CIRCLE SEAL CONTROLS
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1. 1 Disconnect the coil s electrical leads 2 Loosen the housing screw and remove the nameplate 3 Pull the coil and can assembly off of the cylinder cap tube 4 DC only remove the upper end plate 5 Separate the coil from the coil can 6 Replace the coil and reinstall the parts in their original order Note On valves equipped with combination explosion proof and waterproof housings the silicone seal bead must be replaced after adjusting the housing to maintain the integrity of the water proof housing CAUTION Do not apply voltage to the coil until it is installed in the completely assembled housing CAUTION Be certain that all coil housing parts are reinstalled Failure to install end plates coil can or hold down spring will result in coil burn out Note All coils including AC and Dc types can be used interchangeably in the 15 800 series without changing any other parts Operational pressures are lower with DC coils Atkomatic 15 800 Series Manual Circle Seal Controls Inc Cleaning or Replacement of Internal Parts WARNING Turn off electrical power to the coil and reduce the line pressure to 0 psi before beginning disassembly 1 Remove the housing screw and lift the entire coil housing off of the body amp cylinder cap 2 Unscrew the cylinder cap from the valve body and lift it from the body This will expose the plunger assembly which can be held with one hand while lifting the cylinder cap with the other ha2. energized This is particularly important on DC applications Is the ambient temperature above 104 F Is there an audible click when the valve is energized This indicated pilot operation If no click is audible check for contamination and or bent or dented pilot tube Is the fluid the same as that indicated on the nameplate Has the pilot orifice become clogged with contaminates Is there 100 back pressure downstream piping shutoff on the valve 2 Valve has trouble closing 3 Is the fluid clean and free of contamination Is the valve being used for the same type of fluid for which it was built Is the valve mounted in a horizontal line with the coil on top Is the voltage within 10 Is there a regulator or other flow restriction upstream of the valve Is the valve installed in a horizontal line with the coil on top Is the valve actually not closing or closing very slowly or leaking excessively Is there foreign matter lodged under the valve seat Is the fluid more viscous than 150 SUS Has the piston spring been removed from the valve Have the piston rings been damaged during re assembly Have the expander rings beneath the piston rings been removed or damaged Is there 100 back pressure downstream piping shutoff on the valve or does the downstream system pressure exceed the valve s inlet pressure Has the bleed orifice s in the piston become clogged with foreign material Has the disc seal in the piston
3. 50 Hz 62189 126 4 0 50 0 27 110 230 VAC 60 Hz 62187 92 04 0 54 0 28 131 380 VAC 50 Hz 62177 379 3 0 27 0 14 124 460 VAC 60 Hz 62177 379 3 0 27 0 14 124 12 VDC 62174 4 17 2 94 2 11 35 24 VDC 62176 15 92 1 52 1 07 36 32 VDC 62185 32 33 0 98 31 72 VDC 62189 126 4 0 55 40 125 VDC 62178 485 9 0 24 30 250 VDC 62180 2212 0 11 28 Atkomatic 15 800 Series Manual Circle Seal Controls Inc OPERATION Opening When voltage is applied across the coil leads a current is produced in the coil windings which generates a magnetic field The magnetic field attracts the plunger and causes it to move toward the center of the coil or magnetic stop Initially the plunger slides freely on the stem until it impacts the nut or shoulder at the end of the stem The plunger s momentum is then transferred to the stem and the stem is lifted off the seat screw orifice This much of the action is identical to the pilot operated valves The stem plunger assembly continues its motion until the shoulder on the stem contacts the piston rod link The piston rod link is attached to the piston so as the stem plunger assembly completes its motion the piston is pulled from the main valve seat effecting the full opening of the valve In actuality the fluid force affect the motion of the piston at pressures above approximately 5 psig and the magnetic force on the plunger through the mechanical connection of the stem to the plunger via the piston rod link is suffic
4. CIRCLE SEAL CONTROLS ATKOMATIC SOLENOID VALVES INSTALLATION MAINTENANCE AND OPERATION INSTRUCTIONS STAINLESS NORMALLY CLOSED SEMI DIRECT LIFT VALVES 15800 SERIES Installation Instructions WARNING These instructions should be read understood and followed before installation Failure to do this can extremely dangerous and cause valve malfunction 1 An adequate filter system must be installed in the line ahead of each valve to prevent foreign matter from damaging the seal faces and or obstructing the valve orifices causing operational failure and leakage A maximum rating of such a filter is 40 microns to provide adequate protection 2 Pipe thread sealing compounds and tape must be prevented from entering the valve 3 New systems must be adequately flushed to remove all pipe scale weld slag thread burrs etc It is typically necessary to flush new systems several times removing contamination lodged in filters and other components until no debris is present 4 Valves must be installed in a horizontal line with the coil oriented up within 10 degrees 5 Mount the valve in the line such that the arrow cast into the valve body is in the direction of flow 6 Check the nameplate and provide the specified voltage to the coil Voltages must be as specified at the coil rather than the power supply This is particularly important with DC applications due to their typically high voltage drop through supply lines All AC coils are for
5. become worn or damaged Has the valve stem become worn or damaged Is the valve actually closing but leaking excessively Valve is leaking internally Is the any contamination in the fluid How much is the leakage and at what pressure If the leak is excessive it could be caused by a bent or dented pilot tube If the leak is small how does it compare with the factory leakage standard Is the fluid chemically compatible with the seat material Is the temperature of the fluid within the limits of the seat material Is the valve mounted in a horizontal line with the coil on top Atkomatic 15 800 Series Manual Circle Seal Controls Inc 4 Coil has burnt out Is the voltage applied correct Is the voltage within 10 Is the ambient temperature above 40 C 104 F Is adjacent equipment or piping radiating excessive heat to the valve or raising the air surrounding the coil above 104F Is the fluid temperature above that for which the valve is rated Is the valve s coil housing assembled correctly Has the customer opened up the coil housing Are the end plates installed and oriented correctly Has the coil hold down spring been reinstalled Have the coil leads been cut or damaged in handling or installation Is contamination or physical binding preventing the plunger from actuating This will cause an AC coil to burn out Monitoring the AC current draw and comparing the measured value to the holding c
6. f new systems is important to reduce the occurrence of problems however often even through flushing will not eliminate all contaminants that will break loose during the initial operation of a new system Filters are an essential component in many systems to prevent valve problems It is important to locate filters immediately upstream of the valves and to size the filter rating correctly A maximum micron rating to provide adequate protection is 40 microns Note that strainers or screens are generally not capable of providing this degree of filtration and a filter with a depth type of element is necessary Atkomatic 15 800 Series Manual Circle Seal Controls Inc Standard Available Coils Class B coils for 15 800 Series Valves Voltage Part Number Resistance 10 Inrush Amps Holding Amps Volt Amps 110 VAC 50 Hz 62170 32 25 1 0 0 52 110 115 VAC 60 Hz 62211 23 24 1 14 0 58 131 220 VAC 50 Hz 62181 126 1 0 50 0 26 110 380 VAC 50 Hz 62179 381 5 0 28 0 15 129 460 VAC 60 Hz 62179 381 5 0 28 0 15 129 Note There is no class B coils available in DC voltages for these valve series Class H coils for 15 800 Series Valves Voltage Part Number Resistance 10 Inrush Amps Holding Amps Volt Amps 24 VAC 50 Hz 62175 1 25 4 80 2 5 115 24 VAC 60 Hz 62182 0 97 5 73 3 21 138 100 VAC 60 Hz 62171 18 72 1 25 0 60 125 110 VAC 50 Hz 62185 32 33 1 00 0 52 110 115 VAC 60 Hz 62212 23 07 1 14 0 58 131 200 VAC 60 Hz 62172 75 37 0 64 0 31 128 220 VAC
7. ient to lift the piston at lower pressures Closing When voltage is removed from the coil leads the magnetic field collapses Gravity pulls both the plunger and stem down until the stem point seals off the orifice in the piston rod link Fluid flow from the valve s inlet side through the bleed orifice in the piston charges the cavity above the piston to a pressure equal to the valve s inlet pressure Since downstream pressure is acting against the center portion of the bottom of the piston the pressure forces acting on the piston are unbalanced and act to push the piston to the closed position gravity and in some valves a piston spring assists in the closing Note In this type of valve the piston opens and closes fully independent of line pressure or system flow Atkomatic 15 800 Series Manual Circle Seal Controls Inc ss SDR GRO ORR E F zo aa a si yy PE A Jj MAS p A A AAZ A ay f i Ui jj y iu mo ow Ae Eid 7 Shown is a Model 15840 1 Stainless Valve with a Standard NEMA 1 Coil Housing Parts that comprise standard repair kits are identified in the cross section above Repair kit numbers are the valve model number proceeded by a K For instance the repair kit for a 15840 300HPLAAIS valve is K 15840 300HPLAAIS All other valve parts are available for repair purposes When ordering specify the parts desired by description the complete 9 digit catalog number If the catalog number i
8. nd 3 The piston assembly can pulled out of the valve body bore 4 Inspect all components 5 Clean and replace components as required CAUTION When cleaning out bleed and seat screw orifices do not ream the out to larger diameters as this will upset the pressure balance within the valve and prevent proper operation Warning Inspect all o0 rings Worn o rings should be replaced and all Teflon o rings white in color should be replaced as they are not reusable Failure to do this can result in external valve leakage and be extremely dangerous CAUTION Replacement piston rings must have the same gap as the original rings Failure to properly gap the piston rings can cause the valve to malfunction CAUTION Attempting to take apart the plunger assembly is not recommended The threaded parts are not re usable and building the plunger assembly requires the use of special tools at the factory Note Repair kits contain the complete plunger assembly Atkomatic 15 800 Series Manual Circle Seal Controls Inc Troubleshooting 1 Valves has trouble opening Is the fluid clean and free of contamination Is the valve mounted in a horizontal line with the coil on top Is the valve installed in the proper flow direction as indicated by the arrow cast into the body or in and out stamps Is the voltage applied correct Is the voltage within 10 of the nominal Is the voltage measured at the coil and with the valve
9. s unavailable and specify 1 the valve base model 2 the pipe size 3 fluid 4 operational pressure minimum and maximum voltage and frequency 5 temperature if different from ambient and 6 any special requirements Atkomatic 15 800 Series Manual Circle Seal Controls Inc Dimensions Shipping Weights and Cv Flow Factors Catalog Number Pipe Main Seat Shipping Prefix Size Orifice Dia X Y Z Weight Ibs Cv 15800 YA 3 8 7 3 8 6 2 3 7 1 1 15810 3 8 3 8 7 3 8 6 2 3 7 25 15820 Ya 34 84 71 8 45 8 9 5 1 15830 5 y 8 1 71 8 45 8 9 7 5 15840 1 1 93 16 7 11 16 5 15 12 5 We manufacture a complete line of rugged dependable solenoid operated valves for pressure ranging from 0 to 10 000 psi Download a complete catalog of the Atkomatic Valve Product Line from http www circle seal com Atkomatic html Circle Seal Controls Atkomatic Product 2301 Wardlow Cir Corona CA 92880 10
10. single phase use only 7 Coil housings may be rotated as required to match up with supply wiring This is done by loosening the housing nut at the top center of the coil housing rotating the coil housing assembly and re tightening the coil housing nut Do not splice the lead wires inside the coil housing Note On valves equipped with combination explosion proof and waterproof housings the silicone seal bead must be replaced after adjusting the housing to maintain the integrity of the water proof housing Note On valves equipped with explosion proof coil housings it is necessary to use shims to align the coil housing A set of these shims is included with each valve with an explosion proof housing The part number for this shim kit is 61427 Atko p n 229 If the angular alignment of the coil housing is not important the installation of the shims is not required Atkomatic 15 800 Series Manual Circle Seal Controls Inc Instructions for Installing Shims a Unscrew the cast iron coil housing assembly from the valves bonnet or cylinder cap Note If holding the valve in a vise clamp on it either end to end or on the hex portion Do NOT clamp across the width of the valve body This can distort the valve body and prevent proper piston motion b Place the shims over the cylinder cap tube so they rest on the cylinder cap or bonnet c Screw the cast iron coil housing back onto the bonnet or cylinder cap Note There are 4 shims with thickne
11. ss of 005 010 015 and 020 Use any combination of these that allow the coil housing thread to bottom out such that the conduit fitting is oriented in the desired direction d Repeat steps b and c as required Note Do not use more than 050 if shims all those provided or the explosion proof feature of the housing will be compromised 8 Valve should be mounted a minimum of 6 feet from a pressure regulator 9 Use the valve only on the fluid voltage and pressure specified on the nameplate 10 To prevent slow valve operation caused by water loading it is recommended that a steam trap be installed upstream of all valves used on steam service CAUTION Valves should be handled carefully during installation with care taken to prevent damage to the cylinder cap tube inside the coil housing Do Not tighten the valve in the line by applying pressure or torque to the coil housing Use the wrench flats on either end of the valve body Atkomatic 15 800 Series Manual Circle Seal Controls Inc Maintenance Instructions CAUTION Only qualified maintenance personnel should work on the valve If the valve is within the warranty period do not disassemble without approval from the factory Returned Materials Department WARNING Normal coil operating temperatures are high enough to cause severe burns DO NOT TOUCH HOT COILS OR COIL HOUSING WITHOUT ADEQUATE PROTECTION Coil Replacement WARNING Turn off electrical power to the coil
12. urrent given in the catalog can check the presence of this condition Is the cycle rate excessive Is the valve mounted in an enclosure that prevents free circulation of the ambient air Was the coil failure immediate or did the burnout take hours or days If immediate the coil may have been defective or damaged and have shorted internally 5 Valve leaks externally Has the valve been disassembled The body o rings are frequently Teflon and may require replacement to reseal Is the bonnet nut or cylinder cap adequately torqued Is the fluid chemically compatible with the seal material Is the temperature of the fluid within the limits of the seat material 6 Valve wears out quickly What is the cycle rate Is the valve chattering or internal pilot stem amp seat wearing rapidly gas application Is there a regulator upstream of the valve gas application Is the fluid contaminated with an abrasive material Is the ambient or fluid temperature excessive Is the fluid chemically compatible with the seal material Is the temperature of the fluid within the limits of the seat material What is the customer s definition of premature wear Contamination in fluid systems is the largest single cause of operational problems Frequently contamination is present in new systems from sources such as pipe sealant pipe scale weld slag and metallic particles from the assembly of pipe fittings Flushing o
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