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1. How to Order Parts How to Order Parts To order parts the following procedure is recommended 1 On the purchase order clearly state your company name contact person phone number fax number and order number or purchase authority 2 Specify the mode of transportation you prefer for shipping parts 3 Write out the quantity and in parenthesis the number Then identify the part with a description and complete stock number 4 Identify the valve model number For example Purchase Order 12345 Ship by Parcel Post One 1 Seal Disc Stock No D40005 Four 4 Cushion Disc Stock No D40000 For Model 11 valve 21 Drawing and Parts List Continued 22 On the envelope in the lower left corner mark EXPEDITE PARTS ORDER Send the parts order to Siemens Energy amp Automation Inc 408 US Highway 60 Bartlesville Oklahoma 74003 Or phone fax in your order by calling Tel 800 448 8224 USA Tel 001 918 662 7030 International Fax 918 662 7482 USA Fax 001 918 662 7482 Parts to be sent in for repair or returned for other reasons must also be identified with a pre approved RETURN AUTHORIZATION number Drawing and Parts List Continued NOTES 1 Callouts refer to items on parts list see Table 5 1 3 Indicates parts which should be lubricated with KRYTOX 240 AC grease Indicates parts which should be lubricated with KRYTOX 143 AY oil Figure 5 1 Model 11 Valve Assem2. TRAPP hired SAMPLE OUT SAMPLE IN SEALING DISC 2 k A PLUNGER TRAPPED SAMPLE UPPER ACTUATING PISTON ADVANCED OPENING CLOSING LOWER ACTUATING SPRING SPRING PISTON ADVANCED SWITCHING CARRIER IN SWITCHING TO COLUMN CARRIER IN SWITCHING TO COLUMN B SO SAMPLE OUT SAMPLE IN SEALING DISC PLUNGER BODY UPPER ACTUATING y PISTON ADVANCED AIR PRESSURE APPLIED LOWER ACTUATING PISTON RETRACTED z ee enenaizen en range go ENERGIZED is c EXTERNAL SAMPLE LOOP SECTIONAL VIEW INTERNAL SAMPLE LOOP Figure 1 1 Figure 1 2 Figure 1 3 Table 1 1 Model 11 Valve Specifications Internal loop sample size External loop sample size Sample filter Cap screw 33 Torque Setting Base Screw 12 Torque Setting Maximum operating temperature Maximum sample pressure Minimum sample pressure before it is necessary to apply vacuum assistance to lower chamber Maximum leak rate between ports Construction material in contact with sample Connection size and type Actuating air Lower port on manifold Lower Seal Disc Purge Gas Upper 2 ports on the manifold Total switching time Body size Mounting 2 and 5 microliters standard Other sizes on special request 15 microliters and larger 170 microliters is standard 5 micrometer recommended not furnished with valve 35 1 inch pounds 6 5 1 inch pounds 250 F 122 C standard 15 F 66 C 2000627 014 U
3. Remove the Swagelok cap 3 from the tubing to port 4 9 For valves with external loop caps only stock no s 2000627 002 2000627 003 and 2000627 004 a shorter version of the test given in steps 3 through 8 can be performed by doing the following a b Hook up the test stand and valve as described in steps 1 and 2 Connect the tubing from port 2 to the tubing from port 5 using a 1 16 in Swagelok union Plug the ends of the tubing from ports 6 and 3 with 1 16 in Swagelok caps 3 Connect the sample air 9 to port 1 Port to Port Leak Test Continued e Slide the bubble tube 11 over the ferrule on the tubing to port 4 and slightly submerge the open end of the tube in a beaker 10 half full of water Set the actuating air pressure regulator 5 to 50 psig 345 kPa and set the sample air pressure regulator 12 to 100 psig 690 kPal Turn the sample air switch 2 ON and check the end of the tube 11 submerged in the beaker 10 Bubbles from the end of the tube indicate a leak refer to Section 4 for repair procedures If no bubble forms continue with step h Turn the actuating air switch 6 ON while observing the end of the bubble tube 11 submerged in the beaker 10 When the loop between ports 2 and 5 is switched from the pressure side to the outlet side a slug of air should escape from the bubble tube then shut off completely When the actuating air switch is turned OFF switch
4. certain the disc is free of any oil or dirt Place the seal disc over the cushion disc 35 and align both discs over the plungers 9 or 10 Carefully align the cap 37 with the two guide pins on the body 26 and place the cap on the body Put the three cap screws 33 and six washers 32 into the cap and tighten rotationally in the following sequence a Finger tight b 15 inch pound 1 69 Nem c 35 inch pounds 3 95 Nem Adjust the base screw 12 to give proper spring compression by turning it clockwise to a torque setting of 6 5 inch pounds 0 73 Nem 19 Chapter 5 Drawings and Parts Lists Description This Chapter contains drawings and parts lists for the Model 11 valve Table 5 1 lists complete valve assemblies and corresponding cap stock numbers An exploded view of the valve is used to identify its parts see Figures 5 1 and 5 2 The numerical callouts on the drawings refers to item numbers on the same parts list see Table 5 2 Also included are the related parts list for the Model 11 valve repair kit see Table 5 3 and the tool and test kit see Table 5 4 The repair kit contains items most commonly used to repair Model 11 valves plus tools possibly difficult to obtain from other suppliers The tool and test kit contains all items found in the repair kit some in greater quantity plus items for valve testing useful common fittings and tools and a few valve parts occasionally required
5. for repair procedures If no bubble forms continue with step f Port to Port Leak Test Continued 10 Turn the actuating air switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the ON position bubbles should flow from the tube In the OFF position no bubbles should flow Allow at least one minute for a bubble to form atthe end of the tube A bubble indicates a leak refer to Section 4 for repair procedures If no bubble forms continue with step 8 8 Check port 5 to port 6 passage for leaks a b g h Remove the bubble tube 11 from the tubing to port 4 Remove the Swagelok cap 3 from the tubing to port 6 and install it on the tubing to port 4 Slide the bubble tube 11 over the ferrule on the tubing to port 6 and slightly submerge the open end of the tube in a beaker 10 half full of water Turn the actuating air switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the OFF position bubbles should flow from the tube In the ON position no bubbles should flow Allow at least one minute for a bubble to form at the end of the tube A bubble indicates a leak refer to Section 4 for repair procedure Turn the sample air switch 2 OFF Remove the sample air 9 from port 5 Remove the bubble tube 11 from the tubing to port 6
6. see Chapter 4 Repair for detailed procedures The specially constructed manifold eliminates leakage of air used for valve actuation This feature is especially beneficial when bottled helium or nitrogen is used in place of instrument air Functional Description of the Model 11 Valve Filtering Purging Below the Seal Disc The Model 11 valve is a 6 port two position air actuated valve The six ports are arranged in a circular configuration as show in Figure 1 1 Between each two ports is a plunger that opens or closes the passage between these two ports A Teflon disc seals prevents process fluids from contacting other components of the valve This arrangement is shown in Figure 1 2 Six plungers operate in two sets of three Each set of plungers is controlled by a spring loaded air actuated piston so that one set closes three passages between ports as the other set opens three passages between ports Passages between ports 1 and 6 ports 5 and 4 and ports 3 and 2 are normally closed The other three passages between ports 1 and 2 ports 3 and 4 and ports 5 and 6 are normally open The two operating positions of the valve are shown in Figures 1 2A and 1 2C The two actuating pistons are spring loaded in a manner that assures that all six passages are momentarily closed during the switching operation both energized and de energized This feature prevents unwanted mixing of streams during the switching cycle The plungers and
7. to Section 4 for repair procedures If no bubble forms continue with step 6 6 Check port 3 to port 4 passage for leaks a b Remove the bubble tube 11 from tubing to port 2 Remove the Swagelok cap 3 from the tubing to port 4 and install it on the tubing to port 2 Slide the bubble tube 11 over the ferrule on the tubing to port 4 and slightly submerge the open end of the tube in a beaker 10 half full of water Turn the actuating air switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the OFF position bubbles should flow from the tube In the ON position no bubbles should flow Allow at least one minute for a bubble to form at the end of the tube A bubble indicates a leak refer to Section 4 for repair procedure If no bubble forms continue with step 7 7 Check port 5 to port 4 passage for leaks a b Turn the sample air switch 2 OFF Remove the sample air 9 from port 3 and connect it to port 5 Remove the Swagelok cap 3 from the tubing to port 2 and install it on the tubing to port 6 Leave the bubble tube 11 on the tubing to port 4 and slightly submerge the open end of the tube in a beaker 10 half full of water Turn the sample air switch 2 ON and check the end of the bubble tube 11 submerged in the beaker 10 Bubbles from the end of the tube indicate a leak refer to Section 4
8. voltage listed on the equipment agrees with the available line voltage Ensure that the power supply switch is to the correct input voltage Any interruption of the grounding conductor inside or outside the equipment or loose connection of the grounding conductor can result in a dangerous unit Intentional interruption of the grounding conductor is not permitted If it is determined that the equipment cannot be operated safely it should be taken out of operation and secured against unintentional usage To avoid fire hazard use only a fuse of the correct type voltage rating and current rating as specified in the parts list for your product Use of repaired fuses or short circuiting of the fuse switch is not permitted DO NOT open the equipment to perform any adjustment measurements maintenance parts replacement or repairs until all power supplies have been disconnected Only a properly trained technician should work on any equipment with power still applied When opening covers or removing parts exercise extreme care live parts or connections can be exposed Section 1 Section 2 Section 3 Section 4 Section 5 Table of Contents Introduction Overview Capabilities and Applications Functional Description of the Model 11 Valve Filtering Purging Below the Seal Disc Troubleshooting Description Valve Leakage Plugged Valve Ruptured Sealing Disc Slow or Erratic Switching Bench Test Procedures Port to P
9. 0 1 550 39 4 mm O D Nom PLIERS Retaining Ring V16031 SPRING Compression 52000 BALLS 5 32 4 0 MM Dia V16052 O RING Silicone Rubber Size 10 V16038 O RING Silicone Rubber Size 133 V16040 WASHER Spring SST W10000 O RING Silicone Rubber Size 4 050247 PLUNGER Valve Flat Top V16055 PLUNGER Valve Dish Top P56705 DISC Teflon Seal D40005 DISC Dacron Cushion D40000 WRENCH Allen 3 16 for 3 8 Base Screw T10757 VALVE Syringe to Tubing V14502 on _ o N 2 2o0ow00 28 Drawings and Parts List Continued Lis En STOCK on DESCRIPTION NO ae TEW BIT Adapter Torque Screwdriver to 3 16 Hex T10691 16 PISTON 303 air loaded SST or equivalent V16022 21 1 PISTON Spring Loaded V16023 18 NOTE An optional part is the Model 11 Valve Test Stand Assembly Stock No V05000 shown in Figure 3 1 29 SIEMENS Siemens Energy amp Automation Inc 7101 Hollister Road Houston TX 77040 Phone 1 713 939 7400 Fax 1 713 939 9050 1 2007 Edition M06115 Siemens Energy amp Automation Inc 7101 Hollister Road Houston TX 77040 United States Phone 1 713 939 7400 Fax 1 713 939 9050 www usa siemens com ia
10. 5 mm Th VALVE Plunger Flat Top V16055 Item 9 BALLS 5 32 4 0 mm n Dia V16052 Item 28 NOTE An optional part is the Model 11 Valve Test Stand Assembly Stock No V05000 shown in Figure 3 1 27 Drawings and Parts List Continued Table 5 4 Tool and Test Kit Model 11 Valve Stock No K21041 TABLE FIG STOCK 5 3 5 1 TS on DESCRIPTION NO ITEMS ITEMS 18 BOX Union Steel 6316 B08025 FITTING SST Cap 1 16T F32601 FITTING SST Ferrule Back 1 16T F35701 FITTING SST Ferrule Front 1 16T F35901 FITTING SST Nut 1 16T F36801 FITTING SST Union 1 16T F39401 GREASE KRYTOX 240 AC 2 oz 5 9 ml G87004 SCREW Sap Socket 8 32 x 3 8 SST H09601 SCREW Cap Socket 10 32 x 7 8 SST H09614 REPAIR MANUAL Model 11 Valve 2000615 009 O RING Silicone Rubber Size 24 034024 OIL KRYTOX 143 AY 4 oz 11 8 ml 074995 SYRINGE Plastic B D Plastipak 20 cc S90000 D Oo BR A S NN SYRINGE 10 cc Glass B D 2312 S90002 SYRINGE Plastic B D 5570 S90005 WRENCH Allen 9 64 for 8 32 Screw T10754 WRENCH Allen 5 32 for 10 32 Screw T10758 WRENCH Open End 5 16 x 1 4 T10800 TUBING 316 SS 1 16 O D x 0 015 Wall T85995 TUBING Tygon 1 16 x 1 8 O D T94000 SCREWDRIVER Torque Limiting 35 in lbs 3 95 Nm V05100 ADAPTER 1 4 Sq Female Drive to 5 32 in Hex 1631005 701 SCREWDRIVER Torque Limiting 6 5 in lbs 1631005 001 SPRING Finger 15 16 23 8 mm I D V1110
11. User s Manual Edition 1 2007 4 7 rf j y OPTICHROM Model 11 Valve SIEMENS SIEMENS Optichrom Model 11 Valve For Stock Numbers 2000627 002 2000627 003 2000627 004 2000627 005 2000627 006 2000627 007 2000627 008 2000627 009 2000627 010 2000627 011 2000627 012 2000627 013 2000627 014 Revised Printing January 2007 External Loop Stainless Steel External Loop Monel External Loop Hastelloy Internal Loop 2 uL Stainless Steel Internal Loop 2 uL Monel Internal Loop 2 uL Hastelloy Internal Loop 5 uL Stainless Steel Internal Loop 5 uL Monel Internal Loop 5 uL Hastelloy Internal Loop Stainless Steel Flat Top Plungers External Loop Monel Flat Top Plungers External Loop Hastelloy C Flat Top Plungers Internal Loop 2 uL Stainless Steel Flat Top Plungers Repair Manual MO6115 Copyright Notice 1999 2007 by Siemens All rights reserved This publication is for information only The contents are subject to change without notice and should not be construed as a commitment representation warranty or guarantee of any method product or device by Siemens Reproduction or translation of any part of this publication beyond that permitted by Sections 107 and 109 ofthe 1976 United States Copyright Act without the written consent of the copyright owner is unlawful Inquiries regarding this manual should be addressed to Siemens Energy 8 Autom
12. ainless Steel C04226 20ul Internal Loop Stainless Steel Special Deliveries on these s may be longer than normal 25 Drawings and Parts List Continued Table 5 2 Parts List Model 11 LDV Valve ITEM DESCRIPTION STOCK NO The following parts are used on all Model 11 valves PLUNGER Valve Flat Top V16055 PLUNGER Valve Dish Top P56705 GREASE KRYTOX 240 AC 2 oz 5 9 mL G87004 SET SCREW Socket Head Cup Point 3 8 24 UNF 3A x 3 8 SST H10648 RING Retaining Model IX valve Truarc N5000 200 S MD V16030 BASE Retaining B00065 PLATE Compression P49500 SPRING Compression S52000 PLATE Compensation P49510 PISTON Spring Loaded V16023 O RING Silicon Rubber Size 2 133 1 810 46 0 mm I D 0 100 V16040 2 5 mm W Nom O RING Silicon Rubber Size 2 133 1 810 46 0 mm I D 0 100 V16040 2 5 mm W Nom PISTON 303 Air Loaded SST or equivalent Model X valve V16022 OIL KRYTOX 143 AY 4 oz 11 8 mL 074995 SCREW Cap Socket 8 32 x 2 SST H09607 MANIFOLD Air Signal 2000625 001 O RING Silicon Rubber Size 4 0 070 1 8 mm I D 0 070 1 8 050247 mm W Nom BODY Model 11 valve 2000626 001 SCREW Cap Socket 8 32 x 3 8 5 mm Lg SST H09601 BALL 5 32 4 0 mm Dia V16052 D 6 6 Al 4 4 4 4 4 4 4 2 lt a rs _ D O RING Silicon Rubber Size 24 034024 WASHER Spring SST 0 190 4 8 mm I D 0 375 9 5 mm O D W10000 0 020 0 5 m
13. air 9 to port 1 Slide an 8 in 20 3 mm piece of 1 16 in I D Tygon tubing 11 over the ferrule on the tubing to port 6 and slightly submerge the open end of the tubing in a beaker 10 half full of water Set the actuating air pressure regulator 5 to 50 psig 345 kPa and set the sample air pressure regulator 12 to 100 psig 690 kPal Turn the sample air switch 2 ON and check the end of the tube 11 submerged in the beaker 10 Bubbles forming at the end of the tube indicates a leak refer to section 4 for repair procedures If no bubble forms continue with step f Port to Port Leak Test Continued Turn the actuating air switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the ON position bubbles should flow from the tube In the OFF position no bubbles should flow Allow at least one minute for a bubble to form at the end of the tube A bubble indicates a leak refer to Section 4 for repair procedures If no bubble forms continue with step 4 4 Check port 1 to port 2 passage for leaks a b Remove the bubble tube 11 from tubing to port 6 Remove the Swagelok cap 3 from the tubing to port 2 and install it on the tubing to port 6 Slide the bubble tube 11 over the ferrule on the tubing to port 2 and slightly submerge the open end of the tube in a beaker 10 half full of water Turn the actuating air
14. ation Inc 7101 Hollister Road Houston TX 77040 U S A Safety Practices and Precautions Safety First Terms in This Manual Terms as Marked on Equipment Symbols in This Manual Symbols Marked on Equipment This product has been designed and tested in accordance with IEC Publication 1010 1 Safety Requirements for Electronic Measuring Apparatus and has been supplied in a safe condition This manual contains information and warnings which have to be followed by the user to ensure safe operation and to retain the product in a safe condition WARNING statements identify conditions or practices that could result in personal injury or loss of life CAUTION statements identify conditions or practices that could result in damage to the equipment or other property DANGER indicates a personal injury hazard immediately accessible as one reads the markings CAUTION indicates a personal injury hazard not immediately accessible as one reads the markings or a hazard to property including the equipment itself This system indicates where applicable cautionary or DA other information is to be found DANGER High voltage ATTENTION Refer to Manual amp Protective ground earth terminal Safety Practices and Precautions Continued Correct Operating Voltage Danger Arising From Loss of Ground Safe Equipment Use the Proper Fuse Safety Guidelines Before switching on the power check that the operating
15. bly Detail Exploded View 2 Refer to sectional assembly detail Figure 5 2 23 24 Meo ee OOO oO NE NA A S is a NZ de NES 0 IN VE ee LE ISSN END SO neues 2272 ics PASS N Er NI IN SS N Valve cap is attached on this side 8 SECTION A A NOTES 1 Callouts refer to items on parts list see Table 5 1 a 2 Refer to exploded assembly detail Figure 5 1 3 This drawing shows only those parts that are common to all Model 11 valves Figure 5 2 Model 11 Valve Assembly Without Cap Sectional View Drawing and Parts List Continued Table 5 1 Model 11 Valve Stock Numbers Complete Valve Cap only 2000627 002 C04200 External Loop Stainless Steel 2000627 003 C04201 External Loop Monel 2000627 004 C04202 External Loop Hastelloy C 2000627 005 C04206 2ul Internal Loop Stainless Steel 2000627 006 C04207 2ul Internal Loop Monel 2000627 007 C04208 2ul Internal Loop Hastelloy C 2000627 008 C04209 5ul Internal Loop Stainless Steel 2000627 009 C04210 5ul Internal Loop Monel 2000627 010 Co4211 Sul Internal Loop Hastelloy C 2000627 011 C04200 External Loop Stainless Steel Flat Top Plungers 2000627 012 C04201 External Loop Monel Flat Top Plungers 2000627 013 C04202 External Loop Hastelloy C Flat Top Plungers 2000627 014 C04206 2ul Internal Loop Stainless Steel Flat Top Plungers C04221 10ul Internal Loop St
16. breaks 4 Ifthe discs are brittle or dirty but not ruptured or ruptured but clean visually inspect the rest of the valve If it is clean and in good order install new discs and reassemble the cap follow instructions given in subsection 4 5 If the valve actuating assembly is contaminated or malfunctioning continue disassembly Body Disassembly CAUTION A Cleaning CAUTION A CAUTION A 1 4 Same as steps given in Cap Disassembly 5 Plungers 9 or 10 may be removed by inverting the valve base 26 and shaking it so that the plungers fall into the palm of your hand If the plungers are stuck delay removing them until after the pistons 18 and 21 are removed then force them out from the bottom Do not allow the plungers 10 to fall into any hard surface because nicks can ruin them 6 Remove the manifold 24 7 Remove the retaining ring 13 8 Remove the retainer base 14 compression plate 15 compression spring 16 and compensation plate 17 from the bottom of the valve body 9 Remove pistons 18 and 21 with retaining ring pliers 10 Inspect the interior of the valve body 26 the pistons 18 and 21 and the O rings 19 20 and 25 for contamination odor or mechanical wear The Model 11 valve can be cleaned by the following methods 1 Clean the valve cap using a hypodermic syringe to force cleaning fluid back and forth through each of the tubes while keeping the cap submerged A stron
17. disc move only a few thousandths of an inch to permit flow through the passages For external loop sample valve applications ports 2 and 5 are connected externally by means of tubing as shown in Figure 1 1 The standard sample volume is 170 microliters For internal loop sample valve applications ports 2 and 5 are connected internally by means of a machined passage in the valve cap as shown in Figure 1 3 The standard sample volumes are 2 and 5 microliters The Model 11 valve must be protected against dirt filings column packing material or anything else that might affect the Teflon to metal seal Filter elements should be 5 micrometer or finer Purging below the seal disc area may be necessary in a trap valve when permeation through the seal disc causes air peaks or in a sample valve when corrosive gases attack the seal disc cushion and or other valve parts In the latter case the expected mean time between failure can be increased significantly Purging is normally accomplished with the carrier gas 1 16 tube fittings are provided as inlet and outlet connections for the purge gas Typically a tee can be placed in the carrier inlet line and a needle valve can be used to regulate the flow at 5 cc min SAMPLE OUT SAMPLE IN SEALING DISC PLUNGER UPPER ACTUATING PISTON RETRACTED AIR PRESSURE REMOVED LOWER ACTUATING PISTON ADVANCED CARRIER IN TO COLUMN CARRIER I RE n aa ea DE ENERGIZED j A A
18. e tube then shut off completely When the actuating air switch is turned OFF switching the loop back to the pressure side no air should escape Bubbles forming at the end of the submerged tube indicate a leak refer to Section 4 for repair procedures Port to Port Leak Test Continued ITEM NO ROND SAMPLE AIR PRESSURE GAUGE 0 100 psig 0 695 kPa SAMPLE AIR SWITCH 1 16 in SWAGELOK CAP ACTUATING AIR PRESSURE GAUGE 0 60 psig 414 kPa ACTUATING AIR PRESSURE REGULATOR ACTUATING AIR SWITCH ACTUATING AIR CONNECTION MODEL 11 SAMPLE VALVE SAMPLE AIR CONNECTION BEAKER OF WATER BUBBLE TUBE TYGON SAMPLE AIR PRESSURE REGULATOR ADAPTER TUBE 9 Figure 3 1 Model 11 Valve Test Stand Assembly Stock No V05000 13 Port to Port Leak Test Continued 100 PSI 689 kPa 10 MICROMETRE FILTER NOT FURNISHED 0 60 PSIG 0 414 kPa ACTUATING IN AIR SUPPLY BUBBLE TUBE Figure 3 2 14 x lt ATMOSPHERE N LA 4 GW N en CAP gt gt lt ca 0 100 PSIG 0 689 kPa K N SAMPLE AIR SUPPLY OPEN WITH AIR OFF Model 11 Valve Test Flow Diagram Chapter 4 Repair Description Under normal operating conditions the Model 11 valve will perform a minimum of 500 000 cycles without failure However contamination or abuse will drastically shorten the operating life of the valve Process upsets improper filtering or improper maintenance p
19. g detergent solution hexane acetone or methanol is satisfactory An ultrasonic cleaner is a good aid for loosening particles in port holes Do not allow the polished face of the valve cap to rest on the bottom of an ultrasonic cleaner container or against any object in the container Rinse and shake out the tubes then let the cap air dry before reassembly 2 Wipe off grease and contamination from all other valve parts and clean as described in step 1 above Do not wash O rings in hexane or other solvents Do not allow anything to rest on the top surface polished surface of the body while in the ultrasonic cleaner Allow the parts to air dry 17 Reassembly NOTES Body Reassembly CAUTION A 18 The Model 11 valve can be reassembled by the following methods e All parts need to be clean before reassembly Clean hands clean tools and a clean dust free area in which to work are recommended The numbers in parenthesis below refer to similarly numbered callouts on Figures 5 1 and 5 2 1 If the valve body was disassembled reassemble it by following the steps described below and then proceed with the cap reassembly Apply a bead of KRYTOX 240 AC grease in both O ring grooves of the spring loaded piston 18 Install silicone O rings 19 and 20 and apply grease to their outer surfaces Apply KRYTOX 240 AC grease to each of the six fingers of the finger spring on the air loaded piston 21 Place the a
20. he liquid sample streams may have pressures several hundred pounds higher than the carrier gas Leaking between ports will show up on the analyzer recorder as base line shift when the sample pressure is removed from the valve Plugged Valve Ruptured Sealing Disc Slow or Erratic Switching Plungers in the valve are pressed upward by air or spring action but when released depend on their own weight and sample pressure to drop them to the open position Very small sample pressures 1 to 10 oz 0 4 to 4 3 kPa may be insufficient to open the flow path ifthe sealing disc has been held against the cap for a long time such as a valve in storage Check flow across alternate flow paths air on and air off It may be necessary to temporarily increase the sample pressure to get the flow started and then reduce it to normal after a few cycles To test for a ruptured sealing disc apply air to valve ports one at a time while sealing off all others Place a small amount of soap solution such as Leak Tec M over the upper control port s bleed tube see callout 24 on Figures 5 1 and 5 2 Any escaping air at this point indicates a ruptured disc If this occurs proceed with a disc replacement If the disc does not appear to be ruptured remove the valve from service and proceed with a bench test as described in Section 3 Bench Test Procedures Excessive friction on the actuating pistons of the valve can be caused by lack of lubricant or dir
21. ing the loop back to the pressure side no air should escape Bubbles forming at the end of the submerged tube indicate a leak refer to Section 4 for repair procedures 10 For valves with internal loop caps only stock no s 2000627 005 2000627 006 2000627 007 2000627 008 2000627 009 2000627 010 and 2000627 014 a shorter version of the test given in steps 3 through 8 can be performed by doing the following a b Hook up the test stand and valve as described in steps 1 and 2 Plug the ends of the tubing from ports 6 and 3 with 1 16 in Swagelok caps 3 Connect the sample air 9 to port 1 Slide the bubble tube 11 over the ferrule on the tubing to port 4 and slightly submerge the open end of the tube in a beaker 10 half full of water Set the actuating air pressure regulator 5 to 50 psig 345 kPa and set the sample air pressure regulator 12 to 100 psig 690 kPal Turn the sample air switch 2 ON and check the end of the tube 11 submerged in the beaker 10 Bubbles from the end of the tube indicate a leak refer to Section 4 for repair procedures If no bubble forms continue with step g 11 Port to Port Leak Tests Continued 12 Turn the actuating air switch 6 ON while observing the end of the bubble tube 11 submerged in the beaker 10 When the internal loop between ports 2 and 5 is switched from the pressure side to the outlet side a slug of air should escape from the bubbl
22. ir loaded piston 21 over the small diameter of the spring loaded piston 18 with the finger spring outside and position with the guide pin Apply a bead of KRYTOX 240 AC grease to the O ring groove Install silicone O ring 19 Apply grease to the O ring outer surface Apply a thin film of KRYTOX 240 AC grease to the inside of the valve body 26 where the pistons will be sliding Inset both pistons into the bottom of the cylinder Use retaining ring pliers to position pistons with the guide pin in the hole of the body Be careful not to damage the O rings when sliding them past the lower retaining ring groove 7 9 Place the spring 16 on the compression plate 15 Apply KRYTOX 240 AC grease to the beveled cone of the compression plate 15 and insert the ball 28 into the greased cone Insert both of these into the retainer base 14 Apply KRYTOX 240 AC grease to the base screw 12 and then screw it into the retainer base 14 Place the compensation plate 17 over the spring 16 Apply a thin film of KRYTOX 240 AC grease to the outside of the compensation plate 17 and inside of the retainer base 14 before final assembly Place the assembly containing the spring 16 compression plate 15 set screw 12 base 14 and compensation plate 17 in the valve body 26 Reinstall the retaining ring 13 10 Reinstall the manifold 24 with 3 o rings 25 Cap Reassembly If the valve body was disassembled
23. m Th SCREW Cap Socket 10 32 x 7 8 22 2 mm Lg SST H09614 DISC Teflon Seal D40005 DISC Dacron Cushion D40000 See Table 5 1 for Various Cap s DuPont KRYTOX 240 AC grease is used to lubricate O rings DuPont KRYTOX 143 AY oil is used to lubricate plungers item 9 and 10 See Table 5 1 where Item 9 is used 26 Drawings and Parts List Continued Table 5 3 Repair Kit Model 11 Valve Stock No K21040 1 O RING Silicone Rubber Size 133 V16040 Item 19 2 O RING Silicone Rubber Size 10 V16038 Item 20 3 O RING Silicone Rubber Size 4 050247 Item 25 4 DISC Teflon seal D40005 Item 34 5 DISC Dacro Cushion D40000 Item 35 6 GREASE KRYTOX 240 AC 2 oz 5 9 mL G87004 Item 11 7 OIL KRYTOX 143 AY 4 oz 11 8 mL 074995 Item 22 8 WRENCH Allen 9 64 for 8 32 Screw T10754 9 WRENCH Allen 5 32 for 10 32 Screw T10758 WRENCH Allen 3 16 for 3 8 Base Screw T10757 PLIERS Ret Ring V16031 SCREWDRIVER Torque Preset to 35 in lbs V05100 O RING Silicone Rubber Size 24 034024 Item 31 ADAPTER Y Sq Female Drive to 5 34 Hex 1631005 701 SCREWDRIVER Torque Limiting 6 5 in Ibs V05110 BIT Adapter Torque Screwdriver to 3 16 Hex T10691 REPAIR MANUAL Model 11 Valve 2000615 009 BOX Union Steel 6316 B08025 PLUNGER Dish Top P56705 Item 10 SCREW Cap Socket 8 32 x 3 8 SST HO9601 Item 27 WASHER Spring SST W10000 Item 32 0 190 5 mm I D 0 375 10 mm O D 0 020 0
24. ort Leak Test Repair Description Cleaning of Flow Passages Disassembly and Inspection Cleaning Reassembly Drawings and Parts List Oo O O1 O1 O1 D D D A NN 21 i ii Chapter 1 Introduction Overview The Model 11 Valve Maintenance Manual has preventative maintenance repair and test information for trained plant personnel who are responsible for in plant maintenance of the Model 11 Chromatograph Valve In This Chapter This Chapter covers the following topics Topic Capabilities and Applications Functional Description Filtering Purging Below the Seal Disc Capabilities and The Model 11 valve can be applied in process chromatographs as a Applications liquid or vapor sample valve column switching valve or a column backflush valve It provides the uniform sample volume high reliability 500 000 cycle life on clean gas low internal volume and high speed switching time in milliseconds required by process chromatography Plus it provides the added benefits of minimum wear critical parts move only thousandths of an inch for switching dependable reproducibility and simplified construction for easy maintenance See Table 1 1 for detailed specifications The Model 11 valve body and cap are constructed so cleaning or replacement of sealing and cushion discs can be done without removing the valve from the chromatograph oven Removal of three bolts allows access to the disc with no special tools required
25. p to 300 psig 2068 4 kPa Up to 60 psig 413 7 kPa 2000627 014 5 psig 34 5 kPa Less than 1 microliter per minute 316 stainless steel and Teflon standard Monel and Teflon or Hastelloy and Teflon available on request 1 16 in O D tubing with Swagelok fittings 50 psig 345 kPa instrument air standard Helium or nitrogen may be substituted for air 20 milliliters at standard temperature and pressure of actuating air required for each valve operation 5 cc min of carrier normally helium 150 milliseconds total time from initiation of command signal to completion of change in valve state 2 25 in 57 2 mm diameter by 3 in 76 2 mm height Clamp type Chapter 2 Troubleshooting Description Chapter Highlights Valve Leakage The following tests can be made while the valve is in the analyzer Testing may require analyzer shut down depending on the installation Valve ports will need to be disconnected Description Valve Leakage Plugged Valve Ruptured Sealing Disc Slow or Erratic Switching Vapor analyzers generally have the sample at atmospheric pressure so any leakage would be from a carrier port to a sample port within the valve With the sample inlet flow turned off the sample outlet flow should be zero in either the air off or air on condition Check for small leaks by immersing the sample outlet tubing in a beaker of water Bubbles indicate internal leakage T
26. reassemble it by following the steps given in the Body Reassembly section then proceed with the cap reassembly as described below Place the valve body 26 on a clean surface with the two pins up Check to see if the plungers 9 or 10 protrude above the top surface of the body 26 If they do not tighten the base screw 12 until the plungers protrude about 1 16 in 1 6 mm It is normal for three of the plungers to protrude slightly farther then the other three Do not tighten the base screw beyond the point where the plungers rise readily Place one drop of KRYTOX 143 AY oil in the narrow space between each pair of plungers 9 or 10 Using tweezers move each plunger 9 or 10 up and down to lubricate it thoroughly Leave any excess oil to be soaked up by the cushion disc 35 Loosen the base screw 12 until the plungers no longer protrude above the top surface of the body 26 This is necessary to make sure that a plunger will not cut through the discs 34 and 35 when the valve is fully assembled Install the silicone rubber O ring 31 in the groove surrounding the plungers 9 or 10 This O ring is for static sealing and it does not require a lubricant Pick up the cushion disc 35 and flick it with your fingers to remove any lint or dust particles Position the cushion disc on the body over the plungers 9 or 10 Pick up the seal disc 34 and clean it by sliding it between your index finger and middle finger Make
27. rocedures which introduce foreign material into the valve can cause component damage or complete valve failure When valve trouble is diagnosed to be port to port leakage or low flow rate plugging the valve may be cleaned without disassembly However if the cause of trouble is not found or is diagnosed to be a ruptured disc proceed as outlined in the Disassembly and Inspection section Cleaning of Flow Passages ee i i er Disassembly and Inspection Cleaning of Flow The valve must be cleaned if the trouble with the valve is leakage port to Passages port or if the valve fails to allow flow port to port when the passage is switched to open The trouble may be dirt or contamination in the flow passages or excess friction in the lower section of the valve Dirt and contamination may possibly be removed by the following methods 1 Using a large syringe fitted with a tubing adapter fill it with a cleaning fluid such as hexane acetone or methanol Prepare a small beaker approximately half full of the fluid 2 Connect the syringe to port 1 on the valve Place Tygon tubing from port 2 into the beaker containing cleaning fluid With the syringe force cleaning fluid back and forth through the passage between port 1 and port 2 15 Disassembly and Inspection NOTE Cap Disassembly 16 3 Remove the Tygon tubing from port 2 and install it on port 6 and into the beaker Apply actuating air to switch the valve Use the
28. switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the OFF position bubbles should flow from the tube In the ON position no bubbles should flow Allow at least one minute for a bubble to form at the end of the tube A bubble indicates a leak refer to Section 4 for repair procedure If no bubble forms continue with step 5 5 Check port 3 to port 2 passage for leaks a b Turn the sample air switch 2 OFF Remove the sample air 9 from port 1 and connect it to port 3 Remove the Swagelok cap 3 from the tubing to port 6 and install it on the tubing to port 4 Leave the bubble tube 11 on the tubing to port 2 and slightly submerge the open end of the tube in a beaker 10 half full of water Turn the sample air switch 2 ON and check the end of the bubble tube 11 submerged in the beaker 10 Bubbles from the end of the tube indicates a leak refer to Section 4 for repair procedures If no bubble forms continue with step f Port to Port Leak Test Continued Turn the actuating air switch 6 ON and OFF several times while observing the end of the bubble tube 11 submerged in the beaker 10 In the ON position bubbles should flow from the tube In the OFF position no bubbles should flow Allow at least one minute for a bubble to form at the end of the tube A bubble indicates a leak refer
29. syringe and force the cleaning fluid back and forth through the passage between port 1 and port 6 Remove actuating air pressure 4 Attach the syringe to port 3 and place the Tygon tubing from port 4 into the beaker With the syringe force cleaning fluid back and forth through the passage between port 3 and port 4 5 Place the Tygon tubing from port 2 into the beaker Apply actuating air to switch the valve Use the syringe to force the cleaning fluid back and forth through the passage between port 3 and port 2 Remove the actuating air 6 Attach the syringe to port 5 and place the Tygon tubing from port 6 into the beaker Use the syringe to force cleaning fluid back and forth through the passage between port 5 and port 6 7 Place the Tygon tubing from port 4 into the beaker Apply actuating air to switch the valve Use the syringe to force the cleaning fluid back and forth through the passage between port 5 and port 4 8 Bench test the valve to determine if the cleaning corrected the valve problem The Model 11 valve can be disassembled and inspected by the following methods e The numbers in parenthesis below refer to similarly numbered callouts on Figures 5 1 and 5 2 1 Relieve the pressure on the base screw 12 by turning it counterclockwise until it turns easily 2 Remove the three socket head screws 33 and separate the cap 37 from the body 26 3 Inspect the sealing disc 34 and cushion disc 35 for dirt or
30. t or contamination on the O rings As a result the valve may switch erratically switch slowly or not switch at all These conditions can cause a leak port to port across the sealing disc double sampling or complete closing off of flow between two or more ports To correct poor switching conditions Disassemble the valve body Discard the old O rings Thoroughly clean all the components Lubricate components Install new O rings Reassemble the valve PLE O TOE Chapter 3 Bench Test Procedures Port to Port Leak Test Description Complete port to port leak test procedures are explained in this chapter A complete test is recommended for a thorough check of the Model 11 valve however a short version of the test for either external loop or internal loop sample valves can be made by doing step 9 or 10 only All tests shall be run with the valve assembled per specifications IMPORTANT e The numbers in parenthesis in the following steps refer to similar numbered callouts on Figure 3 1 Test Stand Assembly e Figures 3 2 Test Flow Diagram can help you visualize the flow at various ports when the actuating air switch 6 is operated Procedures 1 Connect a 100 psig 69 kPa air supply to the test stand see Figure 3 1 2 Connect the actuating air 7 to the test valve 8 3 Check port 1 to port 6 passage for leaks a Plug the end of the tubing from port 2 with a 1 16 in Swagelok cap 3 Connect the sample
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