Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
Before installation these instructions must be fully read and understood
Remove the pressure relief valve prior to
performing any pressure testing of the system.
The safety of lives and property often depends
on the proper operation of the pressure/vacuum
relief valve. The valve must be maintained
according to appropriate instructions and must
be periodically tested and reconditioned to ensure
correct function.
Table of contents
1General valve description������������������������������ 2
2Main valve maintenance������������������������������� 2
3 Pilot maintenance��������������������������������������� 11
4 Pilot adjustment������������������������������������������ 15
5Functional testing of
the complete assembly������������������������������ 16
6Field test procedure������������������������������������ 16
7Repair kits���������������������������������������������������� 17
The intent of these instructions is to acquaint
the user with the storage, installation and
operation of this product. Please read these
instructions carefully before installation.
Safety precautions
When the pressure/vacuum relief valve is under
pressure never place any part of your body near the
pilot exhaust nor the outlet of the main valve.
The main valve outlet should be piped or vented to
a safe location.
Always wear proper safety gear to protect head,
eyes, ears, etc. anytime you are near pressurized
valves.
Never attempt to remove the pressure/vacuum
relief valve from a system that is pressurized.
Never make adjustments to or perform
maintenance on the pressure/vacuum relief valve
while in service unless the valve is isolated from the
system pressure. If not properly isolated from the
system pressure, the pressure/vacuum relief valve
may inadvertently open resulting in serious injury.
Warning
Removal of the seal wires in an attempt to adjust
and/or repair this product by unauthorized
or unqualified persons voids the product warranty
and may cause damage to equipment and serious
injury or death to persons.
The product is a safety related component
intended for use in critical applications.
The improper application, installation or
maintenance of the product or the use of parts
or components not manufactured by Anderson
Greenwood may result in a failure of the product.
Any installation, maintenance, adjustment, test,
etc. performed on the product must be done
in accordance with the requirements of all
applicable Anderson Greenwood procedures and
instructions as well as applicable national and
international codes and standards.
Storage and handling
Pressure/vacuum relief valve performance may
be adversely affected if the valve is stored for
an extended period without proper protection.
Rough handling and dirt may damage, deform,
or cause misalignment of valve parts and may
alter the pressure setting and adversely affect
valve performance and seat tightness. It is
recommended that the valve be stored in the
original shipping container in a warehouse or
at a minimum on a dry surface with a protective
covering until installation. Inlet and outlet
protectors should remain in place until the
valve is ready to be installed in the system.
Engineering Doc. #05.9040.171 Rev. E
www.pentair.com/valves
© 2014 Pentair plc. All Rights Reserved.
VCIOM-03091-EN 15/01
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
1 General valve description
1.1 Operation
The 9200 pilot operated safety relief valve uses
the principle of pressurizing a large diaphragm
area, referred to as dome, with tank pressure
to hold the main valve seat closed up to set
pressure. At set pressure the pilot actuates to
partially reduce the pressure in the dome, and
the downward force acting on the main seat.
The seat then lifts to relieve tank pressure.
When the tank pressure is reduced, the pilot
actuates to repressure the dome with tank
pressure to close the main valve.
Pilot vent
(Atmospheric reference)
Pilot
Pilot exhaust
(Tank pressure)
Remote sense
Dome
1.2 Installation
Inlet flanges are designed for use with 150 class
ANSI flanges. Installation of studs is required in
the base of the vent. Remote pressure pickup is
mandatory on all pressure/ vacuum or vacuum
only units. Internal sense is standard on pressure
only units.
1.3 Start-up
There must be pressure at the vent inlet to
establish a closing force across the main vent
element. Pressure must pass through the pilot
supply tube and pilot and exert force on the
main diaphragm. On normal plant start-up
the vent loads itself without incident as tank
pressure increases. It is not uncommon that
slight leakage past the seat occurs until system
pressure reaches the dome chamber.
If block valves are used under the safety vent,
be sure all block valves are open. If block valves
are opened after system start-up the safety
vents briefly vent to the atmosphere past the
main seat before the dome gets pressurized.
It will close off positively once dome pressure
has been established. Open the block valve
slowly to minimize venting.
Main vent
Outlet
Inlet
2 Main valve maintenance
(Refer to Figure 1)
2.1 General
Since the Series 9200 vent can be either
a pressure only, a vacuum only, or a
pressure/vacuum relieving device, it is built
in a modular fashion. The standard single
chamber diaphragm unit will function on
pressure and vacuum, however opening under
very low vacuum requires use of the auxiliary
diaphragm chamber. The vent can also be
repaired in a modular fashion. The seat can
be replaced without complete disassembly of
the diaphragm cases. Selective repair can be
performed as required.
2
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
2.2 Main seat replacement
1.Remove bolts (700) that connect the main
diaphragm case to the vertical column
supports (830).
2.Remove the operational assembly including
diaphragm cases (210, 280), shield (860),
and seat plate assembly (Details D and E) as
a single unit.
Note: use a hoist on large sizes.
3.While holding the shield (860) up, unscrew
the seat plate assembly from the shaft (320).
This is normally a hand operation, however a
9/16" [14.3 mm] wrenching flat is provided on
the seat hub (420) if required. The connecting
thread will run free then tighten and run free
again as it disengages from a locking helicoil
(330) in the vertical shaft (320).
4.Refer to Details D and E for the appropriate
valve seat plate size, material and pressure
range. Remove the seat jam nut (450) and
screws (120) and nuts (130) or seat band
clamp (125). Remove the seat retainer (140).
Remove seat film (610).
5.Install new seat film (610) and reassemble
hub (420) in accordance with Detail D.
Note: on reassembly pay special attention
to the stack-up sequence to make sure the
parts are assembled properly.
6.Install seat retainer (140) over new film per
Detail E and cross tighten seat screws (120)
and nuts (130) until secure.
7. On the stainless steel seat plate with band
clamp (125), tighten clamp before tightening
seat jam nut (450).
8.Reinstall seat plate assembly to main shaft
(320).
Note: shield (860), tube (760), and seal (650)
must be in place before installation of seat
assembly
9.The thread on the seat plate assembly will
at first run free then tighten then run free
again. The seat plate assembly is then in
place and will swivel to assure good seat
contact on the nozzle (460).
Note: seat hub (420) must not be tightened
to shoulder tightly on the shaft (320).
2.3 Diaphragm replacement
All dual chamber diaphragm 9240C models
(Refer to Figure 2)
1.Remove the pilot and tubing from the
auxiliary diaphragm case.
2.Remove auxiliary diaphragm case bolts
(700/710) and nuts (730).
3.Remove the upper auxiliary diaphragm
case (210).
4. Install a small retaining wire in the lift rod
(250) as shown in Detail C to retain the lift rod.
5.Lift the auxiliary and main diaphragm
assemblies to the full open position using
the auxiliary vacuum plate (160B). The open
dome port can be temporarily capped to
hold the main diaphragm assembly up.
6.Remove nuts (530 and 520B) and O-ring
(670). See Detail A.
7. The lift rod (250) is attached to the auxiliary
plate bushing (240) with threads. See Detail A.
Unscrew the lift rod (250) from the plate
bushing (260) by rotating the rod. The rod will
unscrew from the bottom of the assembly. An
extension on the upper end of the rod has been
provided if wrenching is required. The auxiliary
diaphragm assembly can now be removed to
replace the auxiliary diaphragm (170B).
Note: on 2" and 3" valves with aluminum
internals or low pressure stainless steel
internals, a diaphragm reinforcement (175B)
is used under the auxiliary diaphragm and
should also be replaced.
8. Remove the jam nut (520B) on the auxiliary
diaphragm assembly and replace diaphragm
(170B) and diaphragm reinforcement (175B),
where used.
Note: see detail a and pay special attention
to the stack-up sequence on reassembly.
9. Remove the main diaphragm case bolts
(700/710). Remove the studs (840) from the
column supports (830). Remove the lower
auxiliary diaphragm case (280B) and the
upper main diaphragm case (220) as a unit,
assembled to the diaphragm case adapter
(230). Allow the lift rod (250) to slip from the
center hole and lift items (280), (220) and
(230) upwards as one unit.
10.Remove the main diaphragm assembly,
lower main diaphragm case (280A) and seat
plate assembly from the base.
Note: on the 2” and 3” valves a
reinforcement diaphragm (175a) is used
between the main diaphragm (170a) and
the lower main diaphragm case (280a).
it should be replaced also.
11.See Detail C. Remove jam nut (520A) and
disassemble. Replace main diaphragm
(170A) and diaphragm reinforcement (175A),
where used.
Note: pay special attention to stack
sequence shown.
12. Remove the O-ring (690) from the upper end
of the adapter bore (230). Lubricate O-ring
with Dow Corning FS3451 or equivalent
when the new one is installed.
Note: for oxygen service valves, use only
lubricants suitable for this service, such as
Krytox 240aC.
13.If cap gaskets (620A) are to be replaced,
apply PTFE gasketing to upper diaphragm
cases (210, 220) only as shown in Figure 3.
14.Reassemble in reverse order. Apply a light
film of Dow Corning No. 33 silicone grease
or equivalent to all threaded parts.
Note: for oxygen service valves, use only
lubricants suitable for this service, such as
Fluorolube lg-160.
3
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
All single chamber diaphragm 9240P Series
(Refer to Figure 1)
1.Remove pilot and tubing from the
diaphragm case.
2. Remove the upper main diaphragm case
(220).
3.Remove the main diaphragm assembly,
lower main diaphragm case (280) and seat
plate assembly from the base (100).
Note: on the 2” and 3” valves, a
reinforcement diaphragm (175) is used
between the main diaphragm (170) and the
lower main diaphragm case (280).
4.See Detail C. Remove jam nut (520) and
disassemble. Replace main diaphragm (170)
and diaphragm reinforcement (175), where
used.
Note: pay special attention to stack
sequence shown.
5.Remove remaining internal assembly as a
unit including lower diaphragm case (280),
and internal assembly.
6.If cap gasket (620) is to be replaced, apply
PTFE gasketing to upper diaphragm case
(210) as shown in Figure 3.
7.Reassemble in reverse order. Apply a light
film of Dow Corning No. 33 silicone grease
or equivalent to all threaded parts
Note: for oxygen service valves, use only
lubricants suitable for this service, such as
Fluorolube LG-160.
2.4 Nozzle replacement
(Refer to Figure 1 or 2)
1.Remove nozzle retaining screws (110) and
gently tap nozzle (460) with soft face mallet.
Note: inspect nozzle seating surface
for nicks or scratches. if they cannot
be removed with crocus cloth or fine
sandpaper, the nozzle must be remachined.
2.Nozzle face can be remachined. Do not
remove more than .060" [1.52 mm] of
material.
3.If nozzle gaskets (630) are to be replaced,
install PTFE gasketing as shown in Figure 3.
4.Reinstall nozzle (460) and retaining screws
(110).
Parts list - Main vent
Item
100
110
120
125
130
140
150
160
170
175
210
220
230
240
250
260
270
280
290
300
320
330
340
360
420
430
440
450
460
500
520
530
Description
Base flange
Screw nozzle retainer
Screw - seat (Used with item 120 seat
plate assembly option 1)
Clamp band - seat (Used in place of item
120 and 130 seat plate assembly option 2)
Nut, lock (Used with item 130 seat plate
assembly option 1)
Retainer seat
Plate - main pressure
Plate - main vacuum
Diaphragm - main
Diaphragm reinforcement
(Used on 2” and 3” only)
Case, upper diaphragm
Case, upper main
(Used on dual chamber diaphragm only)
Adapter
(Used on dual chamber diaphragm only)
Bushing
(Used on dual chamber diaphragm only)
Rod
(Used on dual chamber diaphragm only)
Bushing - rod
(Used on dual chamber diaphragm only)
Washer
(Used on dual chamber diaphragm only)
Case, lower diaphragm
Plate - aux. pressure
(Used on dual chamber diaphragm only)
Washers (Used under 700/710 on
aluminum cases only)
Shaft - assembly
(Includes item 330 as part of assy.)
Helicoil
Sleeve guide
Bushing split
Hub seat
Spacer seat
Bushing seat
Nut seat jam
Nozzle (assembly)
Bushing guide
Nut - jam
Nut
Parts list - Main vent (continued)
Item
580
590
600
610
620
630
640
650
660
670
680
690
700
710
730
760
810
820
830
840
850
860
870
880
890
900
910
920
930
940
950
960
970
Description
Washer
Washer
Gasket clamp plate
Seat - film
Gasket - case
Nozzle gasket
Spacer (O-ring/-018)
Weather seal
Gasket - adapter
(Used on dual chamber diaphragm only)
Seal - adapter
(Used on dual chamber diaphragm only)
Retaining - ring
(Used on dual chamber diaphragm only)
Seal - rod
(Used on dual chamber diaphragm only)
Cap bolt - hex
Cap bolt - eye (not shown used on 4” and
above)
Nuts (Used on dual chamber diaphragm
only)
Tube thrust (not used on 2” or 3”)
Stud (Not shown)
Nut (Not shown)
Column support
Stud - 2nd chamber support
(Used on dual chamber diaphragm only)
Nuts
(Used on dual chamber diaphragm only)
Shield deflector
Screen seat
Bushing - support
Screen - lower case
Screen upper case
(Used on dual chamber diaphragm only)
Plate - seat
Plate - seat protector
Nameplate (Not shown)
Rivets (Not shown)
Diaphragm slipper outer
Diaphragm slipper inner
Washer seat (used prior to 1990)
Note
A/B – Next to item # on drawing – denotes parts used
in 2 places (Dual chamber diaphragm only)
4
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
210
See detail A
160
500
700/710
620
170
175
280
760
150
890
730
650
340
360
320
910
860
920
See detail E
See detail D
880
830
870
630
100
850
460
110
Single chamber diaphragm assembly
Figure 1
5
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
See detail A
700/710
530
210
690
730
620B
170B
160B
175B
290
280B
900
730
680
840
110
230
See detail B
730
220
250
See detail C
500
620A
160A
170A
175A
150A
280A
890
760
730
650
360
340
910
860
320
920
See detail E
See detail D
880
830
870
630
850
110
Dual chamber diaphragm assembly
100
460
Figure 2
6
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
680
690
580
170
900
580
110
590
175
600
230
500B
Detail A
Single chamber diaphragm
Details A and B
Assembled
530
520B
670
580
160B
590B
170B
175B
Retaining wire for
assembly and disassembly
250*
270
600
240
520A
Detail A
Auxiliary diaphragm chamber assembly
260*
230
160A
660
220
580
170A
590
175A
150A
600
320
500B
Detail B
Detail C
*Used only with dual chamber diaphragm model
deTailS a, B and C (For figures 1 and 2)
7
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
2” thru 4” Valve inlet size
6” Valve inlet size
320
320
330
330
450
450
640
910
360
640
910
610
430
420
920
430
610
420
920
8” thru 10” Valve inlet size
12” Valve inlet size
320
320
330
330
450
910
360
450
910
640
640
430
610
920
420
430
610
920
420
deTail D (For figures 1 and 2)
Main valve seat plate assembly
8
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
Low pressure aluminum
130
610
910
910
140
610
130
140
120
460
630
120
460
630
2” Inlet size
3” thru 12” Inlet size
Low pressure stainless steel
610
140
910
140
125
125
910
610
460
630
460
630
2” Inlet size
3” thru 12” Inlet size
deTail D (For figures 1 and 2)
Main valve seat plate assembly (Internal pressure sense shown)
9
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
1. The contact surfaces must be clean, free from grease and dry.
2. Remove the protective strip on the adhesive tape.
3. Lightly press in place as shown below.
Upper case(s) and top of body
Put tape just inside of bolt holes, overlapping ends at a bolt hole. Put tape on top case only.
Put tape on top surface of body. Do not put on lower case of mating pair.
Nozzle
A
A
Place tape toward outer edge of each gasket ledge. Put overlaps on opposite sides.
Use ⅛” tape on 3” and 4” nozzles. 3/16” tape on all cases and larger nozzles.
Figure 3
PTFE Tape (gasket) mounting instructions
10
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
3 Pilot maintenance
(Refer to Figure 4)
The pilots used for the 9240P Positive Relief
Valve, for the 9240C Positive and Negative
Pressure Relief Valve and the 9204V Negative
Pressure Relief Valve are shown in Figure 4 and
in Figure 4, Details A and B. Both pilots have
the same construction, except for the location
of the connections to the main valve diaphragm
actuators, or the connections for the pressure
sense. For either the positive or positive and
negative pressure relief valve, the pilot controls
only the positive pressure relief. The negative
pressure relief is controlled by the weight of the
parts that move in the main valve when it opens.
For the negative pressure relief valve, the pilot
controls the negative pressure relief.
3.1 Pilot disassembly for non-flowing
modulating pilots (Type 400B)
(Refer to Figure 4)
1.Remove bonnet cap (5), loosen adjustment
screw lock nut (7), back out adjusting screw
(6) to relieve spring (9) tension. Remove
bonnet nuts (11), bonnet washers (10 and 54),
bonnet assembly (4, 29, 51), bonnet gasket
(12), spring washer (8), and spring (9).
2. Push down on spool retaining nut (30)
with a Phillips screwdriver engaging the
spool anti-rotation pin (21), and remove
nut (30) with a ½" open end wrench turning
counterclockwise.
3.Remove spindle spring (31), case bolts (13
and 48), nuts (17 and 49), washers (16 and
50) and upper case (3). Remove the bonnet
studs (43).
Note: internals are now accessible for
removal.
4. Remove O-ring [-014] (32), O-ring [-022]
(18), sense plate (33), sense diaphragm (34),
gasket (15), ring lantern (35), diaphragm (19),
feedback diaphragm (38), gasket (15),
feedback diaphragm plate (14) and
gasket (15).
5.Remove spool (36) and spindle (24).
6.Remove the lower spindle, O-ring [-013]
(23), outlet seat (22), O-ring [-014] (32) from
the spindle (24). Now the spindle (24) may
be removed from the spool (36). Remove the
top inlet seat O-ring from the spindle.
7.Remove the lower diaphragm case (2) from
the body by removing the 4 inner case bolts
(20).
8.Remove the inlet connector (27) and inlet
screen (41) by removing the 2 bolts (28) on
the side of the pilot body (1).
9. Clean all metal parts, and throw away all
gaskets, diaphragms and seals.
Note: pay particular attention to all port
holes and polished areas.
3.2 Pilot assembly for non-flowing modulating
pilots (Type 400B)
Assembly is done in reverse order of disassembly.
1.Lubricate all O-rings, sliding surfaces, screw
threads and spring washer pivot points
with Dow Corning No. 33 silicone grease or
equivalent.
Note: for oxygen service valves use only
lubricants suitable for this service, such as
Krytox 240aC.
2.The spindle O-ring and bearing surface
should be lubricated with Dow Corning
FS 3451 or equivalent. note: do not lubricate
inlet or outlet seat o-rings.
3.Assemble the diaphragm lower case (2) to
the body (1). note: For pilots with Kalrez®
o-rings, use two PTFE gaskets (37) between
the lower diaphragm case (2) and the body (1).
4.Assemble the inlet screen (41) to the inlet
connector (26) and the inlet connector (26) to
the body (1).
5.Assemble the inlet seat (upper O-ring [-014])
(UPPER 32) and the spindle O-ring (23) to the
spindle (24).
6.Assemble the spindle (24) to the spool (36)
and install the outlet seat (Lower O-ring
[-014]) (LOWER 32) to the spindle (24).
7.Install the spool (36) with spindle (24) in the
body (1). Position the spool (36) to engage
the anti-rotation groove pin (21).
8.Install a diaphragm case gasket (15) on the
lower diaphragm case (2) and the feedback
diaphragm support plate (14).
Note: install the support plate (14) with
the rounded edge up towards the feedback
diaphragm (38).
11
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
9.Install the following parts in the order listed
on the spool (36):
a. Feedback diaphragm support plate (14)
b. Gasket (15)
c. Feedback diaphragm (38)
d. Diaphragm (19)
e. Lantern ring (35)
f. Gasket (15)
g. Sense diaphragm (34)
h. Sense plate (33)
Note: install the sense plate (33)
with the round edge towards the sense
diaphragm (34).
i. Install O-ring [-022] (18) around the
spindle. On the sense, add plenty of
lubricant to the O-ring.
10.Install bonnet studs (43) thru upper
diaphragm case (3). Install the upper
diaphragm case (3), case bolts (13, 48),
washers (16, 50) and nuts (17, 49).
11.Install the spindle spring (3) and spool
retainer nut (30). Lube nut with Dow Corning
33 on bevel and use Fluorolube on the
threads. Push down on the spool retainer
nut (30) with a Phillips screwdriver engaging
the anti-rotation pin (21) and tighten the
nut to 10 foot pounds using ½" open end
wrench.
Note: do not over tighten, the diaphragms
may be damaged.
12.Pretest pilot function by depressing
spindle/diaphragm assembly stack
downward. The spindle spring should return
the stack assembly to the upward position.
If it doesn’t return to upward position,
disassemble pilot and re-check assembly.
13.Install spring (9), spring washer (8),
bonnet gasket (12) and bonnet (4) onto upper
diaphragm case (3). Install bonnet washers
(10, 53) and nuts (11) and tighten.
14.Install pressure adjustment screw (6),
lock nut (7) and cap (5). This Pilot is now
ready for testing
12
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
5
53
6
8
7
32
29
9
Detail A
30
11
54/10
4
12
51
31
3
32
33
48
34
35
2
49/50
36
43
Inlet ½ NPT
38
18
Inlet pressure pilot
19
21
20
22
Auxiliary dome
connection ½ NPT
37
Detail B
42
32
Exhaust ports
(front and back)
with vent screen item 29
23
24
1
25
26
27
28
41
¾ NPT
Figure 4
Pressure actuator connection
Parts list pilot
Item
1
2
3
4
5
6
7
8
9
10
11
12
18
19
Description
Body
Case - diaphragm, lower
Case - diaphragm, upper
Bonnet assembly
Cap - bonnet
Screw - pressure adjustment
Nut - lock
Washer - spring
Spring
Washer - plain
Nut
Gasket - bonnet
O-ring (-022)
Diaphragm - feedback
Item
20
21
22
23
24
25
26
27
28
30
31
32
33
34
Description
Bolt
Pin - groove
Bushing - guide
O-ring (-013)
Spindle
Ferrule - tubing
Retainer - inlet connection
Connector - inlet
Bolt
Nut - spool retainer
Spring - spindle
O-ring (-014)
Plate - sense
Diaphragm - sense
Item
35
36
37
38
41
42
43
48
49
50
51
52
53
54
Description
Ring - lantern
Spool
Gasket - body
Slipper - feedback diaphragm
Screen - inlet
Plug - pipe
Stud - bonnet
Bolt
Nut
Washer
Plug
Insert
O-ring
Seal - thread
13
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
Parts list
Item
13
14
15
16
17
19
29
34
39
40
44
13
Description
Bolt
Plate, diaphragm support
Gasket, diaphragm case
Washer, lock
Nut
Diaphragm, feedback
Vent screen
Diaphragm, sense
Ferrule, tubing
Retainer, dome tubing
Bushing
34
15
14
19
15
16
17
Detail A
28
27
40
1
39
26
Detail B
Vacuum actuator connection
deTailS a and B (For figure 4)
14
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
4 Pilot adjustment
(For non-flowing modulating pilots - Type 400)
The pilot may be set separate from the main
valve provided there is access to a pilot
test system similar to the one shown in Figure 5.
4.1 Adjustment of set pressure
1.Install the pilot valve onto the pilot test
system and attach gage sensing lines to the
supply and dome connections.
2.Remove cap.
3.Screw the set pressure adjustment screw
clockwise until it is screwed IN 80% to 90%.
4.Increase the supply pressure to nameplate
setting and slowly back out the adjustment
screw until flow through the pilot exhaust
begins.
5. Continue to back the set pressure
adjustment screw out until the dome
pressure is 70% of the supply pressure.
When the dome pressure reaches 70% of
the supply pressure, read the supply gage
pressure. If it is below set pressure, you will
need to tighten down on the pressure screw,
or back off it if it is high. Tighten the locknut
once the desired set pressure is achieved.
Note: adjust the set pressure for 101% ± 1%
of the nameplate set pressure.
6. Cycle the pilot valve a minimum of 5 times
to assure that the dome pressure reduction
at set pressure is consistent. Increase the
pressure very slowly in order to obtain an
accurate reading of the cracking pressure
and to expose any erratic performance.
Note: cracking pressure on vacuum pilots
is that pressure at which the initial dome
pressure change is noted.
7.Hold the pilot valve at set pressure to obtain
the dome pressure reading.
Note: the first 6 steps should be completed
before this step is undertaken. in
modulating 400B pilots, the dome pressure
decreases proportional to increase in
inlet pressure. Full dome reduction
(dome pressure) occurs ≤ 6% over pressure.
8. Check the pilot exhaust for leakage when
the pilot is in null position betweencrack and
reseat.
Note: maximum leakage allowed is
60 bubbles per minute.
4.2 Reseat pressure
Reseat is defined as the supply pressure when
the dome pressure is 75% of the
supply pressure.
Note
Blowdown adjustment is not required on Type 400B
pilots.
4.3 Adjustment tolerances
Pressure
Set pressure
Crack pressure
Reseat pressure
Tolerance
± 3%
98% of set
96% of set
Set pressure adjustment
Test pilot
½” Pipe (min)
Supply pressure gauge
Vent
Supply
pressure
Accumulator .25 ft3 [.007 M3]
Supply port
Dome pressure gauge
Positive pressure pilot
Vacuum set adjustment
Test pilot
½” Pipe (min)
Supply vacuum gauge
Vent
Supply
vacuum
Accumulator .25 ft3 [.007 M3]
Supply port
Figure 5
Dome vacuum gauge
Negative pressure pilot
15
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
5 functional testing of complete
assem. of main valve and pilot
Field test valve “A”
Pressure regulator
w / test gauge or manometer
5.1 General
Assemble the pilot to the main valve, and
install remaining tubing and accessories.
The complete valve assembly should be leak
tested for internal and external leaks using a
pressure equal to 30% and 90% of set.
Vent valve “C”
Leakage check - pressure relief valves
Apply pressure to the inlet equal to 30% of
the set pressure. Check for leakage at the
main valve seat, no visible leakage shall occur.
Hold time is 1 minute.
Increase the inlet pressure to 90% of the set
pressure. Check for leakage at the cap seal,
casting, pilot support pipe and supply tube and
other applicable connections using leak test
solution and at the main valve seat. No visible
leakage shall occur for a hold time of 1 minute.
Block valve “B”
Compressed
nitrogen
Leakage check - vacuum relief valves
Valves equipped with vacuum pilots shall be
leak tested per 5.1.1 on positive pressure with
the set pressure equal to the reciprocal of
the vacuum set pressure.
Valves with weighted diaphragms shall be
tested for leakage at 50% of their weighted set.
Back flow preventers and/or field test
The use of some field test connection or back
flow preventers necessitates the use of check
valves. These valves shall be installed per the
applicable assembly drawings and in the free
flow direction shall open at less than .5" W.C.
The check valves may be tested for forward
flow either before or after assembly at the
shops option. The output check valve of back
flow preventers shall be checked for zero
leakage per 5.1.1 paragraph 2.
6 Field test procedure for nonflowing modulating positive pressure
pilot (Type 400B pilot)
6.1 General
An optional field test accessory is available
for checking the positive set pressure without
removing the valve from service. The field test
accessory consists of a 3-way ball valve to allow
the pilot to sense pressure from either the
process or from the test gas source.
A standard bottle of nitrogen equipped with a
pressure regulator, block valve, pressure gage,
and convenient length of high pressure flexible
hose is recommended for testing.
A set up similar to that shown in Figure 6
should be used. Such a test kit is available from
Anderson Greenwood under the part number
04.4812.001 plus additional dash numbers for
the pressure gages required.
Remote sense connection (to tank)
Figure 6
6.2 Procedure
1. Connect gas bottle as shown in Figure 6.
2. Close valve “C”.
3. Open block valve “B” to supply regulator.
Note: regulator pressure should be set at 0.
4. Connect bubble tester bottle to pilot exhaust
vent and block the second pilot vent if the
pilot is equipped with one.
5.Increase pressure at field test port to
slightly above tank pressure by slowly
increasing regulated pressure.
6. Open field test valve “A” and slowly increase
regulator pressure until bubbles are seen in
the bottle. That pressure will be within 3% of
the set pressure.
7.To remove the test set-up, close valves “A”
and “B” and open valve “C”.
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Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
7 Repair kits
Soft goods repair kits contain all the diaphragms,
seals, and seats to repair a valve. To order a
kit, specify the base number and select the last
three digits from the following tables. To ensure
the purchase of the correct repair kit, the
order should specify the valve model and serial
number. For chloride rich environments, the
bolts in the main valve and pilot exposed to the
environment should be replaced during routine
maintenance or at least every five years.
7.1 - 400A/B pilot repair kit (06.0235.xxx)
Pilot type
400A/B
400A/B
400A/B
400A/B
400A/B
400A/B
400A/B
400A/B
400A/B
1. PTFE diaphragms
Pressure
Pilot 4" WC - 10" WC
Pilot 4" WC - 10" WC
Kit type
Soft goods
Soft goods
Materials
NBR [1]
FKM [1]
Pilot 4" WC - 10" WC
Pilot 4" WC - 10" WC
Pilot >10" WC - 15 PSIG
Pilot >10" WC - 15 PSIG
Pilot >10" WC - 15 PSIG
Pilot >10" WC - 15 PSIG
Pilot 4" WC thru 15 PSIG
Soft goods
Soft goods
Soft goods
Soft goods
Soft goods
Soft goods
Bolt
EPR [1]
Kalrez® [1]
NBR [1]
FKM [1]
EPR [1]
Kalrez® [1]
SST
7.2 - Accessory repair kit (06.0235.xxx)
Accessory
Shuttle check
Shuttle check
Kit type
Soft goods
Bolt
Materials
PTFE
SST
Internals
Aluminium
SST
Aluminium
SST
Materials
PTFE
PTFE
SST
SST
7.4 - Main valve repair kit type 9240C - dual chamber diaphragm (06.0235.xxx)
Kit type
Soft goods
Soft goods
Bolt
Bolt
Internals
Aluminium
SST
Aluminium
SST
Materials
PTFE
PTFE
SST
SST
Vacuum
149
150
151
456
562
563
564
565
409
140
410
7.3 - Main valve repair kit type 9240P or 9204V - single chamber diaphragm (06.0235.xxx)
Kit type
Soft goods
Soft goods
Bolt
Bolt
Pressure
127
128
129
455
558
559
560
561
409
2”
305
482
280
431
3”
307
484
281
432
4”
309
486
282
433
6”
311
488
283
434
8”
313
490
284
435
10”
315
492
285
436
12”
317
494
286
437
2”
291
468
273
417
3”
293
470
274
418
4”
295
472
275
419
6”
297
474
276
420
8”
299
476
277
421
10”
301
478
278
422
12”
303
480
279
423
17
Anderson Greenwood series 9240 POSRV with non-flowing modulating pilot
Installation and Maintenance Instructions
Parts
Item
1
2
3
5
6
7
8
6
Description
Body - shuttle
Shuttle assembly
Cap - shuttle
Gasket - shuttle
Bolt
Nut
Washer - lock
5
7
A
4
1
3
2
Section A-A
A
Figure 7
Shuttle check valve
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