Emerson Yarway 7100 Series User manual

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Before installation these instructions must be fully read and understood

GENERAL

Yarway 7100 Series ARC®Automatic

Recirculation Control valve for all valves

SerialNo. A71230 and below.

Engineering doc. #968155 Rev. D

INSTALLATION

General instructions

1. Look at typical installation diagram

(seeFigure 1).

2. Valve can be installed in any position.

However, flow arrow on body must match

flow direction in pipe.

3. Valve body material is either carbon steel

(ASME-SA 216 WCB) or stainless steel

(ASME SA351 CF8M).

Look at the valve nameplate - it will

identifythe material for your valve!

4. When welding valve in line, select

compatible weld rod and follow all

applicable codes and regulations.

5. Follow recommendations on installation

diagram (opposite page) for straight pipe,

maintenance clearances and auxiliary valve

locations. Refer to 'ISA handbook of control

valves' Chapter 12 for other recommended

installation practices.

CAUTION!

The valve you are about to install contains

elastomer seals. If welding the valve in line,

doone of two things;

OPERATION

CAUTION!

There are only two adjustments described in the

following notes, which can be made to an installed

and operating valve. Your valve has been preset

and tested at the factory for your conditions.

Adjustments are necessary only when conditions

change and are not to be made before contacting

a Yarway application engineer to determine how

much adjustment, if any, is necessary. Making

adjustments onyour own can cause serious

damage to the pump and system.

1. The 7100 Series valve is a self-contained,

fully automatic device which requires no

external power or signals to perform its

function.

2. The valve does two things: (1) it protects the

pump from reverse flow, and (2) prevents

the pump from overheating during low

loadperiods.

3. Your valve has a modulating bypass. The

bypass will open or close gradually so

that the sum ofmain flow and bypass flow

will never be below the minimum flow

requirement of the pump.

4. If operating conditions should change,

two adjustments can be made in the

valve(withinlimits). They are:

a. Switchpoint.

b. Bypass capacity.

Switchpoint is the main flow quantity at

which the bypass will open or close.

Bypass capacity is the flow quantity that

willpass through the bypass.

either:

1. Keep the main body of valve below 300°F

during preheat, welding and post weld heat

treatment.

2. Disassemble the valve to remove seal

containing parts (refer to Maintenance section

for procedures - disc/bonnet removal and

bypass bushing cartridge removal).

Note: failure to follow these precautions will

result in damaged seals!

3” 18” 12”

4” 24” 15”

6” 34” 21”

8” 41” 28”

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Block valve

Recommended location of

back pressure orifice or

back pressure regulator

when specified

L is recommended minimum straight run of pipe

L1= 10 pipe dias. (min.)

L2= 5 pipe dias. (min.)

L3= 5 pipe dias. (min.)

e.g. - 4” pipe L1= 40 in.

Block valveFrom pump

Inlet Outlet

Bypass outlet

Flow

arrow

Receiver vessel

Check valve

MAIN FLOW

BYPASS FLOW

(VIEW A-A)

Valve size F G

FIGURE 1

Minimum clearance

to remove bonnet/disc

assy

Minimum clearance

to remove cascade

bushing

INSTALLATION DIAGRAM

Switchpoint adjustment

CAUTION!

Switchpoint adjustment requires some valve disassembly. Make sure valve is properly isolated, cooled

down and all pressure relieved before any work is performed. Follow all applicable safety precautions.

Instructions

1. Switchpoint adjustment can be made by removing either the bonnet/disc assembly or bypass

cartridge assembly - to find out how, refer to maintenance section.

2. Look at illustration (see Figure 2).

3. Once the adjustment has been made, refer to maintenance section to reassemble thevalve.

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

WARNING!

Lowering switch point could damage pump.

To lower switchpoint - turn screw clockwise.

To raise switchpoint - turn screw counterclockwise.

The switchpoint adjustment screw will not turn easily. It is held in place by a friction producing insert

which prevents its movement while in service.

Bonnet/disc assembly

(as removed from valve)

Bonnet/disc compression

and removal tool

Bonnet

Disc

Slotted switchpoint

adjustmentscrew

FIGURE 2

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Bypass capacity adjustment

CAUTION!

This adjustment does not require valve disassembly. However, make sure valve is properly isolated,

cooled down and all pressure relieved before any work is performed. Follow all applicable safety

precautions.

Instructions

1. Adjustment screw is located at bottom of valve - directly opposite bonnet end.

2. Look at illustration - (see Figure 4).

3. Loosen lock nut, make adjustment, retighten lock nut.

Bonnet

Locknut

Adjustment screw

Bypass capacity

adjustmentscrew

WARNING!

Reducing bypass capacity could damage pump.

To reduce bypass capacity - turn screw clockwise.

To increase bypass capacity - turn screw counterclockwise.

FIGURE 3

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

General instructions

1. There are only two major disassembly

procedures:

a. Bonnet/disc removal.

b. Bypass cartridge removal.

2. Valve body does not need to be removed

from line to perform any maintenance and

service procedures.

3. Slightly damaged seating surfaces can be

reconditioned by lapping with a fine lapping

compound.

4. When changing lip type seals, make sure

they are installed in proper direction or the

valve won’t work properly.

MAINTENANCE

1. Align bushing in body.

2. Install installation tool in place over two

body studs as shown.

3. Turn stud nuts to press bushing in place.

Bypass bushing installation tool

Instructions for use

Bushing

Bypass bushing

installationtool

CAUTION!

Make sure valve is properly isolated, cooled

down and all pressure relieved before any

work is performed. Follow all applicable

safetyprecautions.

Jacking bar

Bypass bushing installation tool

Spring compression tool

Jacking rods

Switchpoint adjustment tool

Jacking bar - used to assist removal of bonnet/

disc assembly. Complete with lifting lug for

support of assembly upon removal. See bonnet/

disc removal procedure for instruction.

Bypass bushing installation tool - used with

body studs and nuts to assist installation of

bushing in body (overcome friction of O-rings).

See below for procedure.

Spring compression tool - used to compress

disc spring and allow removal of disc/bonnet as

a unit. Used with jacking bar. See bonnet/disc

removal procedure for instruction.

Jacking rods - used with jacking bar. See

bonnet/disc removal procedure for instruction.

Switchpoint adjustment tool - 8” valve only.

Used to adjust switchpoint after removal

of bypass cartridge (other sizes - use long

screwdriver).

FIGURE 4

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Bonnet/disc assembly parts identification

Bonnet/disc removal/installation

Bonnet

Spring

Disc

Pipe plug

Holes for

threaded rods

Use upper nuts

topushbonnet in

Use this nut to

compress spring

Compression tool

Jacking rod

Jacking bar

Use lower nuts

topullbonnet out

Bonnet/disc assembly

(showncompressed)

Segmented ring

retainer

Segmented

ring

FIGURE 5

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Bonnet/disc removal and assembly

Disassembly

1. Look at illustration (see Figure 5).

2. Remove pipe plug.

3. Insert compression tool through the bonnet and screw into disc.

4. Turn nut until disc is in full up position.

5. There are two threaded holes in top of body - use these with jacking rods (can be made from

threaded rod) and jacking bar (can be made from appropriate size angle iron or square tube).

6. Using jacking bar, push bonnet into body approximately ⅛”.

7. Remove segmented ring retainer.

8. Remove segmented rings.

9. Using jacking bar, pull bonnet/disc assembly out of valve.

Assembly

1. Bonnet and disc must be installed as a unit - use compression tool to assemble

bonnet/spring/disc.

2. Using jacking bar, push bonnet/disc assembly into valve until it stops.

3. Insert segmented rings.

4. Install segmented ring retainer.

5. Using jacking bar, pull bonnet/disc assembly until it is snug against segmented rings.

6. With compression tool in place, turn nut until disc is lowered onto seat, then remove tool

frombonnet.

7. Replace pipe plug.

See detail A

New design has

large groove

O-ring

Back-up ring

Valve body

Bypass bushing

Bushing orientation

spring pin

Bypass cover

Bypass capacity adjustment screw

Bypass

Adjustment

screw cover

Retainer

Pilot tube

Piston

Bypass

bushing

Threaded holes

forjack screws Threaded holes

for jack screws

Bypass cover

Anti-rotations keys

Pilot valve

seat

Pilot tube seal

bushing

Retaining ring

Retainer

Pilot tube

Piston

Bypass

bushing

Bypass cover

Anti-rotations keys

Pilot valve

seat

Pilot tube seal

bushing

Piston

3” VALVE ONLY

(new design)

KEY

DETAIL A

DETAIL C

Conical seat pilot tube design

(new design)

DETAIL D

Spherical seat pilot tube design

(old design)

See detail C

orDbelow

Metering

orifice

Metering orifice

retainer

Pilot tube

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

'Old design' designates parts manufactured before 1997; 'New design' designates parts manufactured after 1996.

FIGURE 6

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

Bypass cartridge removal and assembly

Disassembly

1. Look at illustration (see Figure 6).

2. Remove bypass cover.

3. Insert two jacking screws in threaded holes in bypass bushing flange and jack out cartridge.

Once the bypass cartridge is out, and you’ve determined which of the two (2) pilot tube designs

you have, Detail “C” or Detail “D”, complete the disassembly as follows:

Detail “D”

a. Pull out piston.

b. Screw out pilot tube seal bushing.

c. Screw out pilot valve seat.

d. Remove the anti-rotation keys retainer.

e. Pull out pilot tube.

Detail “C”

a. Pull out piston.

b Screw out pilot valve seat.

c. Remove pilot tube seal bushing retaining ring.

d. Pull out pilot tube seal bushing.

e. Remove the anti-rotation keys retainer.

f. Pull out pilot tube.

Then:

4. Carefully pry off the metering orifice retainer (it is press-fitted in place).

5. Pull out metering orifice.

Assembly

There are only four very important points:

1. Press fit metering orifice retainer in place over metering orifice.

2. When installed, the flats on pilot tube must line up with flats of anti-rotation keys in pilot

valveseat.

3. a. If your assembly matches that shown in Detail “D”: securely tighten the pilot tube seal

bushing and pilot valve seat into piston.

b. If your assembly matches that shown in Detail “C”: firmly seat the pilot tube seal bushing

into the pilot valve seat and ensure that its retaining ring has clearly snapped into its

groove. Securely tighten the pilot valve seat into the piston.

4. Bypass bushing outlet must line up with outlet in body. This is accomplished by turning

bushing until spring pin in bushing flange lines up with its matching hole in valve body.

11**

41*

46/46a

3” 1½” 900 4 1”-8UNC 1

16”

1500

900

4” 2” 1500 8 ⅞”-9UNC 1⅝”

6” 2½” 900 8 1”-8UNC 1

16”

1500

900 8 ⅞”-9UNC 1⅝”

8” 3” 1500 8 1⅛”-8UN 2”

YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN

InstallatIon and maIntenance InstructIons

DETAIL A

See detail A

See details

Cand D

See table for bypass

flange thread size and

number of holes

NOTES

* Glyd ring assembly

** Lip type seal

Contact Yarway with valve serial number to ensure

that correct O-ring compound is selected.

'Old design' designates parts manufactured before 1997;

'New design' designates parts manufactured after 1996.

DETAIL C

Conical seat pilot tube design (new design)

DETAIL D

Spherical seat pilot tube design (old design)

FIGURE 7

O-RING SIZES AND BYPASS CONNECTION FLANGE DATA

Item No.

Valve size (O-ring size)

3” 4” 6” 8”

33 263 375 456 464

34 014 014 014 014

35 126 139 236 244

36 008 011 113 118

38 014 014 014 014

39 010 for all conical seat pilot tube design

012 for all spherical seat pilot tube design

43 012 012 012 012

46 (old design) 125 141 232 238

46 (new design) 028 141 232 238

46a (new design) 028 Backup ring N/A N/A N/A

47 131 146 242 354

48 133 147 244 356

BYPASS CONNECTION – THREADED HOLES DATA

Valve

size

Bypass

size Class

No.

holes

Thread

size

Thread

depth

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