Emerson VA001-102-01 Guide

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Low Pressure Diaphragm-Operated Air

Relay Valve

Service and Adjustment for VA001-102-01 & VA001-102-02

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

Page 1

Figure 1: Air Relay Valve with 1-1/4 Diaphragm

A. Disassemble and Clean

Information enclosed in brackets (item 1 etc.) is in reference to the complete assembly

drawings on page 6 and the illustrations throughout the document.

1. Remove spring retainer (item 2), adjusting cap (item 3) and locknut (item 4), by

unscrewing as a unit, from the body (item 1) and set aside.

2. Remove diaphragm cylinder assembly (item 9), by unscrewing as a unit, from the

body (item 1) and set aside.

3. Slowly pull valve stem (item 7) out of body (item 1) and set aside on a clean surface.

4. Carefully remove end valve sleeves (item 6) and center valve sleeve (item 5).

Note how they go together.

5. Clean stem (item 7) with a soft

cloth, Do Not scratch the stem.

Clean the end sleeves (item 6) and

center sleeve (item 5).

6. Lubricate and install new outer o-

ring (item 10) and install new inner

o-ring (item 11), without lube, on

one end sleeve (item 6). From the

spring retainer end, fit the end

sleeve into the bore of the body

with the o-rings toward the spring

retainer threads. Insert the sleeve

until the outer o-ring is about to

enter the bore. (See Figure 2.)

Figure 2: Placing End Sleeve Seals

Adjusting Cap (3) Locknut (4) Spring Retainer (2)

Body (1)

Diaphragm Cylinder Assembly (9)

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

Page 2

7. Install the spring retainer (item 2),

adjusting cap (item 3) and locknut

(item 4), as a unit. As you thread

the spring retainer in, it will push

the o-ring and sleeve into the bore

to the correct position. Tighten

spring retainer hand tight. (See

Figure 3)

Figure 3: Installing Spring Retainer

8. Turn the valve body (item 1) so

that the open end of the bore is up.

Install new inner o-rings (item 11),

without lube, in the center sleeve

(item 5). Place new lubricated o-

ring (item 10) in the bore of the

body (item 1) on top of the end

sleeve (item 6). (See Figure 4)

9. Carefully slide the center sleeve

(item 5) into the bore in of the

body. When it reaches the outer o-

ring (item 10), lying on the end

sleeve (item 6), press the center

sleeve to seat the o-ring. (See

Figure 5)

Figure 4: Placing Center Sleeve

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

Page 3

10.Place a lubricated outer o-ring

(item 10) in the bore of the body

(item 1) on top of the center sleeve

(item 5). Do not try to seat o-ring

at this time. (See Figure 5)

Figure 5: Center Sleeve Seated

11.Install new inner o-rings (item 11),

without lube, and lubricated outer

ring (14) in the second end sleeve

(item 9). Slide the end sleeve into

the bore of the body (item 1) with

the o-ring grooves out toward the

cylinder threads. Insert the sleeve

until the outer o-ring is about to

enter the bore. (See Figure 6)

12.Disassemble the diaphragm

cylinder by removing the 10-32 x

¾” socket head cap screws (items

9-8) retaining the end cap (item 9-

7) and remove the diaphragm

assembly (item 9-3) from the

cylinder (item 9-1). Discard the old

diaphragm assembly (item 9-3).

(See Figure 8) Figure 6: Placing Last End Sleeve

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

Page 4

13.Clean the cylinder and end cap.

Check the breather (item 9-10) and

clean if needed.

14.Install the cylinder (item 9-1). As

you thread the cylinder in, it will

push the o-ring and sleeve into the

bore to the correct position. This

action will also seat the o-ring in

the center sleeve. Tighten cylinder

(item 9-1) hand tight to the body

(item 1).

Figure 7: Installing Cylinder

15.Lubricate the tip of the stem (item 7), note taper, and carefully insert taper end first,

pushing it through bearing (item 9-9) toward the spring end (item 3). (See Figure 8)

Figure 8: Completing Assembly

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

Page 5

16. Lubricate the seal ring on the new diaphragm assembly and install it in the cylinder.

Note: The diaphragm assembly is not repairable and must be replaced in its entirety.

17.Place the end cap on the cylinder.

18.Lubricate the ¾”x10-32 screws with Never-seeze® and torque to 20 In-Lbs max. in a

criss-cross pattern.

19.Hold the assembly by gripping the diaphragm cylinder assembly, item 9, and using a

wrench on the spring retainer flats (item 3) tighten the complete assembly. Torque

to 120 inch pounds.

B. Valve Setting Procedure

1. Mount the air relay valve in a stand that has a 150-psi maximum supply with an

adjustable self-venting regulator. Connect the adjustable supply to the pilot port in

the end of the diaphragm cylinder (item 9).

2. Install a pressure gauge that reads up to 300-psi in the body cylinder port.

3. Install a 150-psi air supply in the normally open or normally close port.

4. Gradually increase or decrease the pressure, at the pilot port until the valve trips.

When the valve trips read the pilot supply gage and make a note of the pressure.

5. To adjust the trip point, remove pressure on the pilot and rotate the adjusting cap

(item 3) clockwise to increase or counter clockwise to decrease. Always remove

pressure at the pilot before adjusting the adjusting cap.

6. Adjust the cap (item 3) and take pressure readings until the valve trips at the

required pressure.

7. Tighten the locknut (item 4) to maintain the setting achieved.

If any further information is required, please feel free to contact:

Emerson Process Management

Valve Automation Inc.

2500 Park Avenue West

Mansfield, Ohio 44906

Phone: (419) 529-4311

Fax: (419) 529-3688

Please visit our website for up to date product data. www.shafervalve.com

The contents of this publication are presented for informational purpose only, and while every effort has been made to ensure their accuracy,

they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use

or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time with out notice.

RAP R11: Low Pressure Air Relay Valve Service and Adjustment

ARV-VA001-102-00

05/05/11

Air Relay Valve

View from VA001-102-00 assembly drawing of valves VA001-102-01 (Buna-N seals) and

VA001-102-02 (Flurocarbon seals.

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