equipment is taking power away from the motor.

Motor runs in the wrong direction. Incorrect wiring. Rewire motor according to wiring schematic provided.

Motor overload protector continually Load too high. Verify that the load is not jammed. If motor is a replacement,
trips. verify that the rating is the same as the old motor. If previous
motor was a special design, a stock motor may not be able to
duplicate the performance. Remove the load from the motor and
inspect the amp draw of the motor unloaded. It should be less
than the full load rating stamped on the nameplate.
Ambient temperature too high. Verify that the motor is getting enough air for proper cooling. Most
motors are designed to run in an ambient temperature of less than
40C. (Note: A properly operating motor may be hot to the touch.)
Protector may be defective. Replace the motors protector with a new one of the same rating.
Winding shorted or grounded. Inspect stator for defects, or loose or cut wires that may cause it
to go to ground.
 Motor Trouble-Shooting Chart
10/13/00 (continued)

Problem: Like Causes: What To Do:

Motor vibrates. Motor misaligned to load. Realign load.

Load out of balance. Remove motor from load and inspect motor by itself. Verify that
(Direct drive application.) motor shaft is not bent. Rule of thumb is .001" runout per every
inch of shaft length.

Motor bearings defective. Test motor by itself. If bearings are bad, you will hear noise or
feel roughness. Replace bearings. Add oil if a sleeve of bearing.
Add grease if bearings have grease fittings.

Rotor out of balance. Inspect motor by itself with no load attached. If it feels rough and
vibrates but the bearings are good, it may be that the rotor was
improperly balanced at the factory. Rotor must be replaced or
rebalanced.
Motor may have too much endplay. With the motor disconnected from power turned shaft. It should
move but with some resistance. If the shaft moves in and out too
freely, this may indicate a preload problem and the bearings may
need additional shimming.

Winding may be defective. Test winding for shorted or open circuits. The amps may also be
high. Replace motor or have stator rewound.

Bearings continuously fail. Load to motor may be excessive or Besides checking load, also inspect drive belt tension to ensure its
unbalanced. not too tight may be too high. An unbalanced load will also cause the
bearings to fail.

High ambient temperature. If the motor is used in a high ambient, a different type of bearing
grease may be required. You may need to consult the factory or
a bearing distributor.

The motor, at start up, makes a Rotor may be striking stator. Ensure that motor was not damaged in shipment. Frame damage
loud rubbing or grinding noise. may not be repairable. If you cannot see physical damage,
inspect the motors rotor and stator for strike marks. If signs of
rubbing are present, the motor should be replaced. Sometimes
simply disassembling and reassembling motor eliminates rubbing.
Endbells are also sometimes knocked out of alignment during
transportation.

Start capacitors continuously fail. The motor is not coming up to speed quickly Motor may not be sized properly. Verify how long the motor takes
enough. to come up to speed, Most single phase capacitor start motors
should come up to speed within three seconds. Otherwise the
capacitors may fail.

The motor is being cycled too frequently. Verify duty cycle. Capacitor manufacturers recommend no more
than 20, three-second starts per hour. Install capacitor with higher
voltage rating, or add bleed resistor to the capacitor.

Voltage to motor is too low. Verify that voltage to the motor is within 10% of the nameplate
value. If the motor is rated 208-230V, the deviation must be
calculated from 230V.

Starting switch may be defective, preventing Replace switch.

the motor from coming out of start winding.

Run capacitor fail. Ambient temperature too high. Verify that ambient does not exceed motors nameplate value.

Possible power surge to motor, caused by If a common problem, install surge protector.
lightning strike or other high transient voltage.

Bulletin 2400 10/00

 DC Motor Trouble-Shooting Chart

Caution:
1. Disconnect power to the motor before performing service or maintenance.
2. Discharge all capacitors before servicing motor.
3. Always keep hands and clothing away from moving parts.
4. Be sure required safety guards are in place before starting equipment.

Problem: Like Causes: What To Do:

Motor fails to start upon Motor is miswired. Verify that the motor is wired correctly.
initial installation.
No output power from controller. Measure voltage coming from the controller.

Motor damaged and the fan guard Replace fan guard.

is contacting the cooling fan.

Motor is damaged and the armature is Disassemble motor and see if the armature can be realigned by
rubbing against the magnets. reassembly. Motor may have to be replaced.

Motor has been running, then Fuse or circuit breaker is tripped. Replace the fuse or reset the breaker.
fails to start.
Armature is shorted or went to ground. Disassemble motor and inspect the armature for a burnt coil. Inspect
Motor may make a humming noise and the commutator for burnt bars. If this condition exists, the motor
the circuit breaker or fuse will trip. needs to be replaced. To test, set your OHM meter to the RX1 scale,
touch probes to bars 180 degrees apart all around the commutator.
The reading should be equal.

The brushes may be worn down too far and Inspect the brushes to make sure that they are still making contact
no longer make contract with the commutator. with the commutator. Refer to manufacturers recommended brush
length chart.

Controller may be defective. Verify voltage is coming out of the controller.

Motor runs but loses power. Load had increased. Verify the load has not changed. Measure the amp draw of motor
against the full load amp rating of the motor. If the amp draw is
higher then rating, motor is undersized for application.

Motor controller not properly set. Check controller manual for adjustments. The torque and/or IR
compensation settings may need adjustment.

Motor may have an open connection. Inspect the armature for an open connection.

Brushes may not be seated properly or Verify that the brushes are properly seated and measure their
worn beyond their useful length. length against the recommended brush length chart.

Motor takes too long to accelerate. Motor controller not properly set. The accel trim pot of the controller should be adjusted.

Brushes are worn. Verify brush length.

Bearings may be defective. Inspect bearings for proper service. Noisy or rough bearings
should be replaced.

Motor runs in the wrong direction. Incorrect wiring. Interchange the two motor leads.

Motor runs ok but has a clicking Suspect a burr on the commutator. Stone the armature commutator with a commutator stone to
noise. remove burr.

Bulletin 2400DC 10/00

 Bulletin C401d
March, 2002

HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications,
Service Instructions & Parts

HCK4 IN-LINE
CHECK VALVES
5
/ 8" thru 4" PORT
(16 thru 100 mm)

Flanged
3
/ 8" thru 4"
FPT, SW, WN, ODS
for refrigerants

HCK4-4 Check Valve

INTRODUCTION KEY FEATURES

The HCK4 series of dependable, compact, rugged
in-line check valves (disc type non-return valves) is
ideally suited for refrigerant flow control applications.
Valves open wide for flow in the arrow direction on
the valve body. Valves close quickly and
reliably when flow reversals occur.

Plated bodies and stainless steel seat discs and

springs enable them to withstand expected
industrial refrigeration conditions. Furthermore, these
check valves can be mounted in any position, close-
coupled to other valves, and use same flanges as
Parker R/S, Frick, and Henry.

ADVANTAGES
These compact check valves offer reliable operation
regardless of position. Corrosion resistant stainless
steel seat disc. Metal-to-metal seats facilitate durable,
tight closing of valves.

APPLICATIONS
These in-line check valves are designed to provide
refrigerant flow control to hot gas lines, liquid lines, ADDITIONAL FEATURES
compressor discharge lines, suction lines, and hot Mounts in any position
gas heated drain pans. Less than 1 PSID wide opening pressure
Can be close-coupled
These valves are not recommended for use with Low bubble leakage tolerance
pulsating loads such as low speed compressor For Ammonia, R22, R134a, and other approved
discharge and screw compressor side port refrigerants
applications. For applications such as these, use Dimensionally replaces R/S CK4A-2, -3, -4, -8, & -1
Hansen HCK1 piston type check valves. U.L. Listed
MATERIAL SPECIFICATIONS INSTALLATION
Body: Valve may be located in any position. Arrow on
5 / 8 " thru 1": Steel, ASTM A108, zinc chromate valve body should match direction of flow. Secure
plated valve with gaskets between flanges and tighten
1" thru 4": Ductile iron, ASTM A536, zinc bolts evenly. Do not use this valve or any component
chromate plated to align pipes or tighten gap between flanges.
Seat Disc: Stainless steel
Seat Cartridge: Do not install on inlet side of solenoid valves or
5 / 8 " thru 1": Stainless steel, ASTM A582 control valves with electric shut-off or shut-off valves
1" thru 4": Steel, ASTM A108, zinc chromate unless a relief valve is used from therein between
plated piping. Do not install on inlet side of outlet pressure
Spring: Stainless steel regulators where liquid may become trapped.
Safe Working Pressure: 400 PSIG (27 bar) Instead, check valves should be located on outlet
Operating Temperature: -60F to 240F (-50 to 115C) side of these valves. Check valves can be close-
coupled to other matching solenoid valves, pressure
regulators, or strainers by using a Male Adapter
Ring and longer bolts supplied when so specified
on order.

INSTALLATION DIMENSIONS

D = Socket Weld Depth

J = Weld Neck
K = ODS Solder

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1035
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1035 
1035 
1035 
1035 
1035 
1035 
1035 
1035
2.50" 3.25" 3.25" 3.25" 5.06" 5.06" 6.06" 6.06" 6.39"
A
(64 mm) (83 mm) (83 mm) (83 mm) (129 mm) (129 mm) (154 mm) (154 mm) (162 mm)
3.19" 4.50" 4.50" 4.50" 4.56" 4.56" 6.00" 6.00" 7.13"
B
(81 mm) (114 mm) (114 mm) (114 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
3.50" 4.50" 4.50" 4.50" 6.38" 6.38" 7.50" 7.50" 8.00"
C
(89 mm) (114 mm) (114 mm) (114 mm) (162 mm) (162 mm) (191 mm) (191 mm) (203 mm)
0.38" 0.50" 0.50" 0.50" 0.75" 0.75" 1.00" 1.00" 1.00"
D
(10 mm) (13 mm) (13 mm) (13 mm) (19 mm) (19 mm) (25 mm) (25 mm) (25 mm)
1.03" 1.22" 1.22" 1.22" 2.56" 2.56" 2.92" 2.92" 3.50"
E=
(26 mm) (31 mm) (31 mm) (31 mm) (65 mm) (65 mm) (74 mm) (74 mm) (89 mm)
1.50" 2.37" 2.37" 2.37" 3.62" 3.62" 4.84" 4.84" 6.06"
F
(38 mm) (60 mm) (60 mm) (60 mm) (92 mm) (92 mm) (123 mm) (123 mm) (154 mm)
1.56" 2.50" 2.50" 2.50" 4.56" 4.56" 6.00" 6.00" 7.13"
G
(40 mm) (64 mm) (64 mm) (64 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
2.19" 3.12" 3.12" 3.12" 3.06" 3.06" 4.00" 4.12" 5.00"
H
(56 mm) (79 mm) (79 mm) (79 mm) (78 mm) (78 mm) (102 mm) (105 mm) (127 mm)
3.26" 4" 4" 4" 6.06" 6.06" 7.06" 7.06" 9.89"
J
(83 mm) (102 mm) (102 mm) (102 mm) (154 mm) (154 mm) (179 mm) (179 mm) (251 mm)
0.33" 0.49" 0.59" 0.62" 0.71" 0.87" 0.96" 1.08" 1.40"
K
(8 mm) (12 mm) (15 mm) (16 mm) (18 mm) (22 mm) (24 mm) (27 mm) (36 mm)
Valve Cv (Kv) 5.8 (5) 8.2 (7) 11.7 (10) 14.0 (12) 39 (33) 50 (43) 74 (63) 93 (80) 210 (180)
Pipe Size ", " " 1" 1" 1" 2" 2" 3" 4"

*Dimensionally replaces R/S check valve models CK4A-2, -3, -4, -8, and -1. = "E" dimension is check valve body outside
edge to outside edge. Flange groove depth: nominal 0.12" each of two; gasket thickness: nominal 0.06" each of two.

2
 PARTS LIST
HCK4-2 (2-BOLT) HCK4-2 (2-BOLT)
*5&. %&4$3*15*0/ 25: 1"35
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7BMWF
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Above Kit Consists of:
1 Seat Disc 1 72-0069
2 Closing Spring 1 72-0070
3 Seat Cartridge 1 72-0068
4 Seat Cartridge O-ring 1 72-0071
5 Flange Gasket 2 70-0065
6 Body, HCK4-2 1 72-0067

7 Bolt ( 7/ 16" - 14 x 3.25") 2 70-0225

8 Nut (7/ 16 " - 14) 2 70-0055
9 Flange (FPT, SW, WN, ODS) 2 FACTORY

Socket weld shown. FPT, weld neck, ODS: available.

HCK4-3, -4, -5 (2-BOLT)
*5&. %&4$3*15*0/ 25: 1"35
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Above Kit Consists of:
HCK4-3, -4, -5 (2-BOLT)
1 Seat Disc 1 72-0006
2 Closing Spring 1 70-0204
3 Seat Cartridge 1 72-0002
4 Seat Cartridge O-ring 1 72-0003
5 Flange Gasket 2 70-0132
6a Body, HCK4-3 1 72-0004
6b Body, HCK4-4 1 72-0008
6c Body, HCK4-5 1 72-0001

7 Bolt ( 5/ 8" -11 x 4") 2 72-0005

8 Nut ( 5/ 8" -11) 2 70-0136
9 Flange (FPT, SW, WN, ODS) 2 FACTORY

HCK4-7, -8, -9, -0, -1 (4-BOLT)

*5&. %&4$3*15*0/ 25: 1"35
/0
1a Seat Disc 1", 2" 1 72-0016
1b Seat Disc 2", 3" 1 72-0034
1c Seat Disc 4" 1 72-0053 Socket weld shown. FPT, weld neck, ODS: available.
2a Closing Spring 1", 2" 1 72-0021
2b Closing Spring 2", 3" 1 72-0032
2c Closing Spring 4" 1 72-0048
3a Seat Cartridge 1", 2" 1 72-0020 HCK4-7, -8, -9, -0, -1 (4-BOLT)
3b Seat Cartridge 2" 1 72-0029
3c Seat Cartridge 3" 1 72-0028
3d Seat Cartridge 4" 1 72-0047
4a Seat Cartridge O-ring 1", 2" 1 72-0017
4b Seat Cartridge O-ring 2", 3" 1 72-0027
4c Seat Cartridge O-ring 4" 1 72-0049
5a Flange Gasket 1", 2" 2 75-0138
5b Flange Gasket 2" 2 75-0125
5c Flange Gasket 3" 2 75-0137
5d Flange Gasket 4" 2 75-0253
6a Body, HCK4-7 1 72-0042
6b Body, HCK4-8 1 72-0019
6c Body, HCK4-9 1 72-0025
6d Body, HCK4-0 1 72-0026
6e Body, HCK4-1 1 72-0046
7a Bolt, HCK4-7, -8 (5/8" - 11 x 6") 4 70-0268
7b Bolt, HCK4-9, -0 (" - 10 x 7") 4 72-0033
7c Bolt, HCK4-1 ( 7/ 8" - 9 x 7.5") 4 72-0051
8a Nut, HCK4-7, -8 ( 5/ 8" - 11) 4 70-0136
8b Nut, HCK4-9, -0 (" - 10) 4 75-0210
8c Nut, HCK4-1 (7/ 8" - 9) 4 75-0280
9 Flange (FPT, SW, WN, ODS) 2 FACTORY Socket weld shown. Weld neck, ODS: available.
3
OPERATION WARRANTY
HCK4 check valves are normally closed valves. As Hansen valves are guaranteed against defective
inlet pressure increases, it overcomes the closing materials or workmanship for one year F.O.B. our
spring force. As the seat disc is pushed back and plant. No consequential damages or field labor is
away from the seat cartridge, flow through the valve included.
occurs. The valve will remain open until the inlet
pressure drops below the closing spring force or
there is a flow reversal, at which time the seat disc ORDERING INFORMATION,
will close against the seat cartridge, preventing HCK4 CHECK VALVES
reverse flow. '-"/(&
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SIZING 45% "-40 45%

Check valves are normally selected on the basis of HCK4-2* 5 8
/" (16) " 3 8
/ ", " 5 8
/ "
line size. However, for gas flow applications at low HCK4-3* " (20) " 1", 1" 7 8
/ "
load conditions, a minimum of 1 psid across the
HCK4-4* 1" (25) 1" ", 1" 1 1/ 8"
valve is essential. This will maintain valve at full
open position. Valve Cv (Kv) is listed in the HCK4-5 1" (32) 1" ", 1" 1 3/ 8"
installation dimension table on page 2. Factory valve HCK4-7 1" (40) 1" 2" 1 5/ 8"
sizing assistance is available. HCK4-8* 2" (50) 2" 1" 2 1/ 8"
HCK4-9 2" (65) 2" 3" 2 5/ 8"
HCK4-0 3" (80) 3" -- 3 1/ 8"
SERVICE AND MAINTENANCE HCK4-1* 4" (100) 4" -- 4 1/ 8"
These valves are a reliable part of a refrigeration
system. However, if valve does not appear to be * Replaces R/S CK4A-2, CK4A-3, CK4A-4, CK4A-8, & CK4A-1.
HCK4-2 close-couples to HS6 & HS8 Solenoid Valves.
operating satisfactorily, isolate it from the refrigeration
HCK4-3, -4, & -5 close-couples to HS7 Solenoid Valve.
system. Remove all refrigerant from associated piping FPT available only 3/ 8" to 1".
and valves. Follow the guidelines in the caution
section. Loosen each flange nut on the check valve. TO ORDER: Specify valve type, connection style and
Break each flange gasket seal. Carefully loosen size, and close-coupling information if needed.
flange bolts one at a time, being cautious to avoid
any refrigerant which still may be present. Remove
check valve from flanges and inspect. Lapped seating TYPICAL SPECIFICATIONS
surfaces should be smooth and free of pits or
"Refrigeration in-line check valves shall have steel
scratches.
or ductile iron bodies, stainless steel seat discs,
To confirm valve operation, move seat disc with stainless steel closing springs, and be suitable for
eraser end of pencil. Movement should be free from a safe working pressure of 400 PSIG, as manufactured
friction. If not, disassemble and visually inspect for by Hansen Technologies Corporation type HCK4 or
dirt in valve or burrs on seat disc. Clean or replace approved equal."
parts as necessary. Valve discs and seats can be
restored by lapping on a flat plate. Typical close-coupling to solenoid valve.

Reassemble valve and insert between flanges.

Replace and tighten bolts and nuts evenly. Carefully
check for leaks before returning to service.

CAUTION
Hansen check valves are only for refrigeration
systems. These instructions and related safety
precautions must be completely read and understood
before selecting, using, or servicing these valves.
Only knowledgeable, trained refrigeration mechanics
should install, operate, or service these valves. Stated
temperature and pressure limits should not be
exceeded. Valves should not be removed unless
system has been evacuated to zero pressure. See ISO 9002
Hansen Technologies Corp.
also Safety Precautions in current List Price Bulletin Burr Ridge, IL Cert. # 000472
Orlando, FL Cert. # 001523
and Safety Precautions Sheet supplied with product.
Escaping refrigerant might cause personal injury, HANSEN TECHNOLOGIES
particularly to the eyes and lungs. CORPORATION
6827 High Grove Boulevard
Burr Ridge, Illinois 60527 U.S.A.
Telephone: (708) 325-1565 FAX: (708) 325-1572
Toll-free: 1-800-426-7368
1995 Hansen Technologies Corporation Printed in U.S.A.
 Hansen HA4AOAS
Inlet/Outlet Regulator for Screw Compressor Economizer
(Controls Pressure of accumulator or other types of vessels that is economized and controls
outlet pressure to economizer port on screw compressor)

Inlet Module Range A

Turn CW to increase back pressure
Turn CCW to decrease back pressure
Electric Shutoff

HS2 HA2B Outlet Module Range B

Turn CW to decrease outlet pressure
Turn CCW to increase outlet pressure

M3S Stopping Plug

M3E25
 HA4AOAS - Inlet/Outlet Economizer Port / Side Load Pressure
Regulator
Purpose: To maintain an operating pressure in the economizer or side load vessel, while providing a means
of protecting the compressor motor from overloading from high economizer loads during start-up, or from
high side loads.

Construction: This valve is made up of an Outlet Pressure Regulator Base, an Inlet Pressure Regulator
Module, and a Shut Off Solenoid.

Operation: The Shut Off Solenoid must be energized to activate the HA4AOAS valve. For a flash type or
shell & coil type economizer, or for side load applications, the solenoid must be activated when the
compressor starts. For a direct expansion type, the solenoid is generally activated when the compressor
reaches 30% to 70% compressor capacity, depending on the system.

Adjusting the Inlet / Economizer or Side Load Pressure

The estimated economizer operating pressure of the valve will be as shown on the performance printout for
the compressor unit. Side load pressure settings would be set as required for the system. By means of a
pressure gauge, the actual economizer operating pressure can be determined by placing the Inlet Pressure
Regulator module range spring at minimum force (control module stem should be fully turned counter-
clockwise). Leaving the regulator in this position, the actual economizer compressor port pressure can be
read. NOTE: The compressor must be at 100% capacity and at normal operating suction and discharge
pressures before the actual port pressure can be determined. Once this pressure is known, the module stem
should be turned clockwise until there is a slight increase in pressure shown on the gauge. Increasing the
turns on the module stem will raise the inlet pressure.

Adjusting the Outlet / Maximum Port Pressure

The Outlet Pressure setting is a maximum pressure setting that will allow the compressor to load to 100%.
If too much economizer or side port gas flow occurs, port pressure increases resulting in a motor amperage
increase, which may result in amp limiting and the compressor will not load to 100%. In order to adjust the
Outlet Pressure Module, its range spring should be set near maximum force (control module stem should be
fully turned clockwise). If the compressor is not able to fully load because of Amp limiting, the outlet
pressure needs to be decreased by turning the stem counter-clockwise until there is a decrease in pressure
shown on the gauge. Reduce outlet pressure until motor amperage drops and the compressor is able to load
to 100% capacity. Make sure that the Outlet Pressure setting is at least 10 psig higher than the inlet pressure
to prevent a conflict in operation of the inlet and outlet features of the valve. NOTE: There must be
abnormally high gas flow to set the outlet feature. It may not be necessary to use the outlet feature if the
compressor motor has been sized large enough so that the unit does not amp limit on high economizer or
side load gas flow.
 Bulletin G359b
January, 2003

HANSEN TECHNOLOGIES
CORPORATION Specifications, Applications,
Service Instructions & Parts

BUTT WELD
SHUT-OFF VALVES

2" through 14"

(50 mm through 350 mm)
Globe & Angle
for refrigerants

KEY FEATURES
AW301H 3" (80 mm)
Butt Weld Angle Valve

INTRODUCTION
These low pressure drop refrigerant shut-off valves
are designed to be butt-welded directly to steel
piping, thereby eliminating potential leaky flanges
or threaded joints and simplifying installation. Cast
steel bodies are lightweight, yet have substantial
wall thickness to overcome corrosion potential.
The cast steel body is rigid, reducing the potential
for seat leakage due to flexing of the valve body
under abnormal conditions. The heart of Hansen
shut-off valves is the patented no-leak seal-plus-stem-
packing design. This seal design is used exclusively
on Hansen shut-off valves and virtually eliminates
stem seal leakage.

APPLICATIONS
Typical uses include:

Ammonia refrigeration system suction, liquid,

discharge, recirculating liquid, hot gas, thermosyphon, ADDITIONAL FEATURES
and oil lines, using handwheel or seal cap models. Globe and angle valves available.
Interchangeable handwheel or seal cap.
The low friction, no leak stem seal design permits the 2" thru 10" machined to Schedule 40 pipe, 12" and
use of chain actuation for crossover applications above Standard Weight pipe.
without the need to retighten the packing. Teflon seat disc.
Chain actuators available.
Steel pipe portions of halocarbon, commercial, Suitable for ammonia, R22, R134a, R507, and other
industrial, and air conditioning systems, using seal compatible refrigerants.
cap models. Suitable for CO 2 systems on request.
MATERIAL SPECIFICATIONS INSTALLATION
Body: Cast steel, ASTM A-352, Grade LCB All Hansen weld valves can be installed in horizontal
Bonnet: Ductile iron, 2"-8" A-536; or vertical pipe lines. Stems are normally installed
10", 12", &14 " ASME SA-395 horizontally, but, depending on the application, stems
Stem: Polished stainless steel may be installed vertically. Inlet pressure or direc-
Disc Holder: Plated steel tion of flow for all valve sizes should normally be
Seat Disc: Retained PTFE Teflon under valve seat disc. However, to avoid installing an
Ball Bearings: Stainless steel angle valve with the stem down, it is better to install
Packing Nut: Zinc plated steel the valve with the normal flow opposite the direction
Stem Packing: Graphite composite plus of the arrow.
neoprene O-ring in series
Handwheel: Zinc plated iron alloy 2"-4"; cast Care must be taken when handling and installing large
aluminum 5"-14" valves. Proper lifting devices and safety precau-
Seal Cap: Zinc plated steel 2"-4"; cast aluminum tions must be observed.
5"-14"
Temperature Range: A valve should have its bonnet assembly removed
60F to 240F (50C to 115C), temperatures before welding. This reduces weight during welding,
below 60F (50C) at lower pressures protects the Teflon seat disc from welding sparks,
Safe Working Pressure: 400 psig (27 bar), 600 psig and facilitates cleaning of welding debris from the
(40bar) upon request. body interior prior to valve operation. The valve stem
Connection Dimensions: 2"-10"Match Schedule 40 should be several turns open when removing and
pipe , 12" & Up Match Standard Weight Pipe replacing the bonnet assembly. The Teflon seat disc
should be protected when outside of the valve. Do not
ADVANTAGES allow the Teflon seat to bump the valve body when
Compared to conventional stem seal designs, removing it or stand the bonnet on the seat disc.
Hansens patented no leak seal-plus-stem-packing Where it is necessary or standard practice to weld a
virtually eliminates stem seal leakage. In addition, valve into the line without bonnet removal, the stem
the stem is polished to avoid packing wear, the preci- should be opened several turns to prevent heat dam-
sion stem threads avoid stem wobble and the pack- age to the seat disc. Extra care should be taken when
ing nut is close fitting to remove dirt particles and welding angle valves without disassembly to avoid
frost from the stem. This results in infrequent main- welding sparks striking the seat from the outlet weld
tenance or tightening and almost no refrigerant loss. connection.
Compared to threaded valves, Hansen welding valves Use of welding rings is recommended. They help align-
eliminate the chance of future leaks at pipe threads. ment, control the gap for full penetration welding, and
In addition, a butt weld pipe-to-valve body joint reduce the potential of welding debris entering the
eliminates the inherent weakness and corrosion system. Welds should be annealed as necessary in
vulnerability of the threaded portion of pipe imme- accordance with good practice. Painting of valves
diately adjacent to a screwed valve body or flange. and welds is recommended for corrosion protection.
Pipe covering, where applied, should have a proper
Compared to flanged valves, Hansen welding valves
moisture barrier.
eliminate the gasket joint leakage potential at the
flange joint. This gasket can leak due to pipe and Before putting valves into service, all pipe weld con-
bolt-nut movement as the result of temperature nections, valve seats, bonnet seals, and stem seals
and pressure fluctuations. The pressure drop of should be tested for leaks at pressure levels called
Hansen valves is lower than conventional flanged for in appropriate codes.
cast valve bodies. In addition, nearly all other re-
frigeration flanged valves are made of cast iron or Shut-off valves leading to the atmosphere must not
semi-steel. The cast steel bodies of Hansen valves be left unsupervised and must be plugged or capped
have much greater tensile strength, ductility, and to prevent corrosion inside the valve as well as leak-
impact resistance than cast iron or semi-steel. age due to seat expansion, vibration, pressure shock,
or improper opening. The valve seat should be cracked
Compared to pressed-sheet-steel welding valves, open to prevent hydrostatic expansion between the
Hansen valves have thicker walls for greater rigid- valve and the cap. Valves should never directly feed
ity and corrosion resistance. a water tank because of potential internal corrosion
or seat opening caused by vibration.
Compared to ball valves, Hansen welding valves
have no threaded or flanged-gasket pipe joints.
Hansen valves also will not open or close so rap- INSULATION
idly as to cause severe pipe shock due to sudden Conventional valve-shaped block insulation can oc-
change in liquid velocity. In addition, ball valve casionally be used for both angle and globe valves.
stem packing typically cannot be replaced while However, fabricated insulation shapes are recom-
the valve is in a pressurized line. The stem packing mended. If not available locally, Hansen can rec-
on these Hansen valves can be replaced while the ommend a source of high quality, economical valve
valve is in a pressurized line. Also, dirt or damage insulation. See page 5 of this bulletin for exterior
to ball valve Teflon seats cannot be overcome by valve dimensions.
greater stem closing forces, an advantage of Hansen
valves.
2
 FLOW CAPACITIES
PIPING AND VALVE SIZING GUIDE FOR AMMONIA

SERVICE CONDITIONS CAPACITIES

TEMPERATURE PRESSURE 2" (50 MM) 21/2" (65 MM) 3" (80 MM) 4" (100 MM) 5" (125MM

F C PSIG BAR TONS kW TONS kW TONS kW TONS kW TONS kW

Suction Lines +20 -7 33.5 2.3 35.7 126 51.1 180 81.5 287 146 513 235 352
Single Stage 0 -18 15.7 1.1 22.7 80 34.0 120 53.9 190 94.6 333 156 549
Compressor
Suction Lines -20 -29 3.6 0.3 16.8 59 24.8 87 39.7 140 68.9 242 114 401
Booster -40 -40 8.7 0.6 9.9 35 14.4 51 23.4 82 40.8 144 66.8 235
Liquid +20 -7 33.5 2.3 20.6 72 29.4 103 47.0 165 84.3 296 135 475
Overfeed 0 -18 15.7 1.1 13.6 48 20.5 72 32.4 114 56.8 200 93.8 330
Return Lines -20 -29 3.6 0.3 8.9 31 13.1 46 21.0 74 36.4 128 60.5 213
(4X) -40 -40 8.7 0.6 5.4 19 7.9 28 12.8 45 22.4 79 36.7 129
Hot Gas Feed +70 +21 114.1 7.9 36.5 128 53 186 82.5 290 145 510 231 812
Hot Gas Main +70 +21 114.1 7.9 73.0 257 106 373 165 580 290 1020 463 1682
Compressor +86 +30 154.5 10.7 62.6 220 90.3 318 142 499 249 876 397 1396
Discharge
Condenser +86 +30 __ __ 140 492 220 774 375 1319 740 2603 1320 4642
Drains
Liquid Mains +86 +30 __ __ 454 1597 657 2311 1031 3626 1808 6359 2886 10150
Liquid Feed +86 +30 __ __ 881 3098 1273 4477 1999 7030 3506 12330 5596 19681
Branch
Liquid +10 -13 __ __ 144 506 208 732 327 1150 573 2015 915 3218
Overfeed
Supply (4X)

SERVICE CONDITIONS CAPACITIES

TEMPERATURE PRESSURE 6"(150MM) 8"(200MM) 10"(250MM) 12"(300MM) 14"(350MM)

F C PSIG BAR TONS kW TONS kW TONS kW TONS kW TONS kW

Suction Lines +20 -7 33.5 2.3 343 1206 628 2209 1020 3387 1490 5240 1821 6404
Single Stage 0 -18 15.7 1.1 225 791 414 1456 662 2328 946 3327 1156 4066
Compressor
Suction Lines -20 -29 3.6 0.3 165 580 306 1076 486 1709 709 2494 867 3049
Booster -40 -40 8.7 0.6 97.8 344 181 637 288 1013 419 1474 512 1801
Liquid +20 -7 33.5 2.3 198 696 362 1273 587 2064 856 3010 1046 3679
Overfeed 0 -18 15.7 1.1 135 475 249 876 398 1400 568 1998 694 2441
Return Lines -20 -29 3.6 0.3 87.5 308 162 570 256 900 375 1319 458 1611
(4X) -40 -40 8.7 0.6 53.7 189 100 352 158 556 232 816 284 999
Hot Gas Feed +70 +21 114.1 7.9 338 1189 595 2093 949 3338 1377 4843 1683 5919
Hot Gas Main +70 +21 114.1 7.9 673 2367 1190 4185 1898 6675 2754 9686 3366 11838
Compressor +86 +30 154.5 10.7 580 2040 1021 3591 1629 5729 2363 8311 2888 10157
Discharge
Condenser +86 +3 0 __ __ 2030 7140 4200 14771 __ __ __ __ __ __
Drains
Liquid Mains +86 +30 __ __ 4218 14835 __ __ __ __ __ __ __ __
Liquid Feed +86 +30 __ __ 8179 28766 __ __ __ __ __ __ __ __
Branch
Liquid +10 -13 __ __ 1337 4702 __ __ __ __ __ __ __ __
Overfeed
Supply (4X)

3
SIZING GUIDE
These flow capacity recommendations are not affected Example: Hansen valves have about 145 diameters
by the length of the pipe line. These are approximate of equivalent flow resistance, or 145/700 = 0.2F
optimum sizes based on power costs versus the (0.12C) of equivalent pressure drop at the suction
investment costs of piping and its total installed line capacities shown for a valve in a suction line.
cost. Piping sized to this capacity will have a 1F
(0.6C) pressure drop for the following equivalent The rational for the vapor line sizing was developed
lengths: by William V. Richards in two papers: Refrigerant
Vapor Line Sizing Not Dependent of Length, 16th
suction lines . . . . . . . 700 diameters International Congress of Refrigeration, IIR, Paris,
1983; and Practical Pipe Sizing for Refrigerant
discharge lines . . . . . 1400 diameters Vapor Lines, Sixth Annual Meetings, IIAR, San
Francisco, 1984.
liquid lines . . . . . . . . . 2400 diameters

Example: 275 feet (84 m) of 3" (80 mm) pipe and

equivalent fittings amount to 1100 diameters,
pressure drop for a suction line handling 81.5 tons
(287 kW) at 20F (7C) is 1100/700 times 1F (0.6C)
drop, equals 1.6F (1C) or 1.8 psi (0.12 bar).

FLOW COEFFICIENTS

ANGLE GLOBE

SIZE EQUIVALENT EQUIVALENT EQUIVALENT EQUIVALENT

Cv Kv LENGTH LENGTH Cv Kv LENGTH LENGTH
FEET METERS FEET METERS
2" (50 MM) 80 69 28 8.5 67 58 40 12.2
21/2" (65 MM) 176 152 14 4.3 163 141 16 4.9
3" (80 MM) 205 177 31 9.5 195 169 34 10.4
4" (100 MM) 320 277 51 15.6 290 251 62 18.9
5" (125 MM) 600 519 45 13.7 575 497 49 14.9
6" (150 MM) 820 709 61 18.6 790 683 66 20.1
8" (200 MM) 1435 1241 84 25.6 1380 1194 91 27.7
10" (250 MM) 2450 2121 93 28.4 2350 2035 101 30.8
12" (300 MM) 3400 2944 117 35.7 3270 2731 126 38.4
14" (350 MM) 4600 3983 143 43.6 4350 3766 156 47.6

4
 GLOBE INSTALLATION DIMENSIONS
2" THROUGH 8" (50 MM THROUGH 200 MM)
E
(DIA)
E (DIA)

A'

A
A (WIDE OPEN)
A' (WIDE OPEN)

T 50
T
F F

C P
C
2", 2", AND 3" 4", 5", 6", AND 8"
(50 MM, 65 MM, AND 80 MM) (100 MM, 125 MM, 150 MM, AND 200 MM)
SIZE A A' C E F P T
2" (50 mm) 8.88" (225 mm) 9.13" (232 mm) 7.25" (184 mm) 4.25" (108 mm) 2.13" (54 mm) -- 2.38" (60 mm)
21/2" (65 mm) 12.13" (308 mm) 11.75" (298 mm) 9.25" (235 mm) 7.63" (194 mm) 2.75" (70 mm) -- 2.88" (73 mm)
3" (80 mm) 12.13" (308 mm) 11.75" (298 mm) 9.25" (235 mm) 7.63" (194 mm) 2.75" (70 mm) -- 3.50" (89 mm)
4" (100 mm) 13.75" (349 mm) 14.25" (362 mm) 10.00" (254 mm) 14.00" (356 mm) 2.50" (64 mm) 2.50" (64 mm) 4.50" (114 mm)
5" (125mm) 21.38" (543mm) 21.63" (549mm) 11.65" (396 mm) 10.00" (254 mm) 3.00" (76mm) 2.65" (67 mm) 5.56" (141 mm)
6" (150mm) 22.10" (561 mm) 22.15" (563 mm) 13.26" (337 mm) 10.00" 254 mm) 3.50" (89 mm) 2.73" (69 mm) 6.63" (168 mm)
8" (200mm) 29.10" (739 mm) 29.51" (750mm) 18.10" (459 mm) 16.00" (406mm) 4.61" (117 mm) 3.98" (101 mm) 8.63" (219 mm)

E
(DIA)

A'

A
(WIDE OPEN)
GLOBE INSTALLATION
DIMENSIONS
D
(WIDE OPEN) 10", 12", AND 14"
(250 MM, 300 MM, AND 350 MM)

50

T
F

P
C

SIZE A A' C D E F P T

10" 35.29" 36.16" 23.38" 33.24" 16.00" 5.81" 5.19" 10.75"

(250mm) (896 mm) (918 mm) (594 mm) (844 mm) (406 mm) (148 mm) (132 mm) (273 mm)

12" 42.16" 46.39" 29.20" 38.51" 20.00" 7.00" 6.27" 12.75"

(300mm) (1071 mm) (1178 mm) (742 mm) (978 mm) (508 mm) (178 mm) (159 mm) (324 mm)

14" 47.55" 49.66" 32.86" 47.55" 20.00" 7.63" 7.23" 14.00"

(350mm) (1208 mm) (1261 mm) (835 mm) (1208 mm) (508 mm) (194 mm) (184 mm) (356 mm)

5
 ANGLE INSTALLATION DIMENSIONS
2" THROUGH 8" (50 MM THROUGH 200 MM)

E
DIA

SIZE B E T X Y Y'
2" 3.38" 4.25" 2.38" 1.88" 7.75" 8.00"
(50 mm) (86 mm) (108 mm) (60 mm) (48 mm) (197 mm) (203 mm)
21/2" 3.38" 7.63" 2.88" 2.38" 11.00" 10.63"
(65 mm) (86 mm) (194 mm) (73 mm) (60 mm) (280 mm) (270 mm)
Y
Y' 3" 3.38" 7.63" 3.50" 2.38" 11.00" 10.63"
(WIDE OPEN)
(80 mm) (86 mm) (194 mm) (89 mm) (60 mm) (280 mm) (270 mm)
4" 3.88" 7.63" 4.50" 3.00" 11.00" 10.63"
(100 mm) (98 mm) (194 mm) (114 mm) (76 mm) (280 mm) (270 mm)
5" 4.47" 10.00" 5.56" 3.47 16.42 16.62
(125 mm) (131 mm) (254 mm) (141 mm) (88 mm) (417 mm) (422 mm)
T 6" 5.15" 10.00" 6.63" 3.85" 16.55" 16.78"
(150 mm) (131 mm) (254 mm) (168 mm) (98 mm) (420 mm) (426 mm)
8" 6.90" 16.00" 8.63" 6.11" 22.12" 22.52"
(200 mm) (175 mm) (406 mm) (219 mm) (155 mm) (562 mm) (572 mm)
B

X B

ANGLE INSTALLATION DIMENSIONS

10", 12", AND 14" (250 MM, 300 MM, AND 350 MM)
E
(DIA)

Y SIZE B E T X Y Y'
Y'
(WIDE OPEN)
10" 9.44" 16.00" 10.75" 6.63" 26.47" 27.34"
(250mm) (240 mm) (406 mm) (273 mm) (168 mm) (672 mm) (694 mm)

12" 12.00" 20.00" 12.75" 8.66" 30.34" 33.86"

(300mm) (305 mm) (508 mm) (324 mm) (220 mm) (783 mm) (860 mm)

14" 12.97" 20.00" 14.00" 9.20" 34.92" 36.91"

(350mm) (329 mm) (508 mm) (356 mm) (234 mm) (887 mm) (938 mm)
T

X B

6
 GLOBE INSULATION DIMENSIONS
2" THROUGH 8" (50 MM THROUGH 200 MM)

N
G (CLOSED) H

N G (CLOSED)
L
K
W M W M
H L
K
50
J J

C P W
C
2", 2", AND 3" 4", 5", 6", AND 8"
(50 MM, 65, MM, AND 80 MM) (100 MM, 125 MM, 150 MM, AND 200 MM)
SIZE C G H J K L M N P W
2" 7.25" 1.38" 3.00" 4.00" 4.38" 1.63" 3.50" 1.25" -- 1.00"
(50 mm) (184 mm) (35 mm) (76 mm) (102 mm) (111 mm) (41 mm) (89 mm) (38 mm) (25 mm)
21/2" 9.25" 1.88" 3.00" 5.38" 5.00" 2.75" 4.00" 2.25" -- 1.75"
(65 mm) (235 mm) (48 mm) (76 mm) (137 mm) (127 mm) (70 mm) (102 mm) (57 mm) (45 mm)
3" 9.25" 1.88" 3.00" 5.38" 5.00" 2.75" 4.00" 2.25" -- 1.75"
(80 mm) (235 mm) (48 mm) (76 mm) (137 mm) (127 mm) (70 mm) (102 mm) (57 mm) (45 mm)
4" 10.00" 7.50" 4.00" 5.00" 1.25" 2.25" 5.75" SQ. 2.25" 2.50 1.75"
(100 mm) (254 mm) (191 mm) (102 mm) (127 mm) (32 mm) (57 mm) (146 mm) (57 mm) (64 mm) (45 mm)
5" 11.65" 1.73" 3.73" 5.94" 5.32" 4.75" 6.81" 2.75" 2.65" 1.60"
(125 mm) (296 mm) (44 mm) (95 mm) (151 mm) (135 mm) (121 mm) (173 mm) (70 mm) (67 mm) 41 mm)
6" 13.26" 1.00" 2.80" 7.00" 6.69" 4.38" 7.75" 2.75" 2.73" 2.10"
(150 mm) (337 mm) (25 mm) (71 mm) (178 mm) (170 mm) (111 mm) (197 mm) (70 mm) (69 mm) (53 mm)
8" 18.10" 1.17" 4.24" 9.22" 10.53" 5.59" 11.75" 3.00" 3.98" 4.00"
(200 mm) (459 mm) (30 mm) (108 mm) (234 mm) (267 mm) (142 mm) (298 mm) (76 mm) (101 mm) (102 mm)

GLOBE INSULATION DIMENSIONS

10", 12", AND 14" (250 MM, 300 MM, AND 350 MM)

H
N

K
L
G
(CLOSED)

P W
C

SIZE C G H J K L M N P W

10" 23.38" 16.79" 3.59" 11.60" 12.02" 10.00" 14.50" 3.00" 5.19" 1.00"
(250mm) (594 mm) (427 mm) (91 mm) (295 mm) (305 mm) (254 mm) (368 mm) (76 mm) (132 mm) (25 mm)

12" 29.20" 21.45" 4.91" 14.00" 16.29" 12.40" 18.37" 4.00" 6.27" 1.00"
(300 mm) (742 mm) (545 mm) (125 mm) (356 mm) (414 mm) (315 mm) (467 mm) (102 mm) (159 mm) (25 mm)

14" 32.86" 24.94" 5.76" 15.25" 17.80" 13.35" 19.00" 4.00" 7.23" 1.00"
(350 mm) (835 mm) (634 mm) (146 mm) (387 mm) (452 mm) (339 mm) (483 mm) (102 mm) (184 mm) (25 mm)

7
 ANGLE INSULATION DIMENSIONS
2" THROUGH 8" (50 MM THROUGH 200 MM)

V (CLOSED)

N
L

M W
P
U

R S

S B

SIZE B L M N P Q R S U V W
2" 3.38" 1.63" 3.50" 1.25" 1.50" 3.75" 3.00" 3.13" 1.25" 1.00"
(50 mm) (86 mm) (41 mm) (89 mm) (38 mm) -- (38 mm) (95 mm) (76 mm) (79 mm) (32 mm) (25 mm)
21/2" 3.38" 2.75" 4.00" 2.25" 2.88" 2.00" 4.75" 3.75" 4.00" 1.13" 1.75"
(65 mm) (86 mm) (70 mm) (102 mm) (57 mm) (73 mm) (51 mm) (121 mm) (95 mm) (102 mm) (29 mm) (45 mm)
3" 3.38" 2.75" 4.00" 2.25" 2.88" 2.00" 4.75" 3.75" 4.00" 1.13" 1.75"
(80 mm) (86 mm) (70 mm) (102 mm) (57 mm) (73 mm) (51 mm) (121 mm) (95 mm) (102 mm) (29 mm) (45 mm)
4" 3.88" 2.25" 5.50" 2.25" 3.00" 2.63" 6.00" 4.75" 4.25" 1.13"
(100 mm) (98 mm) (57 mm) (140 mm) (57 mm) (76 mm) (67 mm) (152 mm) (121 mm) (108 mm) (29 mm) --
5" 4.47" 4.75" 6.75" 2.75" 3.73" 3.46" 6.81" 5.92" 4.65" 1.75"
(125 mm) (114 mm) (121 mm) (171 mm) (70 mm) (95 mm) (88 mm) (173 mm) (150 mm) (118 mm) (44 mm) --
6" 5.15" 4.38" 9.88" 2.75" 2.80" 3.98" 7.75" 7.0" 5.19" 1.00"
(150 mm) (131 mm) (111 mm) (251 mm) (70 mm) (71 mm) (99 mm) (197 mm) (178 mm) (132 mm) (25 mm) --
8" 6.90" 5.59" 12.22" 3.00" 4.24" 6.90" 12.22" 9.15" 7.78" 1.17"
(200 mm) (175 mm) (142 mm) (310 mm) (76 mm) (108 mm) (175 mm) (310 mm) (232 mm) (198 mm) (30 mm) --

ANGLE INSULATION DIMENSIONS

10", 12", AND 14" (250 MM, 300 MM, AND 350 MM)

V (CLOSED)

P
U

R
S
Q

S
B

SIZE B L M N P Q R S U V

10" 9.44" 10.00 14.50 3.00 3.59 4.30 13.25 11.60 8.20 1.69
(250mm) (240 mm) (254 mm) (368 mm) (76 mm) (91 mm) (109 mm) (337 mm) (295 mm) (208 mm) (43 mm)

12" 12.00 12.40 18.37 4.00 4.91 9.07 17.33 13.79 9.81 1.31
(300mm) (305 mm) (315 mm) (467 mm) (102 mm) (125 mm) (230 mm) (440 mm) (350 mm) (249 mm) (33 mm)

14" 12.97 13.33 19.00 4.00 5.76 11.38 18.40 15.25 10.69 2.64
(350mm) (329 mm) (339 mm) (483 mm) (102 mm) (146 mm) (289 mm) (467 mm) (387 mm) (272 mm) (67 mm)

8
SERVICE AND MAINTENANCE VALVE SEAT
Hansen steel butt welding shut-off valves require To inspect or replace the valve seat disc, isolate the
practically no service or maintenance due to the valve from the system and safely pump out all
combination of polished stainless steel stems and refrigerant to zero pressure with the stem open at
reliable O-ring stem seals plus graphite composite least one turn. Evenly loosen all bolts one to two
packing. This almost entirely eliminates stem leak- turns. Using a screwdriver, break the seal between
age, the common ailment of shut-off valves. the bonnet and valve body, proceeding cautiously to
avoid any refrigerant which may still remain inside
To help ensure safety, verify the tightness of the the valve body. Remove the bonnet bolts and bonnet
packing nut whenever the position (open or closed) assembly, being careful not to damage the Teflon
is changed on isolation shut-off valves before open- seat disc surface.
ing the system. Ensuring that the packing nut is
tight helps reduce the possibility that any line or If the seat surface in the body is marred, it may be
system vibration may cause a slight unseating of a possible to repair the seat by polishing with emery
closed valve. paper.

STEM PACKING If the Teflon seat disc is damaged, replace the

When verifying the tightness of the packing nut, entire disc assembly 2" thru 4" by first removing
use an adjustable wrench. Extrusion of some black the ball retainer spring and ball bearings. Install a
graphite packing material along the stem is nor- new disc assembly. Alternately, use a lathe to take
mal. If the O-ring or the adjustable packing ever a 1/ 64" (0.4 mm) by 45 surface cut on the Teflon
needs replacement as evidenced by refrigerant or seat.
oil leakage at the stem, open the valve stem firmly
to the back-seat position. This separates the O- The 5" thru 14" Teflon seats can be replaced by
ring and packing from the system refrigerant. See disassembling the disk holder by loosening and
the CAUTION section. Remove the packing nut care- removing the disk screws. Replace Teflon ring and
fully and then use a wire hook or a small blade reassemble disk.
screwdriver to remove the packing and O-ring. Take
Replace body gasket or o-ring and reassemble
care not to scratch the stem or bonnet sealing
bonnet into body using care not to damage Teflon
surfaces. Carefully install a backup washer, new
seat surface. Ensure the stem is opened at least
lubricated stem O-ring, stem washer, and stem pack-
several turns.
ing. Tighten the packing nut only enough to give
the handwheel slight turning friction. The bonnet cap screws on the 2" (50 m) require a
torque of 40 ft.-lbs (55Nm); 2 1/ 2" and 3" (65mm and
80mm) require valves require a torque of 60 ft-lbs
(82 Nm); 180 ft-lbs (245 Nm) on the 4" (100 mm)
valves, 200 ft-lbs (270 Nm) on the 5", 6", 8", 10",
12" and 14" valves. Test the valve for leaks before
returning it to service.

9
2" THROUGH 4" (50 MM THROUGH 100 MM)
BUTT WELD VALVE

10
 2" THROUGH 4" (50 MM THROUGH 100 MM) BUTT WELD VALVE

REPLACEMENT PARTS
PART PART
ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY.
NO. NO.
Gasket Kit 2" (50 mm) 50-1023 Disc Assembly Kit 2" (50 mm) 50-1025
Gasket Kit 21/2", 3" 50-1043 Disc Assembly Kit 21/2", 3" 50-1045
XX(65 mm, 80 mm) XX(65 mm, 80 mm)
Gasket Kit 4" (100 mm) 50-1065 Disc Assembly Kit 4"(100 mm) 50-1067
Above kits consist of: Above kits consist of:
1a XStem Packing 2" 1 50-0248
10a XDisc Assembly 2" (50 mm) 1 50-0363
1b XStem Packing 21/2", 3", 4" 1 50-0290
10b XDisc Assembly 21/2", 3" 1 50-0374
XX(65 mm, 80 mm, 100 mm)
XX(65 mm, 80 mm)
2a XStem Washer 2" (50 mm) 1 50-0247
10c XDisc Assembly 4" (100 mm) 1 50-0524
2b XStem Washer 21/2", 3", 4" 1 50-0299
11a XBall Retainer 2" (50 mm) 1 50-0257
XX(65 mm, 80 mm, 100 mm)
11b XBall Retainer 21/2", 3", 4" 1 50-0297
3a XBack-Up Washer 2" (50 mm) 1 50-0351
XX(65 mm, 80 mm, 100 mm)
3b XBack-Up Washer 21/2", 3", 4" 1 50-0324
XX(65 mm, 80 mm, 100 mm) 12a XBalls 2" (50 mm) 16 50-0016

4a XStem O-Ring 2" (50 mm) 1 50-0253 12b XBalls 21/2", 3", 4" (65, 80, 100 mm) 15 50-0305
4b 1 2
XStem O-Ring 2 / ", 3", 4" 1 50-0293 5a XBonnet Gasket 2" (50 mm) 1 50-0259
XX(65 mm, 80 mm, 100 mm) 5b XBonnet Gasket 21/2", 3" 1 50-0310
5a XBonnet Gasket 2" (50 mm) 1 50-0259 XX(65 mm, 80 mm)
5b XBonnet Gasket 21/2", 3" 1 50-0310 5c XBonnet Gasket 4" (100 mm) 1 50-0537
XX(65 mm, 80 mm) Handwheel Kit 2" (50 mm) 50-1026
5c XBonnet Gasket 4" (100 mm) 1 50-0537 Handwheel Kit 21/2", 3", 4" 50-1037
6a XSeal Cap Gasket 2" (50 mm) 1 50-0270 XX(65 mm, 80 mm, 100 mm)
6b XSeal Cap Gasket 21/2", 3", 4" 1 50-0315 Above kits consist of:
XX(65 mm, 80 mm, 100 mm)
14a XHandwheel 2" (50 mm) 1 50-0321
7a XPacking Nut 2" (50 mm) 1 50-0251
14b XHandwheel 21/2", 3", 4" 1 50-0319
7b XPacking Nut 21/2", 3", 4" 1 50-0292 XX(65 mm, 80 mm, 100 mm)
XX(65 mm, 80 mm, 100 mm)
15a XScrew 2" (50 mm) 1 50-0254
Bonnet Ass'y Kit 2" (50 mm) 50-1024
15b XScrew 21/2", 3", 4" 1 50-0295
Bonnet Ass'y Kit 21/2", 3" 50-1044 XX(65 mm, 80 mm, 100 mm)
XX(65 mm, 80 mm)
16a XNameplate 2" (50 mm) 1 50-0094
Bonnet Ass'y Kit 4" (100 mm) 50-1066
16b XNameplate 21/2", 3", 4" 1 50-0318
Above kits consist of: XX(65 mm, 80 mm, 100 mm)
8a XBonnet 2" (50 mm) 1 50-0239 17 XSupport Washer 21/2", 3", 4" 1 50-0480
8b XBonnet 21/2", 3" (65 mm, 80 mm) 1 50-0286 XX(65 mm, 80 mm, 100 mm)
8c XBonnet 4" (100 mm) 1 50-0515 18 XBonnet Thread Cap 2" (50 mm) 1 50-0263
9a XStem 2" (50 mm) 1 50-0242 Seal Cap Kit 2" (50 mm) 50-1027
9b XStem 21/2", 3", 4" (65 mm 1 50-0287
Seal Cap Kit 21/2", 3", 4" 501038
XX80 mm, 100 mm)
XX(65 mm, 80 mm, 100 mm)
10a XDisc Assembly 2" (50 mm) 1 50-0363
Above kits consist of:
10b XDisc Assembly 21/2", 3" 1 50-0374
19a XSeal Cap 2" (50 mm) 1 50-0260
XX(65 mm, 80 mm)
19b 1 2
XSeal Cap 2 / ", 3", 4" 1 50-0304
10c XDisc Assembly 4" (100 mm) 1 50-0524
XX(65 mm, 80 mm, 100 mm)
11a XBall Retainer 2" (50 mm) 1 50-0257
6a XSeal Cap Gasket 2" (50 mm) 1 50-0270
11b XBall Retainer 21/2", 3", 4" 1 50-0297
6b 1 2
XSeal Cap Gasket 2 / ", 3", 4"
XX(65 mm, 80 mm, 100 mm) 1 50-0315
XX(65 mm, 80 mm, 100 mm)
12a XBalls 2" (50 mm) 16 50-0016
20a Body, Globe, 2" (50 mm) BW 1 50-0391
12b XBalls 21/2", 3", 4" 15 50-0305
20b 1 2
Body, Globe, 2 / " (65 mm) BW 1 50-0454
XX(65 mm, 80 mm, 100 mm)
13a XBonnet Bolts 2" (50 mm) 4 50-0473 20c Body, Globe, 3" (80 mm) BW 1 50-0455
13b XBonnet Bolts 21/2", 3" 4 50-0294 20d Body, Globe, 4" (100 mm) BW 1 50-0671
XX(65 mm, 80 mm) (GW402)
13c XBonnet Bolts 4" (100 mm) 4 50-0521 20e Body, Angle, 2" (50 mm) BW 1 50-0354
XGasket Kit 2" (50 mm) 1 50-1023 20f Body, Angle, 21/2" (65 mm) BW 1 50-0285
XGasket Kit 21/2", 3"(65, 80 mm) 1 50-1043 20g Body, Angle, 3" (80 mm) BW 1 50-0289
XGasket Kit 4" (100 mm) 1 50-1065 20h Body, Angle, 4" (100 mm) BW 1 50-0516

11
5", 6", AND 8" (125 MM, 150 MM, AND 200 MM)
BUTT WELD VALVE

12
 5", 6", AND 8" (125 MM, 150 MM, AND 200 MM) BUTT WELD VALVE
REPLACEMENT PARTS
ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART
NO. NO.

Gasket Kit 5" (125 mm) 50-1082 Disc Kit 5" (125) 50-1086

Gasket Kit 6" (150 mm) 50-1083 Disc Kit 6" (150) 50-1087

Gasket Kit 8" (200 mm) 20-1084 Disc Kit 8" (200) 50-1088

Above kits consist of: Above kits consist of:

1a Stem Packing 5", 6" 1 50-0703 10a Seat Disc 5" 1 50-0717

1b Stem Packing 8" 1 50-0745 10b Seat Disc 6" 1 50-0716

2a Stem Washer 5", 6" 1 50-0705 10c Seat Disc 8" 1 50-0755

2b Stem Washer 8" 1 50-0747 21a Lower Disc Holder 5" 1 50-0713

3a Back-Up Washer 5", 6" 1 50-0706 21b Lower Disc Holder 6" 1 50-0711

3b Back-Up Washer 8" 1 50-0748 21c Lower Disc Holder 8" 1 50-0752

4a Stem O-Ring 5", 6" 1 50-0707 22a Upper Disc Holder 5" 1 50-0712

4b Stem O-Ring 8" 1 50-0749 22b Upper Disc Holder 6" 1 50-0710

5a Bonnet O-Ring 5" 1 50-0708 22c Upper Disc Holder 8" 1 50-0751

5b Bonnet O-Ring 6" 1 50-0709 23a Disc Holder Screw 5", 6" 4 50-0729

5b Bonnet O-Ring 8" 1 50-0750 23b Disc Holder Screw 8" 6 50-0760
5a Bonnet O-Ring 5" 1 50-0708
6a Seal Cap O-Ring 5", 6" 1 50-0730
5b Bonnet O-Ring 6" 1 50-0709
6b Seal Cap O-Ring 8" 1 50-0761
5c Bonnet O-Ring 8" 1 50-0750
7a Packing Nut 5", 6" 1 50-0704
Handwheel Kit 5", 6" 50-1089
7b Packing Nut 8" 1 50-0746
(125 mm, 150 mm)
Bonnet Ass'y Kit 5" (125 mm) 50-1080
Handwheel Kit 8" (200m) 50-1090
Bonnet Ass'y Kit 6" (150 mm) 50-1081
Above kits consist of:
Bonnet Ass'y Kit 8" (200 mm) 50-1085 14a Handwheel 5", 6" 1 50-0727
Above kit consists of: 14b Handwheel 8" 1 50-2229
9a Bonnet 5" 1 50-0675 15a Screw 5", 6" 1 50-0732
9b Bonnet 6" 1 50-0682 15b Screw 8" 1 50-0763
9c Bonnet 8" 1 50-0699 17a Nameplate 5", 6" 1 50-0728
10a Stem Assembly 5", 6" 1 50-0734 17b Nameplate 8" 1 50-0759
10b Stem Assembly 8" 1 50-1093 Seal Cap Kit 5", 6" 50-1091
11a Bonnet Bolts 5" 4 50-0521 (125 mm, 150 mm)

11b Bonnet Bolts 6" 6 50-0521 Seal Cap Kit 8" (200 mm) 50-1092

11c Bonnet Bolts 8" 8 50-0959 Above kits consist of:

Gasket Kit 5" (125 mm) 1 50-1082 19a Seal Cap 5", 6" 1 50-0715

Gasket Kit 6" (150 mm) 1 50-1083 19b Seal Cap 8" 1 50-0754

Gasket Kit 8" (200 mm) 1 20-1084 6a Seal Cap Gasket 5", 6" 1 50-0730
6b Seal Cap Gasket 8" 1 50-0761
Disc Kit 5" (125 mm) 1 50-1086
20a Body, Globe, 5" Butt Weld 1 50-0677
Disc Kit 6" (150 mm) 1 50-7087
20b Body, Globe, 6" Butt Weld 1 50-0693
Disc Kit 8" (200 mm) 1 50-1088
20c Body, Globe, 8" Butt Weld 1 50-0812
20d Body, Angle, 5" Butt Weld 1 50-0673
20e Body, Angle, 6" Butt Weld 1 50-0680
20f Body, Angle, 8" Butt Weld 1 50-0695

13
 10", 12', AND 14" (250 MM, 300 MM, AND 350 MM)
BUTT WELD VALVE

21 24

20 22
8
6
23

7 4

1
2 3

10 11

18 19
5
12

17 15

25

13

16
14

14
10", 12', AND 14" (250 MM, 300 MM, AND 350 MM) BUTT WELD VALVE
REPLACEMENT PARTS
ITEM DESCRIPTION QTY. PART NO. ITEM DESCRIPTION QTY. PART NO.

Gasket Kit 10" (250 mm) 50-1122 Disk Kit 10" (254 mm) 50-1128

Gasket Kit 12" (300 mm) 50-1123 Disk Kit 12" (305 mm) 50-1129

Gasket Kit 14" (350 mm) 20-1124 Disk Kit 14" (356 mm) 50-1130

Above kits consist of: Above kits consist of:

1a Stem Packing 10" 1 50-2309 12a Ring, Teflon Back Seat 10" 1 50-2233

1b Stem Packing 12" 1 50-2310 12b Ring, Teflon Back Seat 12" 1 50-2213

1c Stem Packing 14" 1 50-2311 12c Ring, Teflon Back Seat 14" 1 50-2248

2a Packing Washer 10" 1 50-2278 13a Ring, Teflon Main Seat 10" 1 50-2234

2b Packing Washer 12" 1 50-2215 13b Ring, Teflon Main Seat 12" 1 50-2212

2c Packing Washer 14" 1 50-2254 13c Ring, Teflon Main Seat 14" 1 50-2249

3a Back-Up Washer 10" 1 50-2217 14a Lower Disk Holder 10" 1 50-2153

3b Back-Up Washer 12" 1 50-2216 14b Lower Disk Holder 12" 1 50-2211

3c Back-Up Washer 14" 1 50-2253 14c Lower Disk Holder 14" 1 50-2145

4a Stem O-Ring 10" 1 50-2224 15a Upper Disk Holder 10" 1 50-2154

4b Stem O-Ring 12" 1 50-2264 15b Upper Disk Holder 12" 1 50-2210

4c Stem O-Ring 14" 1 50-2245 15c Upper Disk Holder 14" 1 50-2146

5a Bonnet O-Ring 10" 1 50-2223 16a Disk Screw 10", 12" 8 50-2236

5b Bonnet O-Ring 12" 1 50-2260 16b Disk Screw 14" 8 50-2251

5c Bonnet O-Ring 14" 1 50-2243 17a Guide Tube 10" 1 50-2155

6a Seal Cap O-Ring 10" 1 50-0761 17b Guide Tube 12" 1 50-2209

6b Seal Cap O-Ring 12", 14" 1 50-2259 17c Guide Tube 14" 1 50-2143

7a Packing Nut 10" 1 50-2149 18a Screw Guide 10", 12" 1 50-2237

7b Packing Nut 12" 1 50-2218 18b Screw Guide 14" 1 50-2252

7c Packing Nut 14" 1 50-2144 19 Washer, Screw Guide 10", 12", 14" 1 50-2238
8a Bushing, Stem Guide 10" 1 50-2179 5a Bonnet O-Ring 10" 1 50-2223
8b Bushing, Stem Guide 12" 1 50-2274 5b Bonnet O-Ring 12" 1 50-2260
8c Bushing, Stem Guide 14" 1 50-2161 5c Bonnet O-Ring 14" 1 50-2243

Bonnet Ass'y Kit 10" (254 mm) 50-1125 Handwheel Kit 10" (254 mm) 50-1131

Bonnet Ass'y Kit 12" (254 mm) 50-1126 Handwheel Kit 12", 14" 50-1132

Bonnet Ass'y Kit 14" (254 mm) 50-1127 (305 mm, 356 mm)
Above kit consists of: Above kits consist of:
9a Bonnet 10" 1 50-2306 20a Handweheel 10" 1 50-2229
9b Bonnet 12" 1 50-2307 20b Handweheel 12", 14" 1 50-2242
9c Bonnet 14" 1 50-2308 21 Screw 10", 12", 14" 1 50-0763
10a Stem Assembly 10" 1 50-2303 22 Nameplate 10", 12", 14" 1 50-0759
10b Stem Assembly 12" 1 50-2304 23 Flat Washer 10", 12", 14" 1 50-0764
10c Stem Assembly 14" 1 50-2305 Seal Cap Kit 10" (254 mm) 50-1133
11a Bonnet Screw 10" 8 50-2235 Seal Cap Kit 12", 14" 50-1134
11b Bonnet Screw 12" 12 50-2250 (305 mm, 356 mm)
11c Bonnet Screw 14" 16 50-2250 Above kits consist of:
Disk Kit 10" 1 50-1128 24a Seal Cap 10" 1 50-0754
Disk Kit 12" 1 50-1129 24b Seal Cap 12", 14" 1 50-2258
Disk Kit 14" 1 50-1130 6a Sea Cap O-Ring 10" 1 50-0761
Gasket Kit 10" (254 mm) 1 50-1122 6b Sea Cap O-Ring 12", 14" 1 50-2259
Gasket Kit 12" (305 mm) 1 50-1123 25a Body, Angle 10" 1 50-2177
Gasket Kit 10" (356 mm) 1 50-1124 25b Body, Globe 10" 1 50-2197
25c Body, Angle 12" 1 50-2186
25d Body, Globe 12" 1 50-2199
25e Body, Angle 14" 1 50-2148
25f Body, Globe 14" 1 50-2195

15
ORDERING INFORMATION, CAUTION
BUTT WELD VALVES Hansen valves are for refrigeration systems only.
Read these instructions completely before select-
ing, using, or servicing these valves. Only knowl-
SIZE DESCRIPTION CAT. NO.
edgeable, trained refrigeration technicians should
Globe, Handwheel GW200H install, operate, or service these valves. Stated tem-
perature and pressure limits should not be exceed-
2" Angle, Handwheel AW200H
ed. Bonnets should not be removed from valves
(50 mm) Globe, Seal Cap GW200C unless the system has been evacuated to zero pres-
Angle, Seal Cap AW200C sure. See also Safety Precautions in the current
List Price Schedule and the Safety Precautions Sheet
Globe, Handwheel GW251H supplied with the product.
21/2" Angle, Handwheel AW251H
(65 mm) Globe, Seal Cap GW251C
Angle, Seal Cap AW251C
Globe, Handwheel GW301H

3" Angle, Handwheel AW301H

(80 mm) Globe, Seal Cap GW301C
Angle, Seal Cap AW301C WARRANTY
Globe, Handwheel GW402H Hansen valves are guaranteed against defective ma-
terials or workmanship for one year F.O.B. our fac-
4" Angle, Handwheel AW402H tory. No consequential damages or field labor is
(100 mm) Globe, Seal Cap GW402C included.
Angle, Seal Cap AW402C
Globe, Handwheel GW500H

5" Angle, Handwheel AW500H

Globe, Seal Cap GW500C
Angle, Seal Cap AW500C
Globe, Handwheel GW600H TYPICAL SPECIFICATIONS
Weldable refrigerant shut-off valves shall have
Angle, Handwheel AW600H stainless steel stems with dual seals, cast steel
6"
Globe, Seal Cap GW600C bodies, back-seating design for packing replacement,
bonnet threads for installation of stem seal caps,
Angle, Seal Cap AW600C
butt weld ends machined dimensionally correct for
Globe, Handwheel GW800H Schedule 40 pipe (sizes 2"-10") size and gauge or
Standard Weight pipe (sizes 12" and above), and
Angle, Handwheel AW800H
8" suitability for a safe working pressure of 400 psig (27
Globe, Seal Cap GW800C bar), as manufactured by Hansen Technologies
Angle, Seal Cap AW800C Corporation, or approved equal.

Globe, Handwheel GW1000H

Angle, Handwheel AW1000H
10"
Globe, Seal Cap GW1000C
Angle, Seal Cap AW1000C
Globe, Handwheel GW1200H
Angle, Handwheel AW1200H
12"
Globe, Seal Cap GW1200C
Angle, Seal Cap AW1200C
Globe, Handwheel GW1400H
HANSEN TECHNOLOGIES
Angle, Handwheel AW1400H CORPORATION
14" 6827 High Grove Boulevard
Globe, Seal Cap GW1400C
Burr Ridge, Illinois 60527 USA
Angle, Seal Cap AW1400C Telephone: 630-325-1565
TO ORDER: Specify the catalog number. Toll-free: 800-426-7368
FAX: 630-325-1572
E-mail: info@hantech.com
2003 Hansen Technologies Corporation Printed in USA Web Site: www.hantech.com
16
 Bulletin R429d
MAR 2002

Specifications, Applications,
Service Instructions & Parts

HA4A MODULAR
PRESSURE REGULATORS
" THROUGH 6" PORT
(20 MM THROUGH 150 MM)

Various Connection
Styles and Sizes
for Refrigerants

KEY FEATURES

HA4AB
Regulator With Electric Wide Opening

INTRODUCTION
These advanced-design, strong-bodied, precision-
manufactured MODULAR regulators are superior in ADDITIONAL FEATURES
their ability to overcome dirt and sticky oil during Tolerant of Dry Systems
opening and tight closing. Models are available for For Ammonia, R22, R134a and other Hansen-
nearly every control function requirement of industrial Approved Refrigerants
ammonia and commercial halocarbon refrigeration. Wide Range of Options
These regulators are ideal for cold storage plants, Inlet, Outlet, or Differential Pressure
poultry plants, meat packing, fish processing, Wide Pressure Ranges
freezers, ice plants, breweries, bottling plants, heat Electric Shut-Off, Dual, or Wide-Opening Available
recovery units, petrochemical plants, pharmaceutical Safe Working Pressure: 400 psig (27 bar)
plants, supermarkets, and many others. CSA Certified, CRN for Canada

Contents Page
APPLICATIONS Regulator Variations 3
Capacities 45
Evaporator Pressure Control
Control Modules (Pilots) 6
Defrost Pressure Control
Main Regulators Only (AR1, AR3) 7
Condensing Pressure Regulation
Operation and Adjustment 811
Receiver Pressure Control
Installation Dimensions 1213
Hot Gas Bypass Capacity Regulation
Parts List 1418
Suction Pressure Control
Service and Maintenance, Abbreviations 19
Air or Liquid Temperature Regulation
Ordering Information, Conversions 20
Internal System Pressure Relief
MATERIAL SPECIFICATIONS The system should be free of dirt, weld slag, and rust
Body: particles. Regulators can be equipped with separate,
" through 4": Ductile iron, ASTM A536 close-coupled inlet strainers. No small, hidden, internal
5" & 6": Cast steel, ASTM A352 LCB screens are used. Gauges and gauge valves should
Adapter: Ductile iron, ASTM A536 be installed on the inlet and outlet to help in system
diagnosis. Because of the many regulator pilot
Piston: Steel, disc type, Teflon piston seal combinations, during installation of a large job, the
V-Port/Seat: ductile iron, with Teflon seat regulator nameplates should be checked against
Main Seat: " through 1": integral ductile iron piping drawings to guarantee proper function for
1" through 6": stainless steel, removable each location. Where pilot solenoid control modules
Gaskets: Nonasbestos, graphite composite are used, the nameplate coil voltage should be
Manual Opening Stem: Steel, plated checked before wiring. Pipe sizing, anchoring, valve
Pilots: Stainless steel trim rating, system design, and other precautionary factors
Pilot Orifice: Stainless steel should be taken into consideration to ensure liquid
Flanges: Forged steel, ASTM A105 hammer will not occur when the valve opens or closes.
Safe Working Pressure: 400 psig (27 bar) The 5" and 6" valves are type HA4W with integral
Operating Temperature: 60F to +240F (50C to butt weld end only. These steel-bodied regulators
+115C), lower temperatures possible at are directly welded into the pipe line. During welding,
pressure downratings the manual-opening stem should be opened
downward several turns to protect the Teflon seat
ADVANTAGES from weld heat.
These valves combine modern design and new age Welds should be annealed as necessary in
materials with advanced manufacturing techniques accordance with good practice. Painting of valves
and intense quality control to offer a significantly and welds is recommended for corrosion protection.
superior and reliable product. Their ductile iron bodies Pipe covering, where applied, should have proper
are stronger and more rugged than common cast moisture barrier. Before putting valves into service,
iron, or so called semi-steel (class B iron), valves. all pipe connections, valve seats, cover seals, and
They are more dirt resistant than full skirted-piston- stem seals should be tested for leaks at pressure
design valves. All regulators use energized Teflon levels called for in appropriate codes.
dirt-wiping piston seals which operate reliably, even
under dry, oil-free conditions. The screw-on control
modules (pilots) are easy to change and can be
ELECTRICAL
used on all valve sizes. All valves incorporate Teflon
When the electric shut-off, wide-opening, or dual
seating and stainless steel spring closing. Manual-
feature is supplied, a Hansen low-wattage, molded
opening stems are located on top of valves, up and
electrical coil is included. Standard coil voltages
away from dirt and rust particles to avoid thread
are 115V, 208/230V, or 24V at 50/60Hz. Other voltages
jamming. Nonasbestos gaskets are standard. These
available. The coil properly operates between 85%
standard regulator valves use the same flanges and
and 110% of the rated voltage. Coils should only be
spacing as R/S model A4A, except 1" (32 mm).
energized while on the pilot solenoid tube. Unless
Special Hansen 1" 4-bolt regulators are available otherwise specified, the standard coil with a " fitting
from stock to exactly replace R/S 1" A4A only. for conduit is supplied with valves.

A watertight solenoid coil with 18" (450 mm) long

SIZING wire pigtail leads and a steel frame housing with a "
Proper regulator valve sizing is important for smooth conduit fitting is standard.
operation and long, trouble-free life of the valve.
Therefore, capacity of the regulator at both the Optional DIN Plug Coils are for grounded cord
maximum and minimum flow and pressure drop connections and include the necessary DIN plug
should be analyzed. Pressure regulators will operate socket with gasket.
satisfactorily to approximately 15% of the maximum
capacity of valve based on the corresponding Coils with Junction Boxes are optional. Integral,
pressure drop. In extreme cases, downsizing or two steel junction box for connection of the 18" (450
smaller regulators in parallel are necessary. For mm) long wire pigtail leads.
pressure drops exceeding 45 psi (3.1 bar), special
construction may be required. Contact the factory. Vibration-resistant, bright, long-life, neon pilot lights
are available. These pilot lights operate on primary
voltage; a special coil with secondary winding is
INSTALLATION not necessary. Optional watertight pilot light
Regulators should be protected from dirt and moisture assembly is also available; see page 20.
during storage. The arrow on the body should be in
the normal direction of refrigerant flow. These valves
will not prevent reverse flow; use check valves where
necessary. Regulators are normally in horizontal pipe
lines with pilots and manual-opening stems on top.
Do not rotate the position of the valve adapter or the
valve will not operate.

R429d
MAR 2002 2
 REGULATOR VARIATIONS
HA4A STANDARD REGULATOR HA4AO OUTLET
This most common pressure regulator PRESSURE REGULATOR
modulates to control evaporator Controls outlet pressure by opening
pressure, condensing pressure, as downstream pressure falls below
pressure in a vessel, or pressure in a the set point. Used for hot gas to
portion of a system. It is frequently provide artificial refrigeration loading,
called an evaporator pressure regulator for condenser and receiver pressure
(EPR) or back pressure regulator. control by means of gas bypass,
HA4A
Opens on rising inlet pressure. See limiting hot gas pressure supply in
page 10. Shown with M3W pilot. defrosting evaporator in conjunction
with liquid drain traps, or for HA4AO
compressor suction pressure limitation.
Can be combined with electric shut-off,
HA4AS REGULATOR WITH temperature-operated, dual, or wide-
ELECTRIC SHUT-OFF opening features. See page 11.
This control is commonly used for
temperature control or defrost.
Regulates at the set-for pressure when HA4AP PNEUMATICALLY
energized. When de-energized, the COMPENSATED REGULATOR
valve closes tight regardless of the Commonly used for precise air or liquid
HA4AS
pressure setting. See page 11. temperature control via pneumatic
controller. An air, vapor, or liquid
pressure signal to the control module
bonnet increases inlet pressure from
HA4AB REGULATOR WITH HA4AP
the set-for pressure value at a 1:1 ratio.
ELECTRIC WIDE OPENING
See page 12.
Commonly regulates for defrost or
temperature, but opens wide for
maximum cooling. Regulating at the
HA4AT TEMPERATURE
set-for pressure when de-energized;
OPERATED REGULATOR
regulator opens when energized. See HA4AB The vapor pressure capillary tubing
page 11.
and bulb system modulates the
regulator open as temperature
increases to control air or liquid
HA4AD DUAL PRESSURE temperature. See page 12. HA4AT
REGULATOR
Regulates (evaporator) pressure at a
setting when energized, and at a higher
HA4AJ ELECTRONICALLY
setting for defrost, temperature control,
CONTROLLED REGULATOR
or pressure relief when de-energized.
HA4AD Electronic pilot and controller provides
See page 11.
very precise temperature control of
various cooled media under fluctuating
load conditions. See page 12. HA4AJ
HA4AL DIFFERENTIAL
PRESSURE REGULATOR
Commonly used as liquid pump relief,
HA4AM ELECTRIC MOTOR
condenser-receiver pressure difference
COMPENSATED REGULATOR
control, discharge pressure boosting
Commonly used for precise room
for defrosting or heat recovery, and
temperature control or liquid chiller
other similar applications. This control
control. The controlling motor changes
modulates to maintain the set-for HA4AL regulator pressure setting in
difference between inlet and outlet
accordance with a temperature
pressure. See page 10.
controller. See page 13.

HA4AM
HA4AK RESEATING
RELIEF REGULATOR
Used for defrost, high-to-low side relief,
or nonatmosphere relief to other parts
of the system. This control opens when NOTE: Many other control functions can be achieved
system upstream pressure is above by combining the control modules in different
the tagged and sealed set point arrangements. For example: a dual regulator with
pressure, and repeatedly reseats after HA4AK electronic pilot and secondary relief pilot; i.e. HA4ADJ.
operation. See page 10.
R429d
3 MAR 2002
 SUCTION VAPOR CAPACITIES (TONS)
(1 Ton= 12,000 Btu/hr= 3.517 kW= 3042 kcal/hr)

R717 R22
PRESSURE
PORT
SIZE (C v
Kv)
DROP
ACROSS
EVAPORATING TEMPERATURE EVAPORATING TEMPERATURE
(m m ) 4 0 F 2 0 F 0F +20F +40F 4 0 F 2 0 F 0F +20F +40F
VALVE
(4 0 C ) (2 8 .9 C ) (1 7 .8 C ) (6 .7 C ) (+ 4 .4 C ) (4 0 C ) (2 8 .9 C ) (1 7 .8 C ) (6 .7 C ) (+ 4 .4 C )
2 psi 4.7 6.4 7.4 9.5 12 2.1 2.8 2.8 3.6 4.4
3
/4"* 6.4 5 psi 6.7 9.7 8.7 15 19 3.2 4.3 4.4 5.5 6.9
(20) (5.5) 10 psi a 13 15 20 26 a 5.8 6.0 7.7 9.6
20 psi a a 19 27 35 a a 7.8 10 13
2 psi 8.5 12 13 17 22 3.9 5.2 5.2 6.5 8.0

1" 11.7 5 psi 12 18 16 27 34 5.8 7.9 8.0 10 13

(25) (10) 10 psi a 23 28 37 47 a 11 11 14 18
20 psi a a 36 49 64 a a 14 19 24
2 psi 12 16 19 24 31 5.4 7.2 7.2 9.1 11.3
11/4" 16.4 5 psi 17 25 22 38 48 8.1 11 11 14 18
(32) (14) 10 psi a 32 39 52 66 a 15 15 20 25
20 psi a a 50 69 90 a a 20 26 34
2 psi 25 35 40 52 65 12 15 15 19 24

11/2" 35 5 psi 37 53 48 81 102 17 24 24 30 38

(40) (30) 10 psi a 69 84 111 141 a 31 33 42 53
20 psi a a 106 147 193 a a 43 56 72
2 psi 34 47 54 70 87 16 21 21 26 32

2" 47 5 psi 49 71 64 108 137 23 32 32 41 51

(50) (40) 10 psi a 92 113 149 190 a 42 44 56 71
20 psi a a 143 198 259 a a 57 76 96
2 psi 56 77 89 114 143 25 34 34 43 53

2/" 1 2 77 5 psi 81 116 105 177 224 38 52 53 67 83

(65) (66) 10 psi a 151 185 243 311 a 69 72 92 116
20 psi a a 234 324 424 a a 94 124 158
2 psi 76 104 120 154 193 34 46 46 58 71

3" 104 5 psi 109 157 141 239 303 51 70 71 90 112

(80) (89) 10 psi a 204 250 329 420 a 93 97 125 156
20 psi a a 316 438 572 a a 127 167 213
2 psi 121 166 191 246 309 55 73 73 92 114

4" 166 5 psi 174 251 226 382 483 82 112 114 144 179
(100) (142) 10 psi a 325 398 525 671 a 149 155 199 249
20 psi a a 505 699 913 a a 203 267 340
2 psi 176 242 278 358 450 80 107 107 135 166
5" 242 5 psi 254 365 329 557 704 120 163 166 210 261
(125) (207) 10 psi a 474 581 765 978 a 218 226 290 363
20 psi a a 736 1019 1331 a a 295 390 496
2 psi 300 412 475 611 768 136 182 183 230 283
6" 413 5 psi 434 624 562 950 1202 204 278 282 358 446
(150) (354) 10 psi a 809 991 1305 1669 a 371 386 496 620
20 psi a a 1256 1739 2272 a a 504 665 847
2 psi= 0.14 bar 5 psi= 0.35 bar 10 psi= 0.69 bar 20 psi= 1.38 bar
*Optional 25% or 50% reduced capacity " (20 mm) plugs are available for unusually low loads if requested.
40F (40C) and 20F (28.9C) capacities are based on a two stage system.
For liquid overfeed evaporator suction between normal 2:1 to 5:1 rate, add 20% to the evaporator load or use the next
larger port size to accommodate liquid volume accompanying the suction gas and to reduce impact velocity.
Conditions: Capacities are based on the evaporator temperatures shown and +86F (+30C) liquid. R717: For each 10F
(5.6C) lower liquid temperature, increase the above table capacity by 3%. R22: For each 10F (5.6C) lower liquid
temperature, increase the above table capacity by 5%. To convert for R134a, multiply the R22 table values by 0.73
(accuracy within 8%). For other refrigerant capacities and suitability, contact the factory.
R429d
MAR 2002 4
LIQUID CAPACITIES (U.S. GPM) OIL CAPACITIES (U.S. GPM)
APPLICATION: REFRIGERANT PUMP RELIEF APPLICATION: SCREW COMPRESSOR OIL
REGULATOR (HA4AL) PUMP RELIEF REGULATOR (HA4AL)
R717 R22 PORT SIZE OIL
PORT SIZE P= 30 psi
P= 30 psi P= 30 psi (mm)
(m m ) (2 bar)
(2 b a r) (2 b a r)
3
3
/4" (20) 45 30 /4" (20) 48
1" (25) 82 56 1" (25) 87
1/"1 4 (32) 122
11/4" (32) 114 78
11/2" (40) 260
11/2" (40) 256 168
2" (50) 350
2" (50) 324 230
2/"1 2 (65) 574
21/2" (65) 553 377
3" (80) 775
3" (80) 733 505
Capacities based on oil with less than 300 SSU viscosity.
Capacities assume no gas flashing. No capacity correction
required for temperatures between 40F (40C) and +40F
(+4.4C).

HOT GAS DEFROST NOMINAL VALVE SIZING CAPACITIES

(DEFROSTING EVAPORATOR SIZE TONS)
PORT SIZE (mm)
R E F R IG . APPLICATION
3
/4" (20) 1 " (2 5 ) 11/4" (32) 11/2" (40) 2 " (5 0 ) 21/2" (65)
Hot Gas Solenoid * 9 to 15 15 to 28 28 to 39 39 to 73 73 to 106 106 to 165
R717 Defrost Relief
17 to 24 24 to 45 45 to 60 60 to 96 96 to 140 140 to 225
Regulator
Hot Gas Solenoid * 6 to 8 8 to 15 15 to 20 20 to 32 32 to 47 47 to 75
R22 Defrost Relief
6 to 8 8 to 15 15 to 20 20 to 32 32 to 47 47 to 75
Regulator

* Or an outlet pressure regulator with electric shut-off (HA4AOS).

Evaporator tons at 10F (5.6C) TD (temperature differential), valve capacities are conservative. These capacities can be
modified up or down depending on type of evaporator, temperature, mass, frost thickness, defrosting time, etc. Typical
for 20F (28.9C) evaporator.

GAS CAPACITIES (TONS)*

(1 Ton= 12,000 Btu/hr= 3.517 kW= 3042 kcal/hr)
DISCHARGE GAS REGULATOR HOT GAS BY-PASS TO SUCTION
R717 R22 R717 R22
+ 8 6 F (+ 3 0 C ) + 8 6 F (+ 3 0 C )
S IZ E C o n d e n s in g C o n d e n s in g + 8 6 F (+ 3 0 C ) + 1 5 F (9 .4 C ) + 8 6 F (+ 3 0 C ) + 1 5 F (9 .4 C )
(m m ) + 1 4 0 F (+ 6 0 C ) + 1 4 0 F (+ 6 0 C ) C o n d e n s in g C o n d e n s in g C o n d e n s in g C o n d e n s in g
D is c h a r g e D is c h a r g e + 1 4 0 F (+ 6 0 C ) + 1 5 F (9 .4 C ) + 1 4 0 F (+ 6 0 C ) + 1 5 F (9 .4 C )
D is c h a r g e D is c h a r g e D is c h a r g e D is c h a r g e
2 p s id 5 p s id 2 p s id 5 p s id
3 4
/ "** (20) 17 27 6.1 9.5 88 27 32 12
1" (25) 31 49 11 17 160 49 58 22
1 4
1/" (32) 44 69 16 24 224 68 81 31
11/2" (40) 94 147 33 52 479 146 173 66
2" (50) 126 197 45 70 643 196 232 89
21/2" (65) 206 323 73 115 1054 321 380 146
3" (80) 279 437 99 155 1424 434 513 197
4" (100) 445 698 158 241 Hot gas bypass capacities are based on above given temperatures.
Liquid temperature is the same as condensing temperature.
5" (125) 649 1017 230 361
Evaporator temperature +40F (+4.4C) or less for +86F (+30C)
6" (150) 1108 1735 393 616 condensing; 22F (30C) evaporator for +15F (9.4C) condensing.

= Bypass from intermediate pressure at saturation temperature to booster suction.

* These capacities are not for hot gas defrost relief. See the chart in the middle of this page.
** Optional 25% and 50% reduced capacity " (20 mm) plugs are available.
Discharge gas capacities are based on +15F (+10C) evaporator temperature.
R429d
5 MAR 2002
 CONTROL MODULES (PILOTS) FOR ANY REGULATOR
When installed, these control modules (pilots) enable RESEATING RELIEF
the main regulator to perform different control Opens wide when pressure exceeds
functions (see page 3, Regulator Variations). Pilots pressure setting and repeatedly reseats
are normally factory installed, but can be retrofitted after operation. Defrost relief or high-
or interchanged in the field. The nonrising stem can to-low system relief. Set and tagged. The
be adjusted by using a " wrench. Catalog standard setting for ammonia defrost is
numbers are for the screw-on pilot module. 70 psig (4.8 bar). Range A, 0 to 150 psig
Interchangeable with Danfoss PM Series, (0 to 10 bar), Part 75-1103; or Range B,
size permitting. 30 to 300 psig (+2 to 21 bar), Part Number
75-1104. Catalog M3K.

Compact welded pressure pilot. Range

INLET PRESSURE A, 0 to 150 psig (0 to 10 bar), Part 75-1127. M3K
Opens as inlet pressure rises. Range: A, Standard on valve sizes " to 1".
0 to 150 psig (0 to 10 bar), Part 75-1097; Catalog M3KW.
or B, 30 to 300 psig (2 to 21 bar), Part M3
75-1098. Also, Range V, 20" to 130 psig
(0.67 to +9 bar), Part 75-1099. Catalog M3. SOLENOID
Normally closed. Opens wide when
Compact welded pressure pilot. Range
energized. Requires coil. See page 2
A, 0 to 150 psig (0 to 10 bar), Part 75-1126.
for coil selection. Less coil: Part
Standard only on valve sizes " to 1".
70-1052, Catalog MS.
Catalog M3W.
MS

ELECTRONICALLY
CONTROLLED
M3W
Mounted electronic actuator changes the
pressure set point in conjunction with a
OUTLET PRESSURE controller and temperature sensor for
Opens as outlet pressure drops. For hot either air or liquid. Very precise. See page
gas bypass to suction or for controlled 12 for the control package which includes
supply pressure of defrost hot gas. Also the necessary controller and sensor.
used for compressor suction pressure Range: J1, 0 to 85 psig (0 to 6 bar), Part
limiting (crankcase pressure regulator). 27B1140; or J2, 25 to 115 psig (1.7 to 8 bar),
Part 27B1141. Catalog M3J. M3J
" NPT connections for outlet pressure
gauge and sensing line (tubing not
included). Range B, 30 to 300 psig (2 to
21 bar), Part 75-1101; or Range V, 20" to TEMPERATURE OPERATED
130 psig (0.67 to +9 bar), Part 75-1100. Bulb opens the control module on
Catalog M3O, specify range. M3O
temperature rise to maintain a constant
temperature. Part 27B1110 with a range
of 40F to +30F (40C to 0C) or Part
27B1111 with a range of +15F to +75F
DIFFERENTIAL PRESSURE
(10 to +25C). Catalog M3T.
Maintains set-for differential between
inlet and outlet or other pressure source.
For pump relief or any differential M3T
control. " NPT connection for pressure
sensing line (tubing not included). Range EXTERNAL CONNECTION
A, 0 to 150 psi (0 to 10 bar) difference, Enables a remote pressure source to be
Part 75-1081, Catalog M3L. introduced to the control via a pilot line
(replaces a pilot). " NPT with separate
M3L
4" (100 mm) long weld nipple, Part
35-1015, Catalog M3E25. M3E25

BLANKING PLUGS
To be used in a control module port when
PNEUMATICALLY the port is not utilized. Stopping plugs
COMPENSATED have square head and are marked with M3S
Air or other pressure in the bonnet raises 0 (75-1063). Straight through flow plugs
inlet pressure on a 1:1 ratio. " NPT have a hex head and are marked with
connection. Range A, 0 to 150 psig (0 1 (75-1064). Catalog M3S (stopping)
to 10 bar), Part 75-1081, Catalog M3P. M3P or M3B (straight through). M3B
R429d
MAR 2002 6
 MAIN REGULATORS ONLY (AR1, AR3)

Hansen regulators are normally furnished with control " through 6" " through 4"
modules (pilots) installed and tested (see page 3). (20 mm through (20 mm through
However, modular regulators less pilots and flanges 150 mm) 100 mm)
are available on order from " to 6" (20 mm to
150 mm). Each AR1 and AR3 includes flange gaskets,
nuts and bolts, and a plugged " FPT outlet pressure
access port. The access port is for connecting outlet
or differential control module sensing lines or gauges.

AR1 is the main regulator body with ONE control

module (pilot) port, control module not included.

AR3 is the main regulator body with THREE control

module (pilot) ports, for a maximum of three control 5" & 6"
modules, not included. The 5" and 6" (125 mm and (125 mm and 150 mm)
150 mm) AR3 regulators have a single control module
port with connection points for up to three total
ports via mounted pilot piping.

TO ORDER: (Main Regulators only) Specify port

size and catalog number (AR1 or AR3).

AR1 AR3

OPERATION OF REGULATORS
The regulator adapter (top cover) is available with
one control module port or three control module
ports. One control module port is often used for a
solenoid valve or a single pressure regulator. Three
control module ports are often used for a dual
regulator and other multiple function variations.

When the modular regulator has three control module

ports, two are in series (SI and SII) and one is in
parallel (P). Inlet pressure enters the internal
equalization passage and goes to both the P port
and the SI port. Inlet pressure enters the SII when
the control module SI port is open. When the control
module in the SI and SII port or the P port is open,
pressure enters the space above the piston which
forces the main valve seat to open and regulate
flow.
R429d
7 MAR 2002
HA4A STANDARD REGULATOR HA4AK RESEATING RELIEF
REGULATOR

OPERATION
(Same as HA4A) Inlet pressure is channeled through
the internal equalization passage to the reseating
relief control module. When inlet pressure exceeds
the relief setting, the control module opens wide to
allow pressure to enter the space on top of the
piston. This causes the main valve seat to open and
relieve the inlet pressure, provided the outlet pressure
is at least 2 psi (0.14 bar) lower. A 5 psid (.35 bar)
closing spring is standard on " through 1" valves.
See page 6 for M3K pilot details.

When used for defrost relief from low side to an

intermediate pressure, a check valve on the outlet is
required to prevent back flow during refrigeration.

ADJUSTMENT
The control module is nonadjustable, factory-set
and sealed. Available in Range A, 0 to 150 psig (0 to
OPERATION 10 bar); or Range B, 30 to 300 psig (2 to 21 bar).
Inlet pressure is channeled through the internal
equalization passage to the inlet pressure control
module. The valve modulates open when inlet HA4AL DIFFERENTIAL PRESSURE
pressure exceeds the pressure setting on the control REGULATOR
module. The gas or liquid passes through the inlet
pressure control module to enter the space on top OPERATION
of the piston, which forces the main valve seat to Inlet pressure is
open and regulate flow. As inlet pressure increases, channeled through the
the main valve seat opens further to maintain the internal equalization
selected inlet pressure. A minimum pressure passage to the
difference of 2 psi (0.14 bar) is adequate to fully differential pressure
open the main valve. When inlet pressure decreases control module. Outlet
below the pressure setting on the control module, pressure (or other) is
the closing spring will cause the main valve seat to introduced to the space
throttle closed. on top of the differential
pressure control module
diaphragm via an
ADJUSTMENT external sensing tube. A
Connect a pressure gauge via a gauge valve at the range spring on the top
gauge port on the regulator adapter. Set the control of the control module
module range spring at minimum force (control diaphragm allows the control of the differential
module stem turned counterclockwise). Operate the between inlet and outlet pressure. Increased range
refrigeration compressor system and achieve spring force increases the differential setting. Inlet
approximate desired suction pressure. Turn the pressure, counteracted by the range spring plus
control module stem clockwise until a slight increase outlet pressure, enters the space on top of the piston
in inlet pressure is detected by the gauge. The inlet which forces the main valve seat to open and regulate
pressure setting can now be increased by turning flow. The external sensing tube on the 5" & 6" valves
the control module stem clockwise or decreased by must be customer supplied and field installed.
turning it counterclockwise. The system should be
allowed to operate for a period of time before the ADJUSTMENT
final adjustment is made. The inlet pressure control Connect a pressure gauge via a gauge valve at the
module is available in Range A, 0 to 150 psig (0 to gauge port on the regulator adapter for the inlet
10 bar); or Range B, 30 to 300 psig (2 to 21 bar). A pressure reading. A pressure gauge downstream is
vacuum Range V, 20" to 130 psig (0.67 to +9 bar) is also required. With the control module range spring
also available. force at the minimum (control module stem turned
fully counterclockwise, at this point pressure
differential is at minimum), slowly turn the control
module stem clockwise until the desired pressure
difference between the two gauges is achieved. A
final adjustment should be made after system has
operated for a period of time. The system must be
capable of generating the desired pressure difference
for the regulator to open. Range A, 0 to 150 psig (0
to 10 bar).
R429d
MAR 2002 8
HA4AO OUTLET PRESSURE HA4AS REGULATOR WITH ELECTRIC
REGULATOR SHUT-OFF

OPERATION OPERATION
Outlet pressure is When the solenoid
channeled through an control module is
external sensing tube to energized, this
the outlet pressure control control operates in
module. The outlet the same manner as
pressure is introduced to the HA4A Standard
the space under the Regulator or other
control module pilot functions. When
diaphragm. When outlet de-energized, valve
pressure decreases below closes tight to stop
the outlet pressure setting flow in direction of
the range spring forces arrow regardless of
the control module to pressure setting on
open further. As the control module opens, more the control module.
inlet pressure enters the space on top of the piston
forcing the main valve seat to open further and ADJUSTMENT
regulate flow. As outlet pressure rises the control Energize the solenoid control module and follow
module reduces the inlet pressure to the piston and the control module adjustment procedures for the
the main valve seat starts closing. The external HA4A Standard Regulator. See page 10.
sensing tube on the 5" & 6" valves must be customer
supplied and field installed. A 5 psid (.35 bar) closing
spring is standard on " through 1" valves. A
lighter spring is available for applications where a
low pressure drop is required, such as holdback or
crankcase pressure regulators.
HA4AD DUAL PRESSURE
ADJUSTMENT
Connect a pressure gauge via a gauge valve to the
REGULATOR
outlet gauge port located on the outlet pressure
control module or the pipe after the regulator. With OPERATION
the control module range spring at minimum force When the solenoid
(control module stem turned counterclockwise) control module is
operate the refrigeration compressor. Turn the control energized, this valve
module stem clockwise until the desired outlet operates in the same
pressure is achieved. Ranges available: B, 30 to manner as the HA4A
300 psig (2 to 21 bar); or vacuum range V, 20" to 130 Standard Regulator
psig (0.67 to +9 bar). or other pilot
functions. When the
solenoid control
HA4AB REGULATOR WITH ELECTRIC module is de-
WIDE OPENING energized, the inlet
pressure is chan-
OPERATION neled to the higher-setting inlet pressure control
When the solenoid module and operates in the same manner as the
control module is HA4A regulator. When inlet pressure rises above
de-energized, this the higher setting, the control module opens to allow
control operates in inlet pressure to enter the space on top of the piston
the same manner as which forces the main valve seat to open and regulate
the HA4A Standard flow. Typically used as a combined evaporator
Regulator or other pressure regulator and defrost internal relief valve.
pilot functions.
When energized, ADJUSTMENT
inlet pressure Connect a pressure gauge via a gauge valve at the
bypasses the gauge port on the regulator adapter. With the solenoid
constant pressure control module de-energized, adjust the constant
control module and enters the space on top of the pressure control module in the P port for the high-
piston which forces the main valve seat to open pressure setting. This may require a warm room or
wide to permit flow in the direction of arrow. hot gas supply to the evaporator. Then, energize the
solenoid control module located on the series SI port
ADJUSTMENT and adjust the constant pressure module in the series
With solenoid control module de-energized, follow SII port for the low-pressure setting. For control module
adjustment procedures for the HA4A Standard adjustment, follow the adjustment procedures for the
Regulator. See page 10. HA4A Standard Regulator. See page 10.
R429d
9 MAR 2002
HA4AP PNEUMATICALLY HA4AJ ELECTRONICALLY
COMPENSATED REGULATOR CONTROLLED REGULATOR

OPERATION OPERATION
A pneumatic controller regulates the amount of air The controller receives signals from an air or liquid
pressure applied to the top of the M3P control module sensor and transmits an electrical voltage to the
diaphragm. A rise in temperature sensed by the M3J electronic actuator control module. An increase
pneumatic controller reduces the air pressure to in temperature lowers the voltage to actuator, opening
the control module, allowing inlet pressure to enter the regulator to increase flow. A decrease in sensor
the space on top of the piston which forces the temperature increases the voltage from the controller
main valve seat to open and regulate flow. A decrease to the M3J electronic actuator control module closing
in sensed temperature increases the pressure of air the valve to reduce flow. This precision control can
to the M3P control module. This increase in air maintain temperatures within 1F (0.5C) of setting.
pressure reduces the opening at the M3P control The M3J electronic actuator control module must
module and restricts the flow of inlet pressure to be operated by one of the control packages below.
the piston, thus reducing the opening at the valve See page 6 for M3J pilot details.
main seat. See page 6 for M3P pilot details.
CONTROL PACKAGES
ECP This standard electronic control package
ADJUSTMENT consists of a controller, controller base,
Disconnect the air line to the M3P control module sensor, and transformer.
and follow the adjustment procedures for the HA4A
Standard Regulator. See page 10. This sets the low DDS This control package includes the standard
inlet pressure setting for the regulator. Connect the ECP components plus a digital temperature
air line back to the M3P control module. For every readout, set-for/actual temperature switch
1 psi (0.069 bar) of increase in air pressure, the to easily check temperature, assembled and
inlet refrigerant pressure setting increases 1 psi mounted on a metal back plate. To display
(0.069 bar). Adjust the controller as specified by the the set-for temperature, simply depress and
manufacturer. In lieu of air, low-pressure refrigerant hold the set-for/actual temperature switch.
or other fluid can be used for compensation. The When released, the digital readout will again
differential between inlet pressure and pressure to display the actual temperature at the sensor.
the M3P control module must not exceed 45 psi (3.1
bar). Range A, 0 to 150 psig (0 to 10 bar). DDL Same as the DDS with a minimum evaporator
pressure adjustment. This adjustment sets
an evaporator pressure floor independent
HA4AT TEMPERATURE of temperature. This is ideal to prevent too
cold of an evaporator surface in flooded
OPERATED REGULATOR evaporators or during loading of critical,
temperature-sensitive products.
OPERATION
Temperature changes are detected by the thermal WTE2 Watertight controller enclosure for the above
bulb. The expansion or contraction of the charge DD series control packages. This industrial-
inside the bulb and capillary tube is transferred grade enclosure is polycarbonate with clear
across the diaphragm in the M3T control module. A gasketed cover.
rise in temperature above the set-for temperature
opens the M3T control module and allows inlet EKA46 This computer interface is available for direct
pressure to enter the space on top of the piston connection of the electronic actuator control
which forces the main valve seat to open and regulate module to a plant computer, PLC, or other
flow. A decrease in temperature closes the M3T controlling device. Input to interface is a
control module which allows the piston to rise and regulated 420 mA or 0 to 10 volt signal
close the main valve seat. A reverse acting model is from an intelligent control device. The EKA46
also available: rising temperature closes the regulator, package includes interface module and
as for reheat. See page 6 for M3T pilot details. transformer.

ADJUSTMENT
ADJUSTMENT Set the desired temperature (REF) using both coarse
Connect a pressure gauge via a gauge valve at the and fine adjustments. Set the alarm limits (LIM) on
gauge port on the regulator adapter. Place a deviation from the desired temperature, +1C to +5C.
thermometer in the cooled medium. With the system Adjust the alarm delay timer (DEL) to delay alarm
operating, set the M3T regulator control module to release from 10 to 60 minutes. Both Proportional
the desired temperature by turning the adjustment amplification (Kp) and Integration time (Tn) are factory
ring clockwise to lower opening temperature or set to 4. Consult the instruction manual or contact
counterclockwise to increase opening temperature. the factory if adjustment is necessary. See the
One turn is equivalent to a change of approximately instructions supplied with the EKA46 for its
11F (6.1C). Tighten the locking ring after the final adjustment recommendations. M3J electronic actuator
adjustment has been made. Range 40F to +30F control module ranges: J1, 0 to 85 psig (0 to 6 bar);
(40C to 0C); or +15F to +75F (10C to +25C). or J2, 25 to 115 psig (1.7 to 8 bar).
R429d
MAR 2002 10
HA4AM ELECTRIC MOTOR
COMPENSATED REGULATOR

OPERATION
The regulator pressure setting is altered as the motor The basic Electric Motor Compensated Regulator
receives a signal from a suitable temperature consists of a nonremovable control module with a
controller. The motor responds to maintain the motor bracket and cam. The control module is
balance in the electrical circuit. The rotation of the available in either Range A, 0 to 150 psig (0 to +10
motor is transmitted through a cam, valve stem, bar); or Range V, 20" to 130 psig (0.67 to +9 bar).
and range spring to the top of the control module The motor bracket comes mounted on the control
diaphragm. An increase in temperature decreases module and is suitable for use with either PENN
the range spring force on top of the control module (standard) or HONEYWELL motors. Two cams are
diaphragm. This decrease in force on the diaphragm available: Low Rise (standard) and High Rise. The
allows inlet pressure to pass through the control table below indicates the pressure change possible
module to enter the space on top of the piston which for each cam and motor combination.
forces the main valve seat open to reduce the
evaporator pressure. A decrease in temperature
PRESSURE CHANGE
causes an increase in the range spring force. This
RANGE CAM
restricts the flow of inlet pressure to the piston
PENN HONEYW ELL
causing a reduction in the opening of the main valve
seat, reducing regulator flow by raising the pressure LOW
45 psig (3.1 bar) 30 psig (2.1 bar)
setting. RISE
A or V
HIGH
90 psig (6.2 bar) 60 psig (4.1 bar)
RISE
APPLICATIONS
This motor compensated regulator is popular for
fruit storage, precision air temperature control, and The PENN motor (standard) has 270 of rotation
liquid chiller control. travel and the HONEYWELL motor has 160 of rotation
travel. Motors are available for either 135 ohm or
420 mA control signal input and require 24 VAC
ADJUSTMENT power input. Electric proportional thermostat
Adjust the temperature controller as specified by controllers (135 ohm output), electronic PID
the manufacturer. Fully open the regulator manually controllers (420 mA output) with sensor, and 24V
by turning in (clockwise) the manual-opening stem transformers are available accessories.
to cool the product or room. Once the temperature
at the sensing device is approximately as desired,
adjust the controller output so that the cam is rotated
to the center position. Put regulator back in automatic
operation by turning the manual-opening stem out
(counterclockwise). Loosen the adjustment locking
nut. See the diagram to the right. Turn the adjustment
stem clockwise to raise the inlet pressure setting or
counterclockwise to lower the inlet pressure setting.
When the desired refrigerant pressure setting is
achieved, tighten the adjustment locking nut. A final
adjustment should be made after the system has
operated for a period of time.

Using a potentiometer slide wire type of controller

(typically 135 ohm), depending on product heat load,
a deviation from desired temperature of about +2F to
+5F (+1.1C to +2.8C) is normal to rotate the regulator
cam for maximum load satisfaction. As the load is
reduced or as the temperature becomes lower, the
cam rotates to create a higher evaporator pressure
just adequate to balance the load and maintain the
desired temperature, usually with 1F (0.5C). Other
controllers are available to operate the motor/cam
rotation.

R429d
11 MAR 2002
 INSTALLATION DIMENSIONS (MM)

" THROUGH 1" REGULATORS 1" THROUGH 4" REGULATORS

M = Additional length for close-coupled strainer

PORT SIZE L
H1 H2 H3 H4 L1 L2 L3 L4 M W*
(m m )
FPT,SW W N ,O D S
3 4
/ ", 1", 11/4" 3.09" 6.77" 3.75" 4.63" 8.20" 8.94" 6.19" 2.38" 4.07" 7.20" 3.70" 4.50"
(20, 25, 32) (78) (172) (95) (117) (208) (227) (157) (60) (103) (183) (94) (114)
11/2", 2" 2.87" 8.84" 4.90" 5.72" 12.39" 13.39" 9.88" 2.35" 4.04" 10.89" 9.83" 4.50"
(40, 50) (73) (225) (124) (145) (315) (340) (251) (60) (103) (277) (250) (114)
21/2" 3.62" 9.69" 5.57" 6.53" 13.01" 14.03" 9.88" 2.35" 4.04" 11.01" 9.83" 5.62"
(65) (92) (246) (141) (166) (330) (356) (251) (60) (103) (280) (250) (143)
3" 4.06" 10.00" 6.03" 6.88" 15.38" 16.40" 12.25" 2.35" 4.04" 13.38" 12.20" 6.50"
(80) (103) (254) (153) (175) (391) (417) (311) (60) (103) (340) (310) (165)
4" 4.69" 10.56" 6.58" 7.46" 17.01" 20.51" 14.12" 2.69" 4.38" 15.01" 14.07" 8.06"
(100) (119) (268) (167) (189) (432) (521) (359) (68) (111) (381) (357) (205)
*Maximum width of valve.
For ", 1", 1" valves add 3" (80 mm) to one side of the valve for external piping as found on HA4AO and HA4AL.
An alternate 4-bolt version of the 1" valve is available with face-to-face dimension (L1) same as R/S 1" for replacements.

P DIMENSION FOR CONTROL MODULES (MM)

CATALOG M3 M 3W MS M 3O M 3K M 3KW M 3L M 3P M 3J M 3T M 3E25 M 3M
Size 6.5" 5.12" 3.25" 7.75" 6.5" 5.12" 6.5" 6.5" 4.63" 4.5" 1" 14.9"
(mm) (165) (130) (83) (197) (165) (130) (165) (165) (118) (114) (25) (378)
The above dimensions do not include seal cap and solenoid coil removal height, or motor-access clearance.
M3E25 = Less 4" (100 mm) long weld nipple. M3M = Electric motor compensated control module with motor.
R429d
MAR 2002 12
 INSTALLATION DIMENSIONS (MM)
5" AND 6" REGULATORS

(See page 8.)

WELD END DIMENSIONS ( MM)

PORT SIZE A T

5" 5.05" 0.26"

(125) (128) (6.6)
6" 6.06" 0.28"
(150) (154) (7.1)

5" AND 6" PILOT PIPING (TOP VIEW)

FOR SERIES ARRANGEMENT (AS) FOR SERIES AND PARALLEL ARRANGEMENT (AD)
SI, solenoid; SII pressure pilot SI, solenoid; SII & P pressure pilots
R429d
13 MAR 2002
 PARTS LIST CONTROL MODULES

IT E M D E S C R IP T IO N QTY PART NO
D i a p h r a g m /G a s k e t K i t
75-1107
M3, M3K, M3L, M3P (M 3 , M 3 K , M 3 L , M 3 P )
Above Kit Consists of:
1 ...Diaphragm 1 75-0716
2 ...Lower Gasket (thick) 1 75-0426
3 ...Upper Gasket (thin) 1 75-0636
4 ...Follower O-ring 1 75-0337
5 ...Fiber Washer 1 75-0617
6 ...Lower Stem O-ring (green dot) 1 75-0520
7 ...Upper Stem O-ring 1 75-0521
8 ...Seal Cap O-ring 1 70-0011

* M3W and M3KW control modules are hermetically sealed,

welded assemblies having no replaceable internal parts.
See page 6 for replacement part numbers. Standard on
"1" (2032 mm) valves.

M3O IT E M D E S C R IP T IO N QTY PART NO

D i a p h r a g m /G a s k e t K i t ( M 3 O ) 75-1108
Above Kit Consists of:
1 ...Diaphragm 1 75-0716
2 ...Lower Gasket (thick) 2 75-0426
3 ...Upper Gasket (thin) 1 75-0636
4 ...Follower O-ring 1 75-0337
5 ...Fiber Washer 1 75-0617
6 ...Lower Stem O-ring (green dot) 1 75-0520
7 ...Upper Stem O-ring 1 75-0521
8 ...Seal Cap O-ring 1 70-0011
9 ...Cartridge O-ring 1 75-0496

MS
IT E M D E S C R IP T IO N QTY PART NO

Solenoid Tube/Plunger Kit (MS) 70-1059

Above Kit Consists of:
1 ...Coil Washer 1 70-0289
2 ...Coil Nut 1 70-0281
3 ...Plunger 1 70-0295
4 ...Solenoid Tube 1 70-0298
5 ...Solenoid Tube Gasket 1 70-0301
6 ...Tube Screws 4 70-0297

R429d
MAR 2002 14
 PARTS LIST " THROUGH 1" (20 MM THROUGH 32 MM)

ITEM DESCRIPTION QTY PART NO ITEM DESCRIPTION QTY PART NO

Piston Kit consists of: 75-1019 Gasket Kit consists of: 75-1023
1 ...Piston 1 75-0191 4 ....Adapter Gasket 1 75-0489
2 ...Piston Seal 1 75-0353 6 ....Bottom Cap O-ring 1 75-0183
4 ...Adapter Gasket 1 75-0489 7 ....Stem O-ring 1 70-0010
20 ...Flange Gasket 2 70-0132 8 ....Stem Washer 1 70-0026
9 ....Stem Packing 1 70-0025
V-Port/Seat Kit "* 75-1020 10 ....Packing Nut 1 70-0019
V-Port/Seat Kit 1"* 75-1021 13 ....Seal Cap O-ring 1 70-0011
20 ....Flange Gasket 2 70-0132
V-Port/Seat Kit 1"* 75-1022
....Solenoid Tube Gasket 1 70-0301
Above kits consist of: ....Port Gasket & O-ring 3 75-1071
3a ...3/4" V-Port/Seat 1 75-0194
3b ...1" V-Port/Seat 1 75-0193 11 Manual-Opening Stem 1 75-0164
3c ...11/4" V-Port/Seat 1 75-0192 12 Seal Cap 1 50-0411
5 ...Closing Spring 1 75-0287 14 Gauge Port Plug (1/4" NPT) 1 75-0189
6 ...Bottom Cap O-ring 1 75-0183 15a Adapter, 1 Port 1 75-0163
15b Adapter, 3 Port 1 75-0162
16 Adapter Bolts, socket cap 4 75-0190
*HA4AK AND HA4AO V- POR T/ SEAT KITS 17 Bottom Cap 1 75-0155
DESCRIPTION PART NO 18a Body 3/4", 1" 1 75-0156
18b Body 11/4", 2-Bolt 1 75-0154
V-Port/Seat Kit 3 /4 " 75-1129
19 Flange (Various) 2 FACTORY
V-Port/Seat Kit 1" 75-1130
21 Flange Bolt (5/8"-11x2.75") 4 70-0339
V-Port/Seat Kit 11 /4 " 75-1131 Flange Nut (5/8"-11) 4 70-0136
Above kits contain V-Port/Seat, bottom cap O-ring, and a
5 psid (.35 bar) closing spring (Part 75-0622). A lighter
spring is available (Part 75-0287).
R429d
15 MAR 2002
 PARTS LIST 1" THROUGH 4" (40 MM THROUGH 100 MM)

ITEM DESCRIPTION QTY. PART NO ITEM DESCRIPTION QTY PART NO

Piston Kit 1", 2" 75-1025 Gasket Kit 1", 2" 75-1039
Piston Kit 2" 75-1026 Gasket Kit 2" 75-1040
Piston Kit 3" 75-1027 Gasket Kit 3" 75-1041
Piston Kit 4" 75-1028 Gasket Kit 4" 75-1042
Above kits consist of: Above kits consist of:
1a ...Piston 11/2", 2" 1 75-0168 3a ...Adapter Gasket 11/2", 2" 1 75-0113
1b ...Piston 21/2" 1 75-0169 3b ...Adapter Gasket 21/2", 3" 1 75-0093
1c ...Piston 3" 1 75-0159 3c ...Adapter Gasket 4" 1 75-0233
1d ...Piston 4" 1 75-0278 6a ...Seat Seal O-ring 11/2", 2" 1 75-0274
2a ...Piston Seal 11/2", 2" 1 75-0292 6b ...Seat Seal O-ring 21/2" 1 75-0275
2b ...Piston Seal 21/2", 3" 1 75-0293 6c ...Seat Seal O-ring 3", 4" 1 75-0276
2c ...Piston Seal 4" 1 75-0236 9a ...Back-Up Washer 11/2" through 3" 1 75-0245
3a ...Adapter Gasket 11/2", 2" 1 75-0113 9b ...Back-Up Washer 4" 1 50-0351
3b ...Adapter Gasket 21/2", 3" 1 75-0093 10a ...Stem O-ring 11/2" through 3" 1 50-0179
3c ...Adapter Gasket 4" 1 75-0233 10b ...Stem O-ring 4" 1 50-0253
23a ...Flange Gasket 11/2", 2" 2 75-0138 11a ...Stem Washer 11/2" through 3" 1 50-0046
23b ...Flange Gasket 21/2" 2 75-0125 11b ...Stem Washer 4" 1 50-0247
23c ...Flange Gasket 3" 2 75-0137 12a ...Stem Packing 11/2" through 3" 1 50-0045
23d ...Flange Gasket 4" 2 75-0253 12b ...Stem Packing 4" 1 50-0248
13a ...Packing Nut 11/2" through 3" 1 50-0013
13b ...Packing Nut 4" 1 50-0251
V-Port/Seat Kit 1" 75-1029 14a ...Seal Cap O-ring 1 50-0432
V-Port/Seat Kit 2" 75-1030 14b ...Seal Cap Gasket 1 50-0270
V-Port/Seat Kit 2" 75-1031 15a ...Stem Pin 11/2" through 3" 1 75-0173
15b ...Stem Pin 4" 1 75-0434
V-Port/Seat Kit 3" 75-1032
23a ...Flange Gasket 11/2", 2" 2 75-0138
V-Port/Seat Kit 4" 75-1033 23b ...Flange Gasket 21/2" 2 75-0125
Above kits consist of: 23c ...Flange Gasket 3" 2 75-0137
4a ...V-Port/Seat 11/2" 1 75-0369 23d ...Flange Gasket 4" 2 75-0253
4b ...V-Port/Seat 2" 1 75-0177 ...Solenoid Tube Gasket 1 70-0301
...Port O-ring and Gasket 3 75-1071
4c ...V-Port/Seat 21/2" 1 75-0178
4d ...V-Port/Seat 3" 1 75-0179
4e ...V-Port/Seat 4" 1 75-0313
3a ...Adapter Gasket 11/2", 2" 1 75-0113 18a Adapter, 1 Port 11/2", 2" 1 75-0060
3b ...Adapter Gasket 21/2", 3" 1 75-0093 18b Adapter, 3 Port 11/2", 2" 1 75-0384
18c Adapter, 1 Port 21/2", 3" 1 75-0056
3c ...Adapter Gasket 4" 1 75-0233
18d Adapter, 3 Port 21/2", 3" 1 75-0493
6a ...Seat Seal O-ring 11/2", 2" 1 75-0274
18e Adapter, 1 Port 4" 1 75-0334
6b ...Seat Seal O-ring 21/2" 1 75-0275
18f Adapter, 3 Port 4" 1 75-0801
6c ...Seat Seal O-ring 3", 4" 1 75-0276
19 Gauge Port Plug (1/4" NPT) 1 75-0189
7 ...Seat Screw 1 75-0220
20a Adapter Bolts 11/2", 2" 4 75-0175
8a ...Closing Spring 11/2", 2" 1 75-0171
20b Adapter Bolts 21/2", 3" 4 65-0057
8b ...Closing Spring 21/2" 1 75-0201
20c Adapter Bolts 4" 4 75-0291
8c ...Closing Spring 3" 1 75-0248
21a Body 11/2", 2" 1 75-0016
8d ...Closing Spring 4" 1 75-0235
21b Body 21/2" 1 75-0018
21c Body 3" 1 75-0019
5a Seat Ring 11/2", 2" 1 75-0084 21d Body 4" 1 75-0215
5b Seat Ring 21/2" 1 75-0170 22 Flange (Various) 2 FACTORY
5c Seat Ring 3" 1 75-0071 24a Flange Bolt 11/2", 2" 8 70-0135
5d Seat Ring 4" 1 75-0231 24b Flange Bolt 21/2", 3" 8 75-0202
16a Manual-Opening Stem 24c Flange Bolt 4" 8 75-0279
..11/2" through 3" 1 75-0079 25a Flange Nut 11/2", 2" (5/8"-11) 8 70-0136
16b Manual-Opening Stem 4" 1 75-0427 25b Flange Nut 21/2", 3" (3/4"-10) 8 75-0210
17a Seal Cap 11/2" through 3" 1 75-0139 25c Flange Nut 4" (7/8"-9) 8 75-0280
17b Seal Cap 4" 1 50-0260
R429d
MAR 2002 16
PARTS LIST 1" THROUGH 4" (40 MM THROUGH 100 MM)

R429d
17 MAR 2002
 PARTS LIST 5" AND 6" (125 MM AND 150 MM)

IT E M D E S C R IP T IO N QTY PART NO IT E M D E S C R IP T IO N QTY PART NO

P is to n K it 7 5 -1 1 1 0 V-Port/Seat Kit 5" 7 5 -1 1 1 2
Above Kit consists of: V-Port/Seat Kit 6" 7 5 -1 1 1 3
1 ...Piston 1 75-0570 Above Kits consist of:
2 ...Piston Seal 1 75-0602 5a ...V-Port/Seat 5" 1 75-0640
3 ...Adapter O-ring, Inner 1 75-0605 5b ...V-Port/Seat 6" 1 75-0641
4 ...Adapter O-ring, Outer 1 75-0606 3 ...Adapter O-ring, Inner 1 75-0605
4 ...Adapter O-ring, Outer 1 75-0606
G a s k e t K it 7 5 -1 1 1 1 7 ...Seat Seal O-ring 1 75-0613
Above Kit consists of: 8 ...Seat Screw (1/4"-20 x 1/2") 1 75-0220
3 ...Adapter O-ring, Inner 1 75-0605 9 ...Closing Spring 1 75-0601
4 ...Adapter O-ring, Outer 1 75-0606
7 ...Seat Seal O-ring 1 75-0613 6 Seat Ring 1 75-0558
10 ...Back-up Washer 1 50-0324 17 Manual-Opening Stem 1 75-0581
11 ...Stem O-ring 1 50-0293 18 Seal Cap 1 50-0304
12 ...Stem Washer 1 50-0299 19a Adapter, 1 Port 1 75-0554
13 ...Stem Packing 1 50-0290 19b Adapter (1 Port) with Plugged
14 ...Packing Nut 1 50-0292 Access Holes for Mutiple Pilots 1 75-0720
15 ...Seal Cap Gasket 1 50-0315 20 Gauge Port Plug 1 75-0189
16 ...Manual-Opening Stem Pin 1 75-0607 21 Adapter Bolts 8 75-0604
...Solenoid Tube Gasket 1 70-0301 22a Body, 5" 1 75-0542
...Port O-ring and Gasket 3 75-1071 22b Body, 6" 1 75-0541
R429d
MAR 2002 18
SERVICE AND MAINTENANCE Remove burrs and nicks, clean or replace piston as
Failure to open: Wrong coil or control module necessary. Long-life seal on disc piston need only
pilot; low line voltage; controlling switch or thermostat be replaced when damaged or severely worn. If
not contacting; coil is burned-out; adjacent shut-off replacing the disc piston seal, make sure the seal is
valve closed; adapter gasket hole not aligned with properly installed, with the edge up, and does not
hole in body and adapter; dirt packed under Teflon twist during installation. These valves also have
seal ring enabling excessive blow by; large quantity a removable stainless steel main valve seat. To
of dirt particles in solenoid module passages; dirt remove seat ring for inspection, first remove small
blocking internal pilot passages; main valve seat is hex head seat screw. Turn the seat ring
dirt jammed. counterclockwise by turning it out with a wrench
and a steel bar tool positioned horizontally or by
Failure to close: Controlling switch or thermostat carefully tapping the seat ring notch with a punch
not opening contacts; manual-opening stem is turned and a hammer. Inspect the V-port/seat and main
in; valve installed in wrong direction; damage or valve seat for nicks, marks, and divots. The main
dirt at main valve seat or pilot seat; piston bleed valve seat may be lapped by hand or power drill to
hole plugged. Under extreme conditions of liquid or remove marks. Grease and replace the seat seal
oil slugging or pressure drops exceeding 45 psi O-ring. Clean and polish, or replace the parts as
(3.1 bar), special construction may be required. necessary. If necessary, the V-port tapered seat may
Contact the factory. be reconditioned by removing up to 0.04" (1 mm) of
Teflon from it on a lathe. Lightly lubricate all parts
Before opening the regulator or disassembling and gaskets with a soft rag containing refrigerant
the pilot for service, be sure it is isolated oil. Align the hole in the valve body, adapter gasket,
from the system and all refrigerant is removed and adapter to assure proper operation. Reassemble
(pumped out to zero pressure). Follow usual the valve. Carefully check the entire valve for leaks
refrigeration system safe servicing procedures. Read before restoring it to service.
the CAUTION section of this bulletin on page 20.
MANUAL OPENING
To check solenoid pilot section of valve, disconnect The manual-opening stem is designed to open the
the electrical coil. Unscrew the coil nut and remove valve, allowing upstream and downstream pressures
washer. Lift coil housing away from valve. Remove to equalize when needed for servicing, but not
the four solenoid tube screws and remove solenoid necessarily to create a full-flow condition. The stem
tube from valve. Inspect for dirt and damage to Teflon is located on the top of the adapter cover. Slowly
seat and stainless steel pilot orifice. Clean, polish remove the seal cap from the manual-opening stem,
or replace parts as necessary, then reassemble. being cautious to avoid any refrigerant which may
have collected under the cap. Using an appropriate
" through 1" (20 mm through 32 mm): Use
wrench, turn the stem in (clockwise) to open the
a 3/ 8" male hexagon wrench to loosen the four adapter
valve manually; counterclockwise to return the valve
bolts, proceeding slowly to avoid refrigerant which
to automatic operation. Do not leave the stem partially
may still remain in the valve. If piston parts are
open because it may be dynamically damaged.
stuck, remove the 2" hex bottom cap in order to
separate the valve V-port/seat from the disc piston.
Inspect disc and piston bore for burrs, nicks, and ABBREVIATIONS
other damage. Remove burrs and nicks, clean or BW: Butt Weld end to match American Pipe
replace disc piston and Teflon seal ring as necessary. Schedule 40
Long-life seal on disc piston need only be replaced CRN: Canadian Registration Number
when damaged or severely worn. If replacing the CSA: Canadian Standards Association
disc piston seal, make sure the seal is properly Cv: Valve capacity factor GPM (U.S.) of water at 1
installed, with the edge up, and does not twist psi differential
during installation. Inspect V-port/seat and main valve FPT: Female Pipe Thread, American National Standard
seat for nicks, marks, etc. The main valve seat may Kv: Valve capacity factor m 3/hr of water at 1 bar
be lapped by hand or power drill to remove marks. differential
Clean, polish or replace parts as necessary. If mA: milliampere
necessary, the V-port tapered seat may be MPT: Male Pipe Thread, American National Standard
reconditioned by removing up to 0.04" (1 mm) of NEMA: National Electrical Manufacturers
Teflon from it on a lathe. Lightly lubricate all parts Association: Class 4, watertight, approximate
and gaskets with soft rag containing refrigerant oil. equivalent to IP65; Class 1, general purpose,
Align hole in valve body, adapter gasket, and adapter approximate equivalent to IP20
to assure proper operation. Reassemble valve. Carefully NPT: National Pipe Thread
check valve for leaks before returning it to service. ODS: Outside Diameter Sweat, for copper tubing
PLC: Programmable Logic Controller
1" through 6" (40 mm through 150 mm): psig: Pounds per square inch, gauge
Loosen adapter bolts using a 12" adjustable wrench R/S: Refrigerating Specialties Division, Parker
(15" wrench for 5" and 6" valves), being careful to Hannifin Corp.
avoid any refrigerant which may still remain in the SPDT: Single Pole Double Throw
valve. If disc piston is difficult to remove, insert a SW: Socket Weld to accommodate American and API pipe
"-20 threaded screw ( 3/ 8 "-16 for 5"& 6" valves) into WN or Weld: Weld Neck to match American Pipe
center of piston and lift straight-up. Inspect piston Schedule 40
and piston bore for burrs, nicks and other damage.
R429d
19 MAR 2002
CAUTION ORDERING INFORMATION, HA4A
Hansen pressure regulators are only for refrigeration MODULAR PRESSURE REGULATORS
systems. These instructions and related safety F L A N G E C O N N E C T IO N
precautions must be read completely and understood PORT S T Y L E S & S IZ E S
S IZ E
before selecting, using, or servicing these valves. FPT, SW, WN ODS
(m m )
Only knowledgeable, trained refrigeration technicians STD ALSO STD
should install, operate, or service these valves. Stated = 3/4" 3
(20) /4" 1", 11/4" 7
/8"
temperature and pressure limits should not be 3/4", 11/4"
1" (25) 1" 11/8"
exceeded. Adapters, bottom cap, control modules,
11/4" (32) 11/4" 3/4", 1" 13/8"
etc., should not be removed from valves unless
11/2" (40) 11/2" 2" 15/8"
system has been evacuated to zero pressure. See
also Safety Precautions in the current List Price 2" (50) 2" 11/2" 21/8"
Bulletin and the Safety Precautions Sheet supplied 21/2" (65) 21/2" 3" 25/8"
with the product. Escaping refrigerant can cause 3" (80) 3" 31/8"
injury, particularly to the eyes and lungs. 4" (100) 4" 41/8"
5" (125) 5" BW
WARRANTY 6" (150) 6" BW
All Hansen Technologies products, except electric 5" & 6" are type HA4W with integral butt weld end only.
motors and electronic items, are warranted against 1" is standard 2-bolt flange design; 4-bolt flange style
defects in workmanship and materials for a period available upon request to field replace 1" R/S.
of one year F.O.B. our plant. Electric motors and =25% and 50% Reduced Capacity Plugs are also available.
electronic items are warranted against defects for
90 days. No consequential damages or field labor is
included. TO ORDER: Specify type, connection style and size,
range, voltage for coil, and close-coupled strainer if
REGULATOR ACCESSORIES required. The strainer is a separate stainless steel
STRAINERS 60 mesh unit which usually connects directly to the
Generous capacity, separate, close-coupled, regulator inlet. Optional pilot lights are available in
60 mesh (233 Micron Rating), accessible. green, red, and amber. Please specify color and
GAUGES voltage when ordering the valve.
Pressure gauges have 3" (90 mm) diameter
faces, safe plastic lenses, " NPT connection, TYPICAL SPECIFICATIONS
and recalibration features. Available for Refrigerant pressure regulators shall be pilot-
ammonia and halocarbon. operated, with disc-type pistons having Teflon seals,
GAUGE VALVES manual-opening stems, equipped with removable pilot
HGV1 Long Neck Gauge Valve, Seal Cap, modules, Teflon main seats and stainless steel pilot
" MPT x FPT. trim and optional, close-coupled inlet strainers, as
PILOT LIGHTS manufactured by Hansen Technologies Corporation
(specify voltage) or approved equal.
Pilot Light with NEMA 1 Box
(green, red, or amber light) OTHER PRODUCTS
Watertight Pilot Light assembly with NEMA 4 box. Small Pressure Regulators and Reliefs
(green, red, or amber light) Gauge, Purge, and Needle Valves
Shut-Off Valves
Hand Expansion Valves (Regulators)
Refrigerant Solenoid Valves
CONVERSIONS Refrigerant Check Valves
1" (inch) = 25.4 mm Gas-Powered Valves
1F = 5/ 9 C Refrigerant Float Switches
Temperature in F = 1.8C + 32 Float Drain Regulators
Temperature in C = 5/ 9 (F 32) Refrigerant Liquid Pumps
1 psi = 0.06895 bar = 6.895 kPa AUTO-PURGER s
Cv (U.S. GPM) = Kv multiplied by 1.156 Vari-Level Adjustable Level Controls
1 U.S. Gallon = 0.8327 Imperial Gallons = 3.7854 Techni-Level Transducer Probes
liters Frost Master Defrost Controllers
1 U.S. GPM (gallons per minute) = 0.06309 dm 3 /s Pressure-Relief Valves
(or L/s) = 0.227124 m 3/hr
1 American Standard Commercial Ton of
Refrigeration = 12000 Btu/h = 3024 kcal/h = 3.517 kW

6827 High Grove Boulevard

Burr Ridge, Illinois 60527 USA
Tel: (630) 325-1565 Fax: (630) 325-1572
Toll: (800) 426-7368 http://www.hantech.com
2004 Hansen Technologies Corporation
R429d
MAR 2002 20
 Bulletin G209h
May, 2000

Specifications, Applications,
Specifications, Applications,
Service Instructions & Parts
Service Instructions & Parts

SOCKET WELD
Pump Guardian
SHUT-OFF VALVES
PUMP CONTROLLER

" through 2"*

for(13 mm through
Refrigerant 65 mm)
Recirculator
Globe and
Packages, Angle
Accumulators,
for Refrigerants
Receivers, and Intercoolers
* 2" (50 mm) to 16" (400 mm) available as butt weld
KEY FEATURES ISO 9002

2" Globe Valve: GS200H

POLISHED
STAINLESS
NON-LEAK STEEL STEM
SEAL PLUS
INTRODUCTION PACKING
The advanced design and materials of the Hansen
Steel Body Socket Weld Refrigerant Valves make
them stronger and far superior to other commonly
available products. This is especially true in regard
to leakage from seats, stems, bonnets, and piping
connections. Socket weld steel bodies permit these
valves to be quickly and easily welded directly into BALL BACK SEAT
piping without the inconvenience of pipe threading BEARINGS FOR SEAL
or using bulkier iron-flanged valves with socket REPLACEMENT
weld steel flanges requiring bolts, nuts, and gaskets.
Compared to butt weld valves, the Hansen socket
weld bodies allow quicker welding, easier pipe
alignment, and cleaner pipe and valve interiors.
TAPER SEAT

APPLICATIONS
Typical uses include: ADDITIONAL FEATURES
Ammonia refrigeration system suction, liquid, Suitable for ammonia, R22, R134a, and other
discharge, recirculating liquid, hot gas, and oil lines Hansen-approved refrigerants
using handwheel or seal cap models. Globe and angle available
Teflon seat disc (no lead)
Steel pipe portions of halocarbon commercial, Available also as an expansion valve
industrial, and air conditioning systems using seal Handwheels or seal caps are interchangeable
cap models. 400 psig (27 bar) safe working pressure
Compressor suction and discharge connections and Temperature range: 60F to +240F (50C to +115C)
condenser and evaporator inlet and outlet connections Below 60F (50C) at lower pressures
for ammonia, R22, R134a, and other Hansen-approved Nonasbestos gaskets
refrigerants. Made entirely in the USA
MATERIAL SPECIFICATION INSTALLATION
Body: " and ", ASTM A108 (connections All Hansen weld valves can be installed in horizontal
ASTM A513) or vertical pipe lines. Stems are normally installed
1" through 2", cast steel, ASTM A352, horizontally, but, depending on the application, stems
grade LCB may be installed vertically. Globe valves in horizontal
Stem: stainless steel suction lines, liquid overfeed return lines, condenser
Disc Holder: steel drain lines, purge lines, oil pot drain lines, or level
Seat Disc: PTFE Teflon, retained control column isolation valves should have stems
Ball Bearings: stainless steel horizontal to avoid liquid or vapor being trapped at
Packing Nut: " through 1", corrosion resistant the valve seat orifice. Inlet pressure or direction of
coated steel flow for all valve sizes should normally be under
valve seat disc. However, to avoid installing an angle
1" through 2", electroless nickel
valve with the stem down, it is better to install the
plated steel
valve with the normal flow opposite the direction of
Stem Packing: graphite composite plus
the arrow.
neoprene o-ring
Handwheel: " through 1", zinc-plated The valve stem should be opened several turns during
Zamak alloy welding to prevent heat damage to the seat disc.
1" through 2", zinc-plated iron alloy Normally, it is not necessary to disassemble these
Bonnet: " through 1", zinc-chromate plated steel socket weld valves for installation welding. However,
if welding is prolonged enough to overheat the valve
1" through 2", ductile iron ASTM A536
body, a wet rag should be wrapped around the valve
Seal Cap: " through 1", glass-filled polymer,
bonnet and upper body while welding. Socket weld
safety vented
fitting and valve codes require that the pipe be inserted
1" through 2", zinc-plated steel
until bottomed against the stop, then backed out
approximately 1/16" (1.5 mm) before welding.
ADVANTAGES Welds should be annealed as necessary in accordance
Compared to threaded valves, Hansen Socket Weld with good practice. Painting valves and welds is
Valves eliminate the chance of future leaks at pipe recommended for corrosion protection. Pipe covering,
threads. In addition, a socket welded pipe-to-body where applied, should have a proper moisture barrier.
joint eliminates the inherent weakness and
Before putting valves into service, all pipe weld
vulnerability of the threaded portion of pipe
connections, valve seats, bonnet seals, and stem
immediately adjacent to a screwed valve body or
seals should be tested for leaks at pressure levels
flange.
called for in appropriate codes. If necessary, retighten
Socket welding is easier than butt welding for at 75 ft-lbs (100 Nm) the threaded bonnet on "
alignment. It also provides cleaner interior weld (13 mm) through 1" (32 mm) valves. These may
joints. have a loosened secondary knife-edge seal after
Compared to flanged valves, Hansen Socket Weld installation due to excessive heating of valve body.
Valves eliminate the leak potential at the gasket Shut-off valves leading to the atmosphere must not
joint. In addition, nearly all refrigeration flanged be left unsupervised and must be plugged or capped
valves are made of cast iron or semi-steel, a to prevent corrosion inside the valve as well as leakage
type of cast iron. Hansens steel valves have much due to seat expansion, vibration, pressure shock, or
greater tensile strength, ductility, and impact improper opening. The valve seat should be cracked
resistance than cast iron. open to prevent hydrostatic expansion between the
Compared to pressed-sheet-steel weld valves, valve and the cap. Valves should never directly feed
Hansen valves have heavier cast steel wall thickness a water tank because of potential internal corrosion
for greater rigidity and a corrosion safety margin. or seat opening caused by vibration.
All Hansen socket weld valves have rising stems.
This allows the operator to know at a glance whether
INSULATION
the valve is open or closed. Readily available, valve shaped block insulation can
be used for both angle and globe valves. Exterior
valve dimensions for insulation are shown on pages,
CONNECTION DIMENSIONS 4, 6, 8, and 10. The W dimension on pages 6, 8, and
The body sockets accommodate US Standard Pipe 10 represents the width of the reinforcement web.
Schedule 40 or Extra Heavy Pipe Schedule 80.
D SERVICE AND MAINTENANCE
WELD FILLET
Hansen Steel Body Socket Weld Shut-Off Valves require
practically no service or maintenance. Stem leakage,
a common problem of shut-off valves, is almost entirely
eliminated by the combination of polished stainless
steel stems and reliable, conventional, adjustable
packing supplementing fluid-tight o-ring stem seals.
For optimum maintenance, occasional cleaning of
the valve stem with a soft rag and refrigerant oil is
The D dimension represents the socket depth. See helpful. The patented o-ring stem seal design permits
pages 4, 6, 8, and 10. low torque operation to open and close the valve.
2
 FLOW CAPACITIES
PIPING AND VALVE SIZING GUIDE FOR AMMONIA
C O N D IT IO N S CAPACITIES
SERVICE Temp. PRESSURE " (13 mm) " (20 mm) 1" (25 mm) 1" (32 mm) 1" (40 mm) 2" (50 mm) 2" (65 mm)
F (C ) P S IG (B A R ) TONS (k W ) TONS (k W ) TONS (k W ) TONS (k W ) TONS (k W ) T O N S (k W ) T O N S (k W )

Suction Lines
+20 (6.7) 33.5 (2.3) 8.6 (30) 15.8 (56) 21.3 (75) 35.7 (126) 51.1 (180)
Single Stage
0 (17.8) 15.7 (1.1) 5.7 (20) 10.4 (37) 13.9 (49) 22.7 (80) 34.0 (120)
Compressor
Suction Lines 20 (28.9) 3.6 (0.2) 4.2 (15) 7.4 (26) 10.3 (36) 16.8 (59) 24.8 (87)
Booster 40 (40) 8.7" (0.3) 4.4 (15) 6.3 (22) 9.9 (35) 14.4 (51)

+20 (6.7) 33.5 (2.3) 5.0 (18) 9.1 (32) 12.3 (43) 20.6 (73) 29.4 (103)
Liquid Overfeed 0 (17.8) 15.7 (1.1) 3.4 (12) 6.3 (22) 8.5 (30) 13.6 (48) 20.5 (72)
Return Lines (4X) 20 (28.9) 3.6 (0.2) 2.2 (8) 4.0 (14) 5.5 (19) 8.9 (31) 13.1 (46)
40 (40) 8.7" (0.3) 2.4 (8) 3.4 (12) 5.4 (19) 7.9 (28)

Hot Gas Feed +70 (+21.1) 114.1 (7.9) 2.2 (8) 4.3 (15) 7.3 (26) 14.1 (50) 19.6 (69) 36.5 (128) 53 (187)
Hot Gas Main +70 (+21.1) 114.1 (7.9) 4.4 (15) 8.6 (30) 14.7 (52) 28.1 (99) 39.2 (138) 73.0 (257) 106 (373)
Compressor
+86 (+30) 154.5 (10.7) 12.6 (44) 24.1 (85) 33.6 (118) 62.6 (220) 90.3 (318)
Discharge
Condenser Drains +86 (+30) 6.0 (21) 14.5 (51) 24.0 (84) 50.0 (176) 77.0 (271) 140 (493) 220 (774)
Liquid Mains +86 (+30) 28.3 (100) 53.1 (187) 90.8 (320) 143 (503) 202 (711) 454 (1598) 657 (2313)
Liquid Feed
+86 (+30) 54.9 (193) 103 (363) 176 (620) 277 (975) 392 (1380) 881 (3101) 1273 (4481)
Branch
Liquid Overfeed
+10 (12.2) 9.0 (32) 17.0 (60) 29.0 (102) 46.0 (162) 65.0 (229) 144 (507) 208 (732)
Supply (4X)

SIZING GUIDE
These capacity recommendations are not affected about 145 diameters of equivalent flow resistance,
by the length of the pipe line. These are approximate or 145/700 = 0.2F (0.1C) of equivalent pressure
optimum sizes based on power costs versus the drop at the suction line capacities shown for a
investment cost of piping and its total installed valve in a suction line. Globe valves equal about
cost. Piping sized to these capacities will have 1F 225 diameters.
(0.6C) pressure drop for the following equivalent The rational for the vapor line sizing was developed
lengths: by William V. Richards in two papers: Refrigerant
Suction lines ............................ 700 diameters Vapor Line Sizing Not Dependent on Length, 16 th
Discharge lines ........................ 1400 diameters International Congress of Refrigeration, IIR, Paris,
1983, and Practical Pipe Sizing for Refrigerant
Liquid lines ............................... 2400 diameters Vapor Lines, Sixth Annual Meeting, IIAR, San
Example: Hansen angle socket weld valves have Francisco, 1984.

FLOW COEFFICIENTS
ANGLE GLOBE

N O M IN A L S IZ E FLOW COEFFICIENT EQUIVALENT LENGTH* FLOW COEFFICIENT EQUIVALENT LENGTH*

IN C H (M M ) Cv (K v ) FEET (M E T E R S ) Cv (K v ) FEET (M E T E R S )

1
/2 (13) 6 (5.2) 5 (1.5) 4 (3.5) 9 (2.7)
3 4
/ (20) 9 (7.8) 8 (2.4) 8 (6.9) 8 (2.4)
1 (25) 26 (22) 5 (1.5) 18 (16) 8 (2.4)
11/4 (32) 30 (26) 14 (4.3) 21 (18) 21 (6.4)
11/2 (40) 53 (46) 11 (3.4) 41 (35) 14 (4.3)
2 (50) 80 (69) 27 (8.2) 67 (58) 34 (10.4)
21/2 (65) 173 (150) 18 (5.5) 163 (141) 20 (6.1)

*Schedule 80 pipe under 2" size

3
 " (13 MM) AND " (20 MM) SOCKET WELD VALVE
INSTALLATION DIMENSIONS INSULATION DIMENSIONS
INCHES (MM) INCHES (MM)

3.50 DIA
(89)

.62 CLOSED
(16)
1.25 HEX
1.25 DIA
(32)
(32) 1.25
4.88 OPEN (32)
5.12 (124)
(130) 1.50 SQ
(38) 2.00
D (51)
.50 .50 D
(13) (13)
B DIA B DIA

1.12
(29) 2.00 2.00 1.12
(51) (51) (29)

1.50 SQ 5.50
(38) (140)

5.50
(140)
SIZE B

1 2 / (13) 1.25 (32)

3 4
/ (20) 1.50 (51)

3.50 DIA
(89)

.62 CLOSED
(16)
1.25 HEX
(32) 1.25 DIA
(32) 1.25
(32)
4.75 4.50 OPEN
(121) (114) 1.50 SQ
(38)
1.50 SQ
(38) 3.12 B DIA
(79)

3.50
.50 (89)
(13) D 2.00
3.50 (51)
.50 (89)
(13)
D 2.75
(70)
2.75
(70) B DIA

SIZE B

1 2 / (13) 1.25 (32)

3
/4 (20) 1.50 (51)

4
 " (13 MM) AND " (20 MM) SOCKET WELD VALVE

PARTS LIST
IT E M D E S C R IP T IO N QTY PART NO* IT E M D E S C R IP T IO N QTY PART NO*
Gasket Kit consist of: 5 0 -1 0 4 0 Handwheel Kit consist of: 5 0 -1 0 0 5
1 xxStem Packing 1 50-0045 12 xxHandwheel 1 50-0953
2 xxStem Washer 1 50-0046 13 xxScrew 1 50-0479
3 xxStem O-ring 1 50-0179 14 xxName Plate 1 50-0094
4 xxBonnet O-ring 1 50-0453 15 xxBonnet Thread Cap 1 50-0434
5 xxSeal Cap O-ring 1 50-0432
11 xxPacking nut 1 50-0933 Seal Cap Kit consists of: 5 0 -1 0 3 6
16 xxSeal Cap 1 50-0423
B o n n e t A s s e m b ly K it 5 0 -1 0 4 1 5 xxSeal Cap O-ring 1 50-0432
Above Kit consists of:
6 xxBonnet 1 50-0422 17a Body, Globe " S.W. 1 50-0449
7 xxStem 1 50-0012 17b Body, Globe " S.W. 1 50-0451
8 xxDisc Assembly 1 50-0803 17c Body, Angle " S.W. 1 50-0450
9 xxBall Retainer 1 50-0439 17d Body, Angle " S.W. 1 50-0452
10 xxBalls 10 50-0016
xxGasket Kit 1 50-1040
*Prior to 1989, " and " socket weld valves had cast steel
bodies. Replacement parts and numbers for these valves
Disc Assembly Kit consists of: 5 0 -1 0 4 2
are the same as the 1" and 1" valves listed on page 7. A
8 xxDisc Assembly 1 50-0803 plated steel seal cap is available. To order specify part
9 xxBall Retainer 1 50-0439 number 50-1064.
10 xxBalls 10 50-0016
4 xxBonnet O-ring 1 50-0453

5
 1" (25 MM) AND 1" (32 MM) SOCKET WELD VALVE
INSTALLATION DIMENSIONS INSULATION DIMENSIONS
INCHES (MM) INCHES (MM)
3.50 DIA
(89)

.50 CLOSED
(13)
1.62 HEX 1.25 DIA
5.25 5.00 OPEN (41) (32)
(133) (127) 2.06
W
(52)
D D 2.06 DIA
(52)

2.31 DIA
(59)
1.50 2.88 DIA
(38) (73)

.06 1.25 DIA

6.50 (2) (32)
(165) 6.50
(165)
SIZE D
W=1.00 (25), WEB THICKNESS
1 (25) 0.50 (13)

11/4 (32) 0.62 (16)

3.50 DIA
(89)

.50 CLOSED
(13)
1.62 HEX
(41) 1.25 DIA
5.25 (32)
1.88
(133) (48)
5.00 OPEN
(127) 2.06 DIA
(52)

1.50
(38)
2.31 DIA
(59)

3.25
(83)
D
3.25
D (83)
W

3.25
1.44 3.25 (83)
(37) (83) 2.31 DIA
(59)
SIZE D
2.88 DIA
(73)
1 (25) 0.50 (13)
W=1.00 (25), WEB THICKNESS
11/4 (32) 0.62 (16)

6
 1" (25 MM) AND 1" (32 MM) SOCKET WELD VALVE

PARTS LIST
IT E M D E S C R IP T IO N QTY PART NO. IT E M D E S C R IP T IO N QTY PART NO.
Gasket Kit consists of: 5 0 -1 0 4 0 Handwheel Kit consists of: 5 0 -1 0 0 5
1 xxStem Packing 1 50-0045 12 xxHandwheel 1 50-0953
2 xxStem Washer 1 50-0046 13 xxScrew 1 50-0479
3 xxStem O-ring 1 50-0179 14 xxName Plate 1 50-0094
4 xxBonnet O-ring 1 50-0017 15 xxBonnet Thread Cap 1 50-0434
5 xxSeal Cap O-ring 1 50-0432
11 xxPacking nut 1 50-0933 Seal Cap Kit consists of: 5 0 -1 0 3 6
16 xxSeal Cap 1 50-0423
B o n n e t A s s e m b ly K it 5 0 -1 0 2 1 5 xxSeal Cap O-ring 1 50-0432
Above kit consists of:
6 xxBonnet 1 50-0429 17a Body, Globe 1" S.W. 1 50-0386
7 xxStem 1 50-0012 17b Body, Globe 1" S.W. 1 50-0387
8 xxDisc Assembly 1 50-0804 17c Body, Angle 1" S.W. 1 50-0389
9 xxBall Retainer 1 50-0026 17d Body, Angle 1" S.W. 1 50-0390
10 xxBalls 10 50-0016 *Plated steel seal cap kits are available (p/n 50-1064).
xxGasket Kit 1 50-1040

Disc Assembly Kit consists of: 5 0 -1 0 0 4

8 xxDisc Assembly 1 50-0804
9 xxBall Retainer 1 50-0026
10 xxBalls 10 50-0016
4 xxBonnet O-ring 1 50-0017

7
 1" (40 MM) AND 2" (50 MM) SOCKET WELD VALVE
INSTALLATION DIMENSIONS INSULATION DIMENSIONS
INCHES (MM) INCHES (MM)
4.25 DIA
(108)

1.38 CLOSED
(35)

1.62
1.75 DIA (41)
9.12 (44)
(232) 8.88 OPEN 3.50 SQ
(225) 1.88
(89)
W (48)
3.50 DIA
D D (89)
2.50
(64)

4.00 DIA
3.00 DIA
(102)
(76)
2.12
(54)
.12
7.25 (3)
.75 .75
(184) (19) 1.50 DIA (19)
(38)
SIZE D 7.25
(184)
1 2
1 / (40) .62 (16)
W=1.00 (25), WEB THICKNESS
2 (50) .88 (22)
4.25 DIA
(108)

1.25 CLOSED
(32)

8.00 1.62
7.75 OPEN
(203) (41)
(197) 1.75 DIA
(44)

D 1.75
(44) 3.50 SQ
(89)

1.38
(35)
3.00 DIA
(76)
1.50 3.75 DIA
(38) (95)
3.50
(89) 3.50
(89)
W

1.88 3.50 D 3.50

(48) (89) 3.00 DIA (89)
(76)
SIZE D
W=1.00 (25), WEB THICKNESS
11/2 (40) .62 (16)

2 (50) .88 (22)

8
 1" (40 MM) AND 2" (50 MM) SOCKET WELD VALVE

18
16

12 15

6
14

2
8

4
17

13
1

7 3

5 19

11
10

PARTS LIST
IT E M D E S C R IP T IO N QTY PART NO. ITEM DESCRIPTION QTY PART NO.
Gasket Kit consists of: 5 0 -1 0 2 3 Disc Assembly Kit consists of: 50-1025
1 xxStem Packing 1 50-0248 9 xxDisc Assembly 1 50-0363
2 xxStem Washer 1 50-0247 10 xxBall Retainer 1 50-0257
3 xxStem O-ring 1 50-0253 11 xxBalls 16 50-0016
4 xxBack-Up Washer 1 50-0351 5 xxBonnet Gasket 1 50-0259
5 xxBonnet Gasket 1 50-0259
6 xxSeal Cap Gasket 1 50-0270 Handwheel Kit consists of: 50-1026
12 xxPacking nut 1 50-0251 14 xxHandwheel 1 50-0321
15 xxName Plate 1 50-0094
16 xxScrew 1 50-0254
17 xxBonnet Thread Cap 1 50-0263
B o n n e t A s s e m b ly K it 5 0 -1 0 2 4
Above kit consists of: Seal Cap Kit consists of: 50-1027
7 xxBonnet 1 50-0239 18 xxSeal Cap 1 50-0260
8 xxStem 1 50-0242 6 xxSeal Cap Gasket 1 50-0270
9 xxDisc Assembly 1 50-0363
10 xxBall Retainer 1 50-0257 19a Body, Globe 1" S.W. 1 50-0232
11 xxBalls 16 50-0016 19b Body, Globe 2" S.W. 1 50-0233
13 xxBonnet Bolts 4 50-0473 19c Body, Angle 1" S.W. 1 50-0268
xxGasket Kit 1 50-1023 19d Body, Angle 2" S.W. 1 50-0269

9
 2" (65 MM) SOCKET WELD VALVE
INSTALLATION DIMENSIONS INSULATION DIMENSIONS
INCHES (MM) INCHES (MM)
7.62 DIA
(194)

1.81 CLOSED
(46)

2.25 THD
(57) 2.75
12.12 OPEN (70)
11.75 (308)
(298)
4.00 SQ
(102) W
D D W 3.00
1.00 1.00
(76)
(25) (25)
4.94
(125)
3.75 DIA
(95)

5.38 DIA
(137)
2.75
(70)
.62 1.75 DIA .06 .62
(16) (44) (2) (16)
9.25 9.25
(235) (235)

W=1.75 (44), WEB THICKNESS

7.62 DIA
(194)

1.12 CLOSED
(28)

2.25 THD
11.00 OPEN (57)
(279) 2.75
10.62 (70)
(270)

D W
1.00 2.88
(25) (73) 4.00 SQ 3.81
(102) (97)

3.75 DIA
2.00 (95)
4.75 DIA
(51)
(121)
3.38
(86)
W
D
1.00 3.75 DIA
(95) 3.38
(25) 3.38 (86)
2.38 3.38
(86)
(60) (86)

W=1.75 (44), WEB THICKNESS

10
 2" (65 MM) SOCKET WELD VALVE

18 16 15 17 14

8
2
12

4 1

13
3

7
5
19

11
10

PARTS LIST
IT E M D E S C R IP T IO N QTY PART NO. ITEM DESCRIPTION QTY PART NO.
Gasket Kit consists of: 5 0 -1 0 4 3 Disc Assembly Kit consists of: 50-1045
1 xxStem Packing 1 50-0290 9 xxDisc Assembly 1 50-0374
2 xxStem Washer 1 50-0299 10 xxBall Retainer 1 50-0297
11 xxBalls 15 50-0305
3 xxStem O-ring 1 50-0293
5 xxBonnet Gasket 1 50-0310
4 xxBack-Up Washer 1 50-0324
5 xxBonnet Gasket 1 50-0310
6 xxSeal Cap Gasket 1 50-0315 Handwheel Kit consists of: 50-1037
12 xxPacking nut 1 50-0292 14 xxHandwheel 1 50-0319
15 xxName Plate 1 50-0318
16 xxScrew 1 50-0295
B o n n e t A s s e m b ly K it 5 0 -1 0 4 4
17 xxSupport Washer 1 50-0480
Above kit consists of:
7 xxBonnet 1 50-0286
8 xxStem 1 50-0287 Seal Cap Kit consists of: 50-1038
9 xxDisc Assembly 1 50-0374 18 xxSeal Cap 1 50-0304
10 xxBall Retainer 1 50-0297 6 xxSeal Cap Gasket 1 50-0315
11 xxBalls 15 50-0305
13 xxBonnet Bolts 4 50-0294 19a Body, Globe 2" S.W. 1 50-0456
xxGasket Kit 1 50-1043 19b Body, Angle 2" S.W. 1 50-0457

11
STEM PACKING ORDERING INFORMATION,
When verifying the tightness of the packing nut, use SOCKET WELD SHUT-OFF VALVES
an 8" adjustable wrench. Extrusion of some black
graphite packing material along the stem is normal. If N O M IN A L D E S C R IP T IO N CAT. NO.
the o-ring or the adjustable packing ever needs S IZ E
replacement as evidenced by refrigerant or oil leakage XXGlobe, Handwheel GS051H
at the stem, open the valve stem firmly to the back-
seat position. This separates the o-ring and packing / 2"
1 XXAngle, Handwheel AS051H
(13 mm) XXGlobe, Seal Cap GS051C
from the system refrigerant. See the CAUTION section.
Remove the packing nut carefully and then use a wire XXAngle, Seal Cap AS051C
hook or a small blade screwdriver to remove the packing XXGlobe, Handwheel GS076H
and o-ring. Take care not to scratch the stem or bonnet / "
3 4 XXAngle, Handwheel AS076H
sealing surfaces. Carefully install a backup washer, (20 mm) XXGlobe, Seal Cap GS076C
new lubricated stem o-ring, stem washer, and stem
packing. Tighten the packing nut only enough to give XXAngle, Seal Cap AS076C
the handwheel slight turning friction. XXGlobe, Handwheel GS100H
1" XXAngle, Handwheel AS100H
VALVE SEAT (25 mm) XXGlobe, Seal Cap GS100C
To inspect or replace the valve seat disc, isolate the
valve from the system and safely pump out all refrigerant XXAngle, Seal Cap AS100C
to zero pressure. With the stem open several turns, XXGlobe, Handwheel GS125H
carefully remove the bonnet assembly. Proceed slowly 11/4" XXAngle, Handwheel AS125H
and cautiously since some refrigerant may still be (32 mm) XXGlobe, Seal Cap GS125C
inside the valve body. The " (13 mm) through 1"
XXAngle, Seal Cap AS125C
(32 mm) valves have a unique safety vent to warn of
internal pressure when removing the threaded bonnet. XXGlobe, Handwheel GS150H
The 1" (40 mm) and larger valves have bolted bonnets. 1/ "
1 2 XXAngle, Handwheel AS150H
Evenly loosen all bolts one to two turns. Using a (40 mm) XXGlobe, Seal Cap GS150C
screwdriver, break the seal between the bonnet and XXAngle, Seal Cap AS150C
valve body, proceeding cautiously to avoid any XXGlobe, Handwheel GS200H
refrigerant which may still remain inside the valve
2" XXAngle, Handwheel AS200H
body. Remove the bonnet bolts and bonnet assembly,
(50 mm) XXGlobe, Seal Cap GS200C
being careful not to damage the Teflon seat disc
surface. XXAngle, Seal Cap AS200C
If the conical seat surface in the body is marred, XXGlobe, Handwheel GS251H
remove the marks with emery paper by hand or with a 2/ "
1 2 XXAngle, Handwheel AS251H
power drill. If the seat disc is damaged, replace the (65 mm) XXGlobe, Seal Cap GS251C
entire disc assembly by first removing the ball retainer
XXAngle, Seal Cap AS251C
ring and ball bearings. Install a new disc assembly,
including new bearings and retainer ring. Prior to All of the above valves are also available as expansion
1998, seat discs in " (13 mm) to 1" (32 mm) socket valves except the 2".
weld shut-off valves were made with lead. All seat
discs are now made with Teflon. The new seat disc WARRANTY
assemblies and replacement kits are interchangeable Hansen valves are guaranteed against defective
with the old. Install new stem packing, stem o-ring, materials and workmanship for one year F.O.B.
stem washers, and bonnet o-ring or gasket, if necessary. our plant. No consequential damages or field labor
Reassemble the bonnet into the valve body with the is included.
stem still open several turns. Tighten the threaded
bonnet to a minimum torque of 75 ft-lbs (100 Nm). TYPICAL SPECIFICATIONS
Bonnet bolts for the 1" (40 mm) and 2" (50 mm) Refrigerant shut-off valves from " (13 mm)
valves require a torque of 40 ft-lbs (55 Nm), and 2" through 2" (65 mm) sizes shall have steel bodies
(65 mm) valves require 60 ft-lbs (80 Nm). machined for socket weld connections, stainless
steel stems, back-seating design for packing
CAUTION replacement, bonnet threads for installation of stem
Hansen valves are for refrigeration systems only. seal caps, and suitability for a safe working pressure
Read these instructions completely before selecting, of 400 psig (27 bar), as manufactured by Hansen
using, or servicing these valves. Only knowledgeable, Technologies Corporation or approved equal.
trained refrigeration technicians should install,
operate, or service these valves. Stated temperature HANSEN TECHNOLOGIES
and pressure limits should never be exceeded. CORPORATION
Bonnets should not be removed from the valves 6827 High Grove Boulevard
unless the system has been evacuated to zero Burr Ridge, Illinois 60521 USA
pressure. See also Safety Precautions in the current Telephone: 630-325-1565
List Price Bulletin and the Safety Precautions Sheet Toll-free: 800-426-7368
supplied with the product. Escaping refrigerant may FAX: 630-325-1572
cause injury, particularly to the eyes and lungs. E-mail: info@hantech.com
2000 Hansen Technologies Corporation Printed in USA Web Site: www.hantech.com
12
 Bulletin G109i
February, 1999

HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications,
Service Instructions & Parts

THREADED
SHUT-OFF
VALVES

3 8
/ " through 1"
(10 mm through 32 mm) FPT
Globe & Angle
for refrigerants

KEY FEATURES

" (20 mm) Globe Valve: GT076H

ISO 9002

INTRODUCTION
The advanced design and materials of Hansen
threaded refrigerant shut-off valves make them far
superior to commonly-available products, especially
in regard to nonleakage of seats, stems, and bonnets.
Anyone who has experienced the failure of a shut-
off valve at a crucial time will take care to insist ADDITIONAL FEATURES
upon these highly-reliable valves. Perfected for ammonia refrigeration
Removable disc on conical polished seat
Teflon seat disc (no lead)
APPLICATIONS 400 PSIG (27 bar) safe working pressure
Hansen refrigeration valves are ideal for shut-off of Temperature range: 60F to +240F
liquid, suction, discharge, recirculating liquid, hot (50C to +115C)
gas, and oil lines in ammonia refrigeration systems. Back seating for packing replacement
When used with seal caps, these valves are also Globe and angle available
suitable for R22, R134a, and other Hansen-approved Handwheel or seal cap versions
refrigerants in steel piping systems where threaded U.S. Patent #4,550,896
joints are desired. Valves can be ordered initially Converts to Expansion Valve
with seal caps, or valves can be converted later by Individually packaged and labeled
removing the handwheel and plastic bonnet thread Nonasbestos gaskets
cap and installation of seal cap with its O-ring. Made entirely in the USA
MATERIAL SPECIFICATIONS Before putting valves into service, all pipe
Body: ductile iron, A-536 connections, valve seats, bonnet seals, and stem
Bonnet: steel, zinc chromate plated seals should be tested for leaks at pressure levels
Stem: stainless steel called for in appropriate codes.
Disc holder: steel, zinc chromate plated
Seat disc: PTFE Teflon, retained
Ball bearings: stainless steel
3 8
/ " TO "
Ball retainer ring: stainless steel
Packing nut: steel, zinc chromate plated INSTALLATION DIMENSIONS
Stem packing: graphite composite plus
neoprene O-ring
Handwheel: zamak alloy, zinc chromate plated
Seal cap: glass filled polymer, safety vented
Seal cap O-ring: neoprene
Bonnet gasket: Neoprene O-ring plus steel
knife edge
Bonnet thread cap: polyethylene (remove
above 200F)

ADVANTAGES
Compared to other ammonia threaded shut-off valves,
Hansen valves are stronger, seals and seats are
tighter, construction is simpler, and pressure drop
is lower. One very important feature is the standard
usage of stainless steel stems. This avoids packing
deterioration and leakage by rust abrasion.

FLOW CAPACITIES (U.S. GPM/PSI)

ANGLE GLOBE
S IZ E
Cv Eq. Length FT. Cv E q . L e n g th F t.
3 8
/" 8 3.0 5 5.0
1 2
/" 9 3.7 6 5.5
3 4
/" 10 6.7 7 13.4
1" 26 3.9 18 8.1
11/4" 30 13.5 21 29.0

INSTALLATION
The most important factor, other than the valve itself,
in achieving a leak-tight and secure threaded valve
installation is selection and preparation of mating
piping. Pipe 1" and smaller should be Schedule 80
Steel ASTM A-106 Grade B or equal, properly cut to
the correct length, and cleanly and properly threaded
with U.S. National Tapered Male Pipe Threads. The
male threads on the piping and the female threads
in the valves should be cleaned and inspected. Proper
pipe thread sealant is recommended. Sealant should
be applied evenly to act as a lubricant between the
ductile iron and steel threads to avoid any chance
of metal-to-metal thread galling. Valve and piping
should be adequately tightened with two wrenches
positioned as close together as possible, but not
touching the pipe threads. While backwelding the
threaded steel pipe to the ductile iron body is possible
for total elimination of thread leakage, this is not
recommended in the field because a special welding
rod and special techniques are necessary. Hansen
weld valves should be used instead wherever a tight
welded joint is desired. In the horizontal piping
of suction, overfeed gas return, or condenser
drain lines, globe valve or angle valve stems
should be horizontal to avoid liquid trapping
of gas flow at the valve body casting seat
orifice.
2
1" AND 1" PARTS LIST
INSTALLATION DIMENSIONS

See page 4 for valve catalog numbers.

IT E M D E S C R IP T IO N QTY PART NO.

GASKET KIT consists of: 5 0 -1 0 4 0
1 XXStem O-ring 1 50-0179
2 XXStem Packing 1 50-0045
3a XXBonnet O-ring 3/8", 1/2", 3/4" 1 50-0453
3b XXBonnet O-ring 1", 11/4" 1 50-0017
7 XXStem Washer 1 50-0046
16 XXSeal Cap O-ring 1 50-0432
9 XXPacking Nut 1 50-0013
BONNET ASSEMBLY KIT 3/8",1/2",3/4" 50-1041
BONNET ASSEMBLY KIT 1",11/4" 5 0 -1 0 2 1
Above kits consist of:
4a XXDisc Assembly 3/8", 1/2", 3/4" 1 50-0803
4b XXDisc Assembly 1", 11/4" 1 50-0804
5 XXBalls 10 50-0016
6a XXBall Retainer 3/8", 1/2", 3/4" 1 50-0439
6b XXBall Retainer 1", 11/4" 1 50-0026
8 XXStem 1 50-0012
10a XXBonnet 3/8", 1/2", 3/4" 1 50-0422
10b XXBonnet 1", 11/4" 1 50-0429
XXGasket Kit 1 50-1040
DISC ASSEMBLY KIT 3/8",1/2",3/4" 5 0 -1 0 4 2
DISC ASSEMBLY KIT 1", 11/4" 5 0 -1 0 0 4
Above kits consist of:
4a XXDisc Assembly 3/8", 1/2", 3/4" 1 50-0803
4b XXDisc Assembly 1", 11/4" 1 50-0804
5 XXBalls 10 50-0016
6a XXBall Retainer 3/8", 1/2", 3/4" 1 50-0439
6b XXBall Retainer 1", 11/4 1 50-0026
3a XXBonnet O-ring 3/8", 1/2", 3/4" 1 50-0453
3b XXBonnet O-ring 1", 11/4" 1 50-0017
HANDWHEEL KIT consists of: 5 0 -1 0 0 5
11 XXHandwheel 1 50-0027
12 XXScrew 1 50-0479
13 XXName Plate 1 50-0094
14 XXBonnet Thread Cap 1 50-0434
SEAL CAP KIT consists of: 5 0 -1 0 3 6
15 XXSeal Cap 1 50-0423
16 XXSeal Cap O-ring 1 50-0432
17a Body, Globe 3/8" 1 50-0504
17b Body, Globe 1/2" 1 50-0505
17c Body, Globe 3/4" 1 50-0506
17d Body Globe 1" 1 50-0035
17e Body, Globe 11/4" 1 50-0036
17f Body, Angle 3/8" 1 50-0507
17g Body, Angle 1/2" 1 50-0508
17h Body, Angle 3/4" 1 50-0509
17i Body, Angle 1" 1 50-0037
17j Body, Angle 11/4" 1 50-0038
Replacement part kits for older, larger style " and "
shut-off valves (GT050, AT050, GT075, AT075): Gasket Kit,
50-1040; Bonnet Assembly Kit, 50-1028; Disc Assembly
Kit, 50-1042 (includes bonnet O-Ring 50-0017).

3
SERVICE AND MAINTENANCE CAUTION
Hansen shut-off valves require practically no service Hansen valves are for refrigeration systems only.
or maintenance. The common ailment of valves Read these instructions completely before selecting,
stem leakageis almost entirely eliminated by the using, or servicing these valves. Only knowledgeable,
combination of polished stainless steel stems and trained refrigeration technicians should install,
reliable, conventional, adjustable packing operate, or service these valves. Stated temperature
supplementing fluid-tight O-ring stem seals. For and pressure limits should not be exceeded. Bonnets
optimum maintenance, occasional cleaning of the should not be removed from the valves unless the
valve stem with a soft rag containing refrigerant oil system has been evacuated to zero pressure. See
is helpful. The patented O-ring stem seal design also Safety Precautions in the current List Price
permits low torque hand operation to open and close Schedule and the Safety Precautions Sheet supplied
the valve because the packing nut does not require with this product. Escaping refrigerant can cause
much tightening. Do not use a wrench on these injury, especially to the eyes and lungs.
small handwheels; it is not necessary and could
bend or break the handwheel. WARRANTY
Hansen valves are guaranteed against defective
STEM PACKING materials or workmanship for one year F.O.B. our
Tightening of the packing nut is seldom necessary plant. No consequential damages or field labor is
because the O-ring portion of stem sealing is included.
continuous. However, if tightening is ever needed,
use a " open end wrench or an 8" adjustable wrench. ORDERING INFORMATION,
Extrusion of some black graphite packing material THREADED VALVES
along the stem is normal. If the O-ring or the S IZ E D E S C R IP T IO N CAT. NO.
adjustable packing ever needs replacement, as
evidenced by refrigerant or oil leakage at the stem, XXGlobe, Handwheel GT038H
open the valve stem firmly to back-seat position. 3 8
XXAngle, Handwheel AT038H
This separates the O-ring and packing from the /"
XXGlobe, Seal Cap GT038C
system refrigerant. Carefully remove the packing XXAngle, Seal Cap AT038C
nut and then use a wire hook or a small blade
screwdriver to remove the packing and O-ring. Take XXGlobe, Handwheel GT051H
care not to scratch the stem or bonnet sealing 1 2
XXAngle, Handwheel AT051H
surfaces. Carefully install a new O-ring and packing. /"
XXGlobe, Seal Cap GT051C
Tighten the packing nut only enough to give the
XXAngle, Seal Cap AT051C
handwheel a slight turning friction.
XXGlobe, Handwheel GT076H
VALVE SEAT 3 4
XXAngle, Handwheel AT076H
To inspect or replace the valve seat disc, isolate the /"
XXGlobe, Seal Cap GT076C
valve from the system and safely pump out refrigerant.
XXAngle, Seal Cap AT076C
With stem open at least one turn, carefully remove
the bonnet assembly. An 18" wrench is required. If XXGlobe, Handwheel GT100H
the conical seat surface in the body is marred, remove XXAngle, Handwheel AT100H
the marks with emery paper by hand or power drill. 1"
XXGlobe, Seal Cap GT100C
If the seat disc is damaged, replace the entire disc
XXAngle, Seal Cap AT100C
assembly by first removing the ball retainer ring
and ball bearings. Install the new disc assembly, XXGlobe, Handwheel GT125H
including new balls and retainer ring. Prior to 1998, XXAngle, Handwheel AT125H
seat discs in 3/ 8" to 1" threaded shut-off valves 11/4"
XXGlobe, Seal Cap GT125C
were made with lead. Now all seat discs are made
with Teflon. New seat disc assemblies (and XXAngle, Seal Cap AT125C
replacement kits) are interchangeable with the old.
Install new stem packing, stem O-ring, and bonnet TYPICAL SPECIFICATIONS
O-ring if necessary. Reassemble the bonnet into Threaded refrigerant shut-off valves shall have
the valve body with the stem still open at least stainless steel stems, ductile iron bodies, back-
several turns, and tighten the bonnet to a minimum seating design for packing replacement, bonnet
torque of 75 foot pounds (102 Nm). This prevents threads for installation of stem seal caps, and be
the seal cap or valve stem excess opening torque suitable for a safe working pressure of 400 psig (27
from unscrewing the bonnet. A tattletale vent hole bar), as manufactured by Hansen Technologies
in the bonnet warns of interior valve pressure before Corporation or approved equal.
the bonnet can be removed. Test the valve for leaks
before returning it to service.
HANSEN TECHNOLOGIES
CORPORATION
6827 High Grove Boulevard
Burr Ridge, Illinois 60521 U.S.A.
Telephone: (630) 325-1565
Toll-free: 1-800-426-7368
1998 Hansen Technologies Corporation Printed in USA FAX: (630) 325-1572
4
Misc Documenation
 HI-TEMP/STANDARD CARTRIDGE
IMMERSION HEATERS

5/8 (15.9 MM) DIA. OIL/WATER

FIBERGLASS LEADS
58" (15.9 mm) dia.

Insert Length 10" (25.4 cm) fiberglass leads inside

octagonal terminal box.
12" (12.7 mm) N. P. T. brass bushing.

FIBERGLASS LEADS 3/4 (19.1 MM) DIA. OIL/WATER

34" (19.1 mm) dia.

Insert Length 10" (25.4 cm) fiberglass leads inside

octagonal terminal box.
34" (19.1 mm) N. P. T. steel bushing.

5/8 (15.9 MM) DIA. OIL/WATER

SCREW TERMINALS
58" (15.9 mm) dia.

Insert Length Screw terminals inside octagonal

terminal box.
12" (12.7 mm) N. P. T. brass bushing.

SCREW TERMINALS 3/4 (19.1 MM) DIA. OIL/WATER

34" (19.1 mm) dia.

Insert Length
Screw terminals inside octagonal
terminal box.
34" (19.1 mm) N. P. T. brass bushing.

FITTING CHART

MALE PIPE N.P.T. FITTINGS FOR CARTRIDGE HEATERS

N.P.T. SIZE 1/8" (3.2 mm) 1/4 (6.4) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)
CART. DIA. 1/4" (6.4 mm) 3/8 (9.5) 1/2 (12.7) 5/8 (15.9) 3/4 (19.1)

Brass, steel or stainless steel fittings are avail-

able for liquid immersion applications. Other
heater N.P.T. combinations available.

40 FAST HEAT, INC.

 WRV COMPRESSOR DATABOOK

7.3.4 Capacity Control

The Linear Position Indicator (LPI)

General:

An electronic device called a Linear Potentiometer gives an indication of the position of the slide
valve which can be used by the compressor control system.
The Linear Position Indicator (LPI) is an electronic contact-less displacement sensor inserted
into a sensor well which allows the LPI to be removed from compressor without loss of oil or gas
from the compressor.

The LPI has several usable options built into one device.

The slide valve position can be indicated in three different ways:

Visual Light Emitting Diodes (LED)
Visual and by an analogue output 4-20mA
Visual and by a digital 24 V DC signal output on minimum and maximum slide valve position

Part Load LED

Max. Load
LED
Min. Load
LED
Calibration
Button Cover

Visual:

It is always possible to see the position of the slide valve.

At minimum load a green LED is illuminated at the lowest light on the left of the LPI.
At maximum load all red LED are illuminated.
At part load only some of the LED are illuminated, eg, at 50% load only half of the red LED will
be illuminated.

NOTE: The compressor can only be allowed to start with the slide valve in the minimum load
position. Therefore a signal from the minimum load electronic position switch is always required
or if the 4 20 mA signal is being used, then a 4 mA signal is required.

February 2003 7-5

 WRV COMPRESSOR DATABOOK

7.3.4 Capacity Control (contd)

Visual and by an Analogue Output (4-20mA):

The minimum load position is given by the 4 mA output and the maximum load position is given
by the 20 mA output. (White Wire)

Part load positions are indicated by intermediate values between 4 and 20 mA.
The LEDs on the indicator also give a visual indication of part load operation. It should be noted
that part load slide valve position is not a direct indication of actual compressor capacity at part
load. Use of the 4 20 mA signal is common for many control systems and may be used on its
own, if required, for all control functions for single and multiple compressor installations, subject
to a suitable control system.

Connections:
Wiring Plug Connections Function
1=Brown Supply Voltage + 24V DC
2=White Output Signal 4-20 Ma
3=Blue Common 0 VDC

Visual and by a Digital 24V Output on Minimum and Maximum load:

There is also another option that can be used to control and get the minimum signal for start-up.
This option works the same as the mechanical micro-switches but instead uses the electronic
switches incorporated in the LPI unit. These electronic switches give a 24 V DC output.
A digital output is given on the Minimum and Maximum position of the slide valve and an
interposing relay, which must be incorporated in the control panel in place of each mechanical
micro-switch, is activated by the digital signal completing the control circuit signal. This
interposing relay must have contacts with suitable ratings. The interposing relay replaces the
original switch function.
The LEDs only give a visual indication of the slide valve position.

If the slide valve is in the minimum position and the LED for minimum is illuminated, there will
be a digital output on the green/yellow wire.
If the slide valve is in the maximum position and all the LEDs are illuminated, there will be a
digital output on the black wire.
Existing installations equipped with the mechanical micro-switches can use this option.

Connections:
Wiring Plug Connections Function
1=Brown Supply Voltage + 24V DC
3=Blue Common 0 VDC
4=Black Digital Output Max. Load
5=Green/Yellow Digital Output Min. Load

Choose the best way for giving a start signal and connect the wires according to the table.

February 2003 7-6

 WRV COMPRESSOR DATABOOK

7.3.4 Capacity Control (contd)

Checking the LPI Calibration

All compressors with variable Vi are despatched from Howden with Vi set at 2.2 and the LPI
calibrated to suit Vi 2.2.
When the Slide Valve is in the unloaded position, the 10% minimum load LED should be
illuminated.
To check that the LPI indicates maximum load when the slide valve is in the fully loaded
position, ie all LEDs are illuminated, the following checks should be made.
Move the slide valve to 100% (by using the oil pump or if the system is shut down, use a
manual oil pump or air pressure). By pressurising the outboard side of the actuator piston the
slide valve will be moved to the fully loaded position. The LPI should indicate 100% by
illuminating all LEDs.
If this is not the case please do the calibration again as follows:

Move the piston to the minimum load position.

Adjust the Vi screw to set VI to suit operating conditions.

Note: This adjustment must only be done when slide valve is in the minimum load (10%
position).

Remove the calibration button cover, Switch power on and disconnect the electrical plug under
the LPI.

Wait for 2 minutes. Re-connect the plug. All the capacity array lights and red LED at the
calibration button will light for 2/3 seconds and then go out. After approximately 20 seconds, the
green LED light at the calibration button will start flashing (the minimum capacity array light may
come on).

Allow 5 minutes to elapse before starting calibration.

To start calibration, press the calibration button once. The green LED by the calibration button
will go off and the red Led by the calibration button will come on steady for approximately 15
seconds and then start flashing.

Now move the slide valve to the maximum load position. During this movement the cylinder
capacity array lights will start to light. When the slide valve is in the max. load position, push the
calibration button once. The red LED by the calibration button will stay on for approximately 15
seconds and then go off. The green LED light will come on, possibly flashing.
The calibration is now complete. Refit the calibration button cover.
Note: If the operating Vi is changed, then the LPI will have to be re-calibrated as from 6 above.

February 2003 7-7

 WRV COMPRESSOR DATABOOK

7.3.4 Capacity Control (contd)

The LPI Linear Position Indicator

Calibration Button

Red LED Green LED

LPI Wiring Diagram

February 2003 7-8

 FORM 1354

Form-Flex
BPU

Installation and Maintenance Manual

TB Woods Incorporated
Chambersburg, Pennsylvania
Phone: 888-TBWOODS
www.TBWOODS.com
 A BH CLAMP HUB INSTALLATION:
THESE INSTRUCTIONS ARE PROVIDED AS AN ADDENDUM
TO THE STANDARD FORM-FLEX INSTALLATION AND
1 2 MAINTENANCE INSTRUCTIONS PROVIDED WITH THE
COUPLING. ALL INSTALLATION STEPS NOT DETAILED
HERE ARE DEFERRED TO THE STANDARD BULLETIN.
3 4 1) INSPECT SHAFTS AND HUBS TO MAKE SURE THEY ARE
FREE FROM BURRS.
2) FIT THE KEY TO THE SHAFT.

NOTE: NEVER TIGHTEN THE CLAMP BOLTS WITHOUT THE

A HUB MOUNTED ONTO THE APPROPRIATELY SIZED SHAFT.
ALSO, DO NOT TIGHTEN THE SETSCREW BEFORE THE
CLAMP BOLTS, MAKE SURE IT IS NOT ENGAGING THE TOP
OF THE KEY BEFORE PROCEEDING TO STEP 3.

3) WITH CLAMP BOLTS LOOSE, SLIDE THE HUB ONTO THE

SECTION A-A SHAFT UNTIL THE HUB FLANGE FACE IS FLUSH WITH THE
SHAFT END. THE HUB SHOULD SLIDE ONTO THE SHAFT
EASILY WITH NO BINDING. THE KEY SHOULD BE FLUSH
WITH THE END OF THE SHAFT AS WELL.
TABLE 1. 4) TIGHTEN THE CLAMP SCREWS IN 3 STAGES. WITH
EACH STAGE, FOLLOW THE TIGHTENING SEQUENCE
BOLT SIZES & TORQUES PATTERN SHOWN IN THE SECTION A-A ILLUSTRATION.
STAGE 1: HAND TIGHTEN WITH AN ALLEN WRENCH.
DISC PACK [REF] CLAMP BOLT SETSCREW STAGE 2: TIGHTEN TO HALF OF THE CLAMP SCREW
COUPLING
SERIES/SIZE SIZE - TORQUE SIZE - TORQUE TORQUE TIGHTENING TORQUE VALUE SHOWN IN TABLE 1,
# BOLTS # BOLTS SIZE
PITCH (lbf*ft) PITCH (lbf*ft) (lbf*ft) ACCORDING TO THE COUPLING SIZE.
BH33 UNDER REVIEW STAGE 3: TIGHTEN TO THE FULL CLAMP SCREW
BH38 6 5/16-24 17 2 1/4-28 120 3/8 10 TIGHTENING TORQUE VALUE SHOWN IN TABLE 1,
BH43 6 7/16-20 40 2 3/8-24 49 3/8 10 ACCORDING TO THE COUPLING SIZE. CONTINUALLY
BH48 6 7/16-20 40 4 3/8-24 49 1/2 20
BH53 6 1/2-20 60 4 7/16-20 78 1/2 20
REPEAT THE TIGHTENING SEQUENCE OF SECTION A-A
BH58 6 5/8-18 120 4 1/2-20 120 1/2 20 UNTIL ALL BOLTS ARE COMPLETELY TIGHTENED.
BH63 6 5/8-18 120 4 1/2-20 120 5/8 40 5) TIGHTEN THE SET SCREW PER THE APPROPRIATE
BH68 6 3/4-16 200 4 5/8-18 240 3/4 80 VALUE SHOWN IN TABLE 1 ACCORDING TO THE COUPLING
BH38U 6 5/16-24 22 4 1/4-28 12 3/8 10 SIZE.
BH41U 6 7/16-20 55 4 5/16--24 23 3/8 10
BH47U 6 9/16-18 120 4 3/8-24 49 1/2 20
6) PROCEED PER THE STANDARD FORM-FLEX
BH54U 6 9/16-18 120 4 7/16-20 78 1/2 20 INSTALLATION AND MAINTENANCE INSTRUCTIONS
BP56U 6 9/16-18 120 4 1/2-20 120 5/8 40 PROVIDED WITH THE COUPLING.
DP42 8 5/8-18 125 4 1/2-20 120 1/2 20

MATERIAL: THIRD ANGLE PROJECTION R

8. FINISH ON MACHINED SURFACES F TB WOOD'S
TOLERANCES LESS THAN OR EQUAL TO .005" 63 Ra
OTHER MACHINED SURFACES 125 Ra MAX. E INCORPORATED
7. TURNED SURFACES MUST RUN TRUE (CONCENTRIC, MECHANICAL DIVISION
PERPENDICULAR, PARALLEL, ETC.) WITHIN .005 TIR TB Wood's
6. 3 PLACE DECIMALS `.010
D
DESCRIPTION:
5. 2 PLACE DECIMALS `.015
" C T.B. WOOD'S INCORPORATED. HEAT TREAT: CUSTOMER: BH CLAMP HUB INSTALLATION INSTRUCTIONS
4. REMOVE ALL SHARP CORNERS AND BURRS C
THIS DRAWING CONTAINS
PROPRIETARY INFORMATION 3. TAPER ON GROUND SURFACES
NOT TO EXCEED .0002 PER INCH CUST. P/N: COMP.: ASSEMBLY
AND SHALL NOT BE USED OR B
REPRODUCED WITHOUT WRITTEN 2. GROUND SURFACES MUST RUN TRUE (CONCENTRIC, WR2-LBS. IN 2 PART NO.:
PERPENDICULAR, PARALLEL, ETC.) WITHIN .001 TIR DRAWN: TDLSM DATE: 7/19/07
CONSENT OR APPROVAL FROM N/A
TB WOOD'S INCORPORATED. 1. LIMIT ON ANGULAR DIMENSIONS, `1~, CHAMFERS `5~ A ORIGINAL RELEASE TDL TDL 7/19/07
APPRVD: TDL DATE: 7/19/07 FINISH WT.-LBS. REV. LEVEL
DRAWING NUMBER
UNLESS OTHERWISE SPECIFIED ECN CHK
REVISIONS
NO. BY BY
DATE SHEET: 1 OF 1 SCALE: NTS S00445 A
 WARNING:
Rotating equipment must be properly guarded.
It is the responsibility of the user to properly guard all rotating equipment to comply with OSHA
or any applicable regulations. Failure to properly guard may contribute to severe injury
should someone come in contact with the rotating parts or should the rotating part fail.

WARNING:
DO NOT use Woods products on any primary aircraft drive or any other drive which
could endanger human life should a drive component fail.

Proper care with installation and alignment of couplings and equipment will permit a coupling to operate to
full capacity, compensate for angular misalignment, and provide long service life.

Shafts may become misaligned as a result of many natural and unavoidable causes. Heat, vibration,
bearing wear, settling of foundations, etc., all tend to alter initial alignment. To ensure long life, recheck
alignment after a short period of actual equipment running time.

Flexible couplings are intended to accommodate misalignment between connected equipment while
minimizing loads that affect bearing and seal life and overall performance of that equipment. All couplings
exert reaction forces on the connected equipment when they are misaligned. While these forces are
small, they can be minimized by holding the alignment TIR at or near zero. If significant thermal growth or
other movements can be measured under operating conditions, we recommend that the coupling
alignment be done so that these growths move the equipment toward a zero operating misalignment.

Figure 1

INSTALLATION
Preparation
Check that the coupling bores and the shaft separation are correct. Inspect the shafts and hubs making
sure they are clean and free from burrs. If the bore is straight, measure the bore and shaft to ensure a
proper fit. Check for proper fit of the keys to the shafts and hubs. If the bore is tapered, check for a good
contact pattern.
Hubs
BPU coupling hubs are normally bored for an interference fit according to ANSI/AGMA 9002-A86, unless
otherwise specified.
Straight Bored Hubs
If the hub was specified with a clearance fit and set screws are used, install the coupling hubs so that
they are in the correct position and tighten the set screw(s). If the hub is bored for an interference fit, the
hub should be heated to expand the bore until it is sufficiently larger than the shaft. A hub temperature of
approximately 300 F is sufficient for most interference fits. DO NOT EXCEED 600 F. DO NOT SPOT
HEAT THE HUB AS IT MAY CAUSE DISTORTION. After the hub has been heated a sufficient amount,
quickly position the hub onto the shaft to the desired axial location. Hold the hub in place as it cools.
Taper Bored Hubs
Carefully mount the hub on the shaft without key(s), O-ring and back-up rings (if applicable), and tap
lightly with a soft mallet to establish a metal to metal fit. This is the initial position for starting the hub
advance. Measure this position, shaft end to hub flange face, with a depth gauge and record this value.
Hub draw must be monitored during installation. This may be done using a dial indicator or by use of a
shaft stop ring. The method of monitoring the hub draw must be established prior to removing the hub
after the initial starting position has been determined. The amount of hub draw is dependent upon the
desired interference and taper angle. Heat the hub to expand the bore until it is sufficiently larger than the
shaft. DO NOT EXCEED 600 DEG. F. DO NOT SPOT HEAT THE HUB AS IT MAY CAUSE
DISTORTION. Place the hub on the shaft the required distance to achieve the level of interference
desired. Use a dial indicator or shaft stop as a guide only to determine the axial location of the hub. Hold
the hub in place as it cools. Check the final results of the hub advance with a depth gauge, and install the
shaft-retaining device provided with the shaft to hold the hub in place.

Figure 2
Figure 3

ALIGNMENT
Axial Spacing
The equipment must sit flat on its base. Any soft foot must be corrected now. Bring the equipment into
approximate position. Measure the length of the spacer and the thickness of the two unitized flex discs
from washer face to washer face to determine the D dimension shown in Figure 1. Measure the
separation between the hub flanges and adjust the equipment until the axial hub separation equals the
sum of the spacer length and the thickness of the two flex discs.
Angular Alignment
Rigidly mount a dial indicator to one of the hubs (or shaft) and place
the pointer on the flange face of the opposite hub, as shown in Figure Total Indicator
Coupling Reading (T.I.R.)
2. Rotate both shafts at the same time making sure the axial spacing
remains constant. Adjust the equipment by shimming and/or moving Size
Angular Parallel
so that the indicator reading is within 0.001 inch per inch of coupling
0.001 Inch per Inch

flange diameter. See Table 1. BP38U 0.005

of D dim.

Parallel Offset BP41U 0.006

Rigidly mount a dial indicator to one of the hubs (or shaft) and place
BP47U 0.007
the pointer on the flange diameter of the opposite hub, as shown in
Figure 3. Compensate for indicator set-up sag. Rotate both shafts at BP54U 0.008
the same time. Adjust the equipment by shimming and/or moving so
that the indicator reading is within 0.001 inch per inch of the axial BP56U 0.009
spacing between flex discs. See Table 1. Table 1
After securely tightening the foundation bolts, the hub separation and alignment should be re-checked
and adjusted if necessary.

NOTE: If the driver or driven equipment alignment specification calls for closer tolerances than these
recommendations, then those manufacturers specifications should be used. In addition verify any thermal
growth, which may occur during normal equipment operation, and compensate for differences.

ASSEMBLY
With the hubs mounted and the axial spacing set, proceed to place the spacer between the two hub
flanges. Care should be taken when handling the spacer. Be sure the spacer is fully supported at this
time. Damage to the unitized flex discs may result after they have been installed if the spacer is
not fully supported.

Once the spacer is in place between the two hubs, rotate the hub or spacer so that the bolt holes in the
spacer line up with the clearance holes in the hub. Install the unitized flex disc at this time. Start a bolt
through a bolt hole in the spacer. Put the unitized flex disc between the hub and spacer until a bushing
hole in the unitized flex disc lines up with the bolt. Slide the bolt through the bushing hole in the unitized
flex disc. Install the locknut until it is snug. Make sure that all bolt threads are clean and lightly oiled. Do
not torque any locknuts at this time. Now pivot the unitized flex disc until the other bushing holes in the
flex disc are in line with the bolt holes in the spacer. Install the rest of the spacer bolts at this time. The
remaining bolts for this end of the coupling can be installed through the hub bolt holes and flex disc
bushing holes.

Install the unitized flex disc in the other end of the coupling using the method as described in paragraph
2. The unitized flex disc as installed should look flat and parallel with the mating hub and spacer flanges.
For reference, the flange to flange distance, dimension G in Figure 1, for each coupling size can be
found in Table 2.

Tighten all of the locknuts evenly and in an alternating fashion to the values shown in Table 2.

Tightening Torque
Table 2 Coupling Locknut (as supplied)
G
Size Size
FT-LBS Nm
BP38U 5/16-24 22 30 .40
BP41U 7/16-20 55 75 .55
BP47U 9/16-18 120 163 .62
BP54U 9/16-18 120 163 .62
BP56U 9/16-18 120 163 .62

IMPORTANT: To ensure long life, recheck alignment after a short period (one to two hours) of actual
equipment running time. It is recommended that all locknuts be retightened at this time to the values
shown in Table 2.
UNITIZED FLEX DISC REPLACEMENT

If it becomes necessary to replace the unitized flex disc, it can be done as follows:

At one end of the coupling remove all of the locknuts. Ensure that the spacer is supported at this time.
Back out and remove all but one of the bolts. Pivot the unitized flex disc out. Remove the last bolt and
slide the unitized flex disc out supporting the spacer at this end of the coupling.

Disassemble the other end of the coupling per the above paragraph, being sure to support the spacer
when taking out the last bolt. Remove the spacer.

Replace parts as necessary. Recheck alignment and reassemble per the previous pages.

Repair Kits
Replacement parts are available from TB Woods Incorporated through your local distributor.

Coupling Size Repair Kits

BP38U B038URKA
BP41U B041URKA
BP47U B047URKA
BP54U B054URKA
BP56U B056URKA
 Thomas Disc Couplings Installation and Maintenance
Types DBZ, DBZ-A & DBZ-B Sizes 50-451 (Page 1 of 4)

ATEX In order for this coupling to meet 4. Hub Mounting

the ATEX requirements, it is mandatory to A. General Clean hub bores and shafts. Remove any
precisely follow these installation instructions nicks orClean hub bores and shafts. Remove any
along with the included supplement form nicks or burrs. If bore is tapered, check for good
0005-08-49-01. This supplement outlines the contact pattern. If the bore is straight, measure the
ATEX requirements. If the operator does not bore and shaft diameters to assure proper fit. The
adhere to these instructions, conformity is immediately key(s) should have a snug side-to-side fit with a
invalidated. small clearance over the top.
WARNING: Because of the possible danger to person(s) NOTE: If the DBZ hub position on the shaft does not
or property from accidents which may result from improper allow enough room to install the short bolts in the
use or installations of products, it is extremely important hub after hub mounting, install the bolts and disc
to follow the selection, installation, maintenance and pack before mounting hub on shaft. See Section 6A
operational procedures. All rotating power transmission & B.
products are potentially dangerous and can cause serious
injury. They must be properly guarded in compliance B. Straight Bore Install the key(s) in the shaft. If
with OSHA, ANSI, and any other local or governmental the hub is an interference fit, heat the hub in an oil
standards for the speeds and applications in which they bath or oven until bore is sufficiently larger than
are used. It is the responsibility of the user to provide the shaft. 350F is usually sufficient. An open flame
proper guarding. For ATEX requirements the guard must is not recommended. However, if flame heating is
have a minimum of inch (12.7 mm) radial clearance to necessary, use a very large rose bud tip to give
the coupling major diameter A (See Figure 1) and allow even heat distribution. A thermal heat stick will help
for good ventilation. determine hub temperature. DO NOT SPOT HEAT
THE HUB OR DISTORTION MAY OCCUR. With the
1. Purpose These instructions are intended to help you hub expanded, slide it up the shaft to the desired
to install, align, and maintain your THOMAS coupling. axial position. A pre-set axial stop device can be
2. Scope Covered here will be general information, hub helpful.
mounting, alignment, assembly, locknut tightening, disc NOTE: All DBZ hubs have pressed in bushings.
pack replacement, and part numbers. Make sure the bushings are facing the disc pack.
3. General Information The coupling, as received, may C. Straight Bore Slip Fit Install the key(s) in the
or may not be assembled. If assembled, the locknuts shaft. Install the set screw(s) in the hub making sure
are not fully tightened. Examine the parts to assure they do not protrude into the keyway or the bore.
there is no visible damage. If coupling is assembled, Now slide the hub up the shaft to the desired axial
remove the bolts, locknuts, and washers that attach the position. The set screw(s) which hold the hub in
hubs to the disc packs. Remove both hubs. Leave the place are tightened, using a torque wrench, to the
disc packs attached to the center member assembly.

STANDARD CENTER STANDARD TYPE DBZ CENTER RING ASSY WASHER (SIZES 101, 125, 163, 201)
HUB ASSEMBLY HUB LINK (SIZES 226 AND LARGER)
DISC PACK
AND HARDWARE LOCKNUT LONG BOLT

STANDARD EXTENDED
A HUB HUB

STANDARD CENTER EXTENDED TYPE DBZ-A SHORT BOLT

HUB ASSEMBLY HUB
AND HARDWARE

E R

EXTENDED CENTER EXTENDED TYPE DBZ-B

HUB ASSEMBLY HUB
AND HARDWARE FIGURE 1

Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953 538-260
Telephone: 262-796-4060 Fax: 262-796-4064 December 2008
e-mail: info@rexnord.com web: www.rexnord.com Supersedes CP-01/05
Installation and Maintenance Thomas Disc Couplings
(Page 2 of 4) Types DBZ, DBZ-A & DBZ-B Sizes 50-451

values shown in Table 1A. both shafts together making sure the shaft axial
NOTE: Never use two set screws one on top of the spacing remains constant. Adjust the equipment
other. by shimming and/or moving so that the indicator
reading is within the values shown in Chart A.
D. Taper Bore Put the hub on the shaft without the
key(s) in place. Lightly tap the hub on the shaft with E. Parallel Offset Rigidly mount a dial indicator
a soft hammer. This will assure a metal-to-metal fit on one hub or shaft, reading the other hub flange
between shaft and hub. This is the starting point outside diameter, as shown in Figure 3. Compensate
for the axial draw. Record the position between for indicator set-up sag. Rotate both shafts together.
shaft end and hub face with a depth micrometer. Adjust the equipment by shimming and/or moving so
Mount a dial indicator to read axial hub movement. that the indicator reading is within the values shown
Set the indicator to 0. Remove the hub and in Chart A.
install the key(s). Heat the hub in an oil bath or
oven until the bore is sufficiently larger than the FIGURE 3
shaft. 350F is usually sufficient. An open flame STRAIGHT EDGE
is not recommended. However, if flame heating is
necessary, use a very large rose bud tip to give
even heat distribution. A thermal heat stick will help
determine the hub temperature. DO NOT SPOT
HEAT THE HUB OR DISTORTION MAY OCCUR.
With the hub expanded, slide it quickly up the
shaft to the 0 set point. Continue to advance the
hub up the taper to the desired axial position. Use CHART A Suggested Maximum
the indicator as a guide only. A pre-set axial stop Alignment Value
device can be helpful. Check the final results with a
COUPLING Total Indicator Reading (TIR) (in.)
depth micrometer. Install the hub shaft end retention
device to hold the hub in place. SIZE Angular Parallel
50 .004 .003
5. Shaft Alignment Move equipment into place. 62 .005 .003
A. Soft Foot The equipment must sit flat on its base. 75 .005 .003
Any soft foot must now be corrected. 101 .006 .004
126 .007 .005
B. Axial Spacing The axial spacing of the shafts 163 .009 .005
should be positioned so that the disc packs (flexing 201 .010 .006
elements) are not distorted when the equipment 226 .012 .007
is running under normal operating conditions. This 263 .014 .009
means there is a minimal amount of waviness in the 301 .016 .010
351 .018 .012
disc pack when viewed from the side. This will result 401 .020 .013
in a flexing element that is centered and parallel 451 .024 .014
to its mating flange faces. Move the connected
equipment to accomplish the above.
NOTE: The disc pack is designed to an optimal NOTE: If the driver or driven equipment
thickness and is not to be used for axial adjustments alignment tolerances are more stringent than our
by removing or adding individual discs. recommendations, the driver or driven equipment
tolerances should be used. Also, be sure to
As a guide, maximum and minimum values for
compensate for thermal movement in the equipment.
dimension E are given. These dimensions are
The coupling is capable of approximately four times
suggested for initial installation. Additional capacity
above shaft misalignment tolerances. However, close
is available to compensate for thermal and structural
alignment at installation will provide longer service
movement. Maximum axial capacity values for these
with smoother operation.
couplings are also given. See Table 1 and Figure 1.
6. Final Assembly With the coupling in good alignment,
C. Laser Alignment is an Option If not available
the bolts will fit through the holes in the flanges and the
proceed with dial indicator method.
disc packs easily.
D. Angular Alignment Rigidly mount a dial
A. If the coupling arrived assembled, the disc packs
indicator on one hub or shaft, reading the face of
are still attached to the center ring. Before taking the
the other hub flange, as shown in Figure 2. Rotate
disc packs off, first install one hub bolt through each
disc pack and secure with a locknut. This will help
FIGURE 2
when the pack is reinstalled later. If the coupling
was shipped disassembled, the bolt through the
pack is not required as the discs in the pack are
factory-taped together.
B. Remove the long bolts. Mount disc packs on the
hubs with the one bolt through the disc pack aligned
with a clearance hole in the hub. Install the short

538-260 Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953
December 2008 Telephone: 262-796-4060 Fax: 262-796-4064
Supersedes CP-01/05 e-mail: info@rexnord.com web: www.rexnord.com
 Thomas Disc Couplings Installation and Maintenance
Types DBZ, DBZ-A & DBZ-B Sizes 50-451 (Page 3 of 4)

bolts through the hub bolt holes, disc pack, bevel NOTE: With the coupling in good alignment the bolts
washers or links, and secure with locknuts. Make should easily fit through the holes in the flanges and
sure all parts pilot on the body ground part of the the disc pack. It is recommended that all locknuts
bolt. Remove the disc pack alignment bolt. be retightened after several hours of initial operation
NOTE: All bolt threads should be lubricated. A clean when ever possible.
motor oil is recommended. E. For further help with the installation or alignment,
C. Position one set of the short bolts in each hub on consult the Factory
top. Now slide the center ring down into place 7. Disc Pack Replacement If it becomes necessary to
straddling the short bolts with the center ring replace the disc pack, it can be done as follows:
bushings. If coupling is dynamically balanced, the A. Remove all the long bolts and lower the center ring
center ring match marks must line up with both hub by sliding it out from between the two disc packs.
match marks. When one bushing is in line with the
hole in the disc pack, slide one long bolt through B. Remove one short bolt from the disc pack/hub
washer or link, disc pack, center ring, disc pack, connection and re-install it through a hub clearance
washer or link, and then secure with a locknut. The hole and into the hole in the disc pack. Put the nut
long bolt requires a minimum clearance R for on. This will keep the discs together and maintains
installation between back side of coupling flange the disc orientation for later reinstallation. Remove
and stationary equipment. See Figure 1 and Table 1 the rest of the short bolts and take off the disc pack.
for value of R. On size 226 and larger a link must Repeat for the second disc pack.
be put on the bolt first. Now install the rest of the C. Replace the pack(s) if required. Recheck alignment
long bolts in the same manner. per Section 5. Reassemble per Section 6.
D. Tighten the long bolt locknuts at this time. See Table 8. Replacement parts See Table 2.
1 for torque values.

TABLE 1 Dimensions & Tightening Torques +

E
Axial Torque
COUPLING A (in.) Thread
Capacity R
SIZE (in.) (in.) Size ft-lbs
Min Max (in) Nm
(in.-lbs)
50 2.00 1.36 1.37 .023 1.41 #6-40 (24) 2.7
62 2.44 1.74 1.75 .028 1.75 #10-32 (36) 4
75 2.69 1.77 1.78 .032 1.75 #10-32 (36) 4
101 3.22 2.08 2.10 .038 1.97 #12-28 (96) 11
126 3.84 2.46 2.48 .046 2.31 1/4-28 (156) 18
163 4.56 2.46 2.48 .057 2.31 1/4-28 (156) 18
201 5.34 2.96 2.98 .067 2.69 5/16-24 25 34
226 6.06 3.83 3.85 .076 3.31 3/8-24 34 46
263 7.00 4.33 4.35 .089 3.75 7/16-20 60 81
301 8.00 4.90 4.93 .102 4.44 1/2-20 95 129
351 9.38 5.90 5.93 .118 5.44 5/8-18 175 237
401 10.69 6.71 6.75 .136 6.16 11/16-16 150 4 203 4
451 12.13 7.27 7.31 .154 6.75 3/4-16 190 4 258 4
+ These torque values are approximate for steel bolts with lubricated threads. The locknuts are prevailing torque type and some resistance will be felt. If galling is
suspected, immediately stop and contact the Factory. Modification will be necessary for stainless steel. For stainless steel the tightening torque must be reduced to 60%
of the values shown. Stainless steel bolt and locknut threads must also be liberally coated with molybdenum disulfide grease.
Bolts should be held from rotating while the locknuts are torqued to the values shown.
4 These locknuts are cad plated.

TABLE 1A Set Screw Tightening Torque

Setscrew Torque Torque Torque
Thread Size in-lb ft-lb Nm
1/4-20 66 6 7
1/4-28 76 6 9
5/16-18 132 11 15
5/16-24 144 12 16
3/8-16 240 20 27
3/8-24 276 23 31
1/2-13 600 50 68
1/2-20 660 55 75

Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953 538-260
Telephone: 262-796-4060 Fax: 262-796-4064 December 2008
e-mail: info@rexnord.com web: www.rexnord.com Supersedes CP-01/05
Installation and Maintenance Thomas Disc Couplings
(Page 4 of 4) Types DBZ, DBZ-A & DBZ-B Sizes 50-451

TABLE 2 Part Numbers & Quantity Required

Center Member
Disc Pack Parts Kit Consists of Washers or Links,
Assembly with
COUPLING Two per Cplg Bolts, and Locknuts for One Coupling
Std Ext Center Hardware
SIZE OF Hub Hub Ring Tomaloy
DBZ Stainless
Tomaloy Stainless Parts Washer
DBZ-A Disc Disc Long Bolt Short Bolt Locknut
Kit or Link
DBZ-B Packs Packs
Part Part Part Part Part Part Part Part Part Part Part Qty Part
Qty Qty Qty
No. No. No. No. No. No. No. No. No. No. No. No.
50 114401 514402 314405 114404 314404 710492 910492 716320 ... ... 312659 2 210495 4 711738 6
62 414412 114413 014416 814415 914415 510601 710601 816320 ... ... 112657 2 010525 4 011739 6
75 114423 814424 514427 314426 414426 710523 910523 816320 ... ... 112657 2 010525 4 011739 6
101 716104 216105 814438 614437 714437 910619 310619 916320 511192 8 711162 2 411161 4 516503 6
126 116106 816107 414445 214444 314444 910618 310618 116320 002161 8 811198 2 510728 4 916504 6
163 816108 616109 016022 414455 514455 410954 610954 416320 002161 16 811198 4 510728 8 916504 12
201 416110 016111 414471 214470 314470 710624 910624 001950 002170 16 411206 4 210721 8 316505 12
226 616112 116113 614482 414481 514481 010689 210689 001953 011874 12 011250 4 010634 8 716506 12
263 716114 216115 514491 314490 414490 920357 120357 001956 211875 12 710788 4 410787 8 116507 12
301 416116 516117 414500 214499 314499 420359 620359 001958 411876 12 310656 4 010655 8 516508 12
351 616118 716119 314509 114508 214508 820361 020361 001960 711877 12 410734 4 110733 8 316510 12
401 816120 916121 914516 714515 814515 220363 420363 001962 011878 12 310241 4 110240 8 716511 4 12
451 016122 116123 514523 314522 414522 310646 510646 001964 311879 12 910642 4 710641 8 116512 4 12
4 These locknuts are cadmium plated.

538-260 Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953
December 2008 Telephone: 262-796-4060 Fax: 262-796-4064
Supersedes CP-01/05 e-mail: info@rexnord.com web: www.rexnord.com
43
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Vilter Manufacturing LLC.
5555 South Packard Ave.
Cudahy, WI. 53110
P:414-744-0111
F:414-744-1769

2009I___(7/09) Vilter Manufacturing LLC are trademarks of Emerson Electric Co. or one of its affi liated companies.
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