Transcript
Instruction Sheet PA-00231 June 2013
Replacement of Electronic Expansion Valve EXV 200, 300, 400, 400C and 800 Ton Using Field Replacement Kit 059074
Replacement of Electronic Expansion Valve EXV 200, 300, 400, 400C and 800 Ton Using Field Replacement Kit 059074 SAFETY INSTRUCTIONS
1. Read all instructions thoroughly. Failure to comply may result in valve failure, system damage, or personal injury. 2. WARNING: If a hand valve is installed ahead of a solenoid valve, it should be closed only to service the system. The hand valve should be opened as soon as the service is complete. If both the solenoid valve and hand valve were closed, trapping liquid between the two can cause dangerous hydrostatic pressure, resulting in personal injury.
3. Disconnect electrical power source, shut-off fluid power source and depressurize valve. 4. Do not attempt to repair the valve before pumping the system down to atmospheric pressure before removing any valve parts. 5. Do not use a solenoid valve as a safety shut-off valve when making repairs to a system.
INSTRUCTIONS ON CHANGING FUSITE FEED-THROUGHS 1. Remove insulating materials around the valve. 2. Remove 4 electrical cover screws using 7 mm socket and remove cover. 3. Disconnect 4 electrical connections from the EXV feed-throughs. 4. Set cover, conduit and wiring aside. 5. Using 17 mm socket with flexible coupling and extension, remove eight motor housing-to-casting bolts. 6. Carefully lift motor housing from casting, remove magnet, remove 4 motor leads from electrical feedthroughs and remove flange O-ring. 7. Put a coating of non-conductive grease (LUB-0008) on all exposed metal of the connector and feed-through terminals. 8. Using 7/16" deep well socket remove 4 feed-throughs from motor housing. 9. Clean and dry motor housing. 10. Clean debris, if any, in the internal threads on the bulkhead plate of the motor housing, where the feedthroughs will be installed. 11. Apply Locktite 554 to 4 new feed-throughs and insert by hand. Make sure to orient the hex head side of the feed-throughs toward the short (cover) end of the motor housing tube. Torque each to 120 in-lbs. 12. Sparingly coat the new "O" ring with refrigeration oil before installing in the valve. Good service practice requires that all external seals be replaced anytime the valve is opened for service. 13. Install wire leads inside motor housing per stamped markings: R - Red B - Brown W-B - White/Brown W-R - White/Red
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14. Place the magnet on the inside diameter of the motor housing tube such that the outside diameter of the magnet is flush with the bottom of the tube and within 3/8" of the dirt filter when finally setting motor housing down on casting. Also ensure that the magnet sticks to the tube and not to the motor. 15. Ensure that lead wires are not pinched between the motor housing and casting when housing is being set down on the casting. 16. With operator facing machine, position motor housing on casting with one lifting lug towards the operator. The position is not critical for valve functioning, but may help in external connections looking like they did before. 17. Loosely install 8 motor housing-to-casting bolts finger tight. Tighten motor housing-to-casting bolts in crisscross pattern to 19 ft-lbs. 18. Tighten motor housing-to-casting bolts to 38 ft-lbs., again in criss-cross pattern. 19. Evacuate and replace any removed refrigerant. 20. Conduct the following tests: • Test for leaks around the 4 electrical feed-throughs and flange O-ring joint with electronic leak detector. A. If there are leaks, repeat step 2 and steps 7 through 20. B. If there are no leaks, replace conduit and conduit fitting. 21. Connect the 4 electrical wires (per Trane markings) to corresponding terminals marked 1, 2, 3 and 4 on top of the bulkhead plate of the motor housing. 22. Position cover and attach with 4 electrical cover screws. Torque to 28 in-lbs. 23. Replace removed insulating materials around valve. 24. Switch power to valve on. Test system for proper operation.
SPECIAL TOOLS REQUIRED 1. 2. 3. 4. 5.
17 mm socket with flexible coupling and extension. 7 mm socket. 7/16" deep well socket. Torque wrench with range: At least 28-120 in-lbs. Torque wrench with range: At least 19-38 ft-lbs.
PARTS/MATERIALS REQUIRED 1. 2. 3. 4.
4 Fusite feed-throughs. New O-ring. Locktite 554 not included in kit. Rust inhibitor (LUB-0008) note included in kit.
EmersonClimate.com/FlowControls Technical Support: 1-866-625-8416 PA-00231 (06/13) Emerson is a trademark of Emerson Electric Co. ©2013 Emerson Climate Technologies, Inc. All rights reserved.
