Armstrong CDLW-1031 Installation And Maintenance Manual Download Page 13

13

Fact:

An

 

unacceptable

 

(high)

 

pressure

 

loss

 

ratio

 

(PLR)

 

is

 

the

 

primary

 

cause

 

of

 

poor

 

mixing

 

valve/hose

station

 

performance.

Symptoms

 

of

 

a

 

high

 

PLR

 

may

 

include

1. Inability

 

to

 

obtain

 

hot

 

water

2. Inability

 

to

 

accurately

 

adjust

 

outlet

 

temperature

3. Inability

 

to

 

stabilize

 

outlet

 

temperature

4. Noisy

 

operation

 

or

 

"

chattering

"

Results

 

of

 

a

 

high

 

PLR

 

may

 

include

1. Premature

 

component

 

failure

2. Unsafe

 

outlet

 

water

 

temperatures

3. Poor

 

overall

 

product

 

performance

To

 

diagnose

 

a

 

high

 

PLR

1. Identify

 

static

 

inlet

 

steam

 

and

 

water

 

pressures

 

at

 

point

 

of

 

installation.

Note

 

any

 

inlet

 

pressure

 

differentials

 

greater

 

than

 

2:1

 

ratio.

2. Remove

 

primary

 

outlet

 

restriction

 

(remove

 

spray

 

nozzle

 

for

 

example)

3. Uncoil

 

hose

 

completely

 

and

 

ensure

 

that

 

there

 

are

 

no

 

kinks

 

or

 

blockages.

4. Operate

 

Hose

 

Station

 

and

 

record

 

performance.

Correcting

 

high

 

PLR

1. Install

 

Pressure

 

regulator(s)

 

and

 

reduce

 

inlet

 

pressure

 

differential*

2. Permanently

 

reduce

 

back

 

pressure/restriction

 

by

 

a)

 

using

 

shorter

 

or

 

less

 

restrictive

 

hose;

 

b)

 

using

 

a

 

less

restrictive

 

nozzle

 

(consult

 

Armstrong

 

Hot

 

Water

 

Group

 

for

 

details

 

on

 

our

 

16

 

and

 

22

 

gpm

 

spray

 

nozzles)

3. Ensure

 

that

 

outlet

 

components

 

such

 

as

 

extension

 

wands

 

and

 

hose

 

reels

 

are

 

not

 

significantly

 

impeding

flow.

*Consult

 

flow

 

charts

 

on

 

page

 

7

 

to

 

ensure

 

that

 

you

 

maintain

 

adequate

 

supply

 

pressures

 

for

 

the

 

application.

Summary of Contents for CDLW-1031

Page 1: ...ing steam and water at a single point of use within specific parameters for industrial applications only This Steamix Hose Station Mixing Unit is not designed and should never be installed to deliver hot water for hygiene or sanitary applications people washing This Steamix Hose Station Mixing Unit is not designed and should never be installed to deliver tepid water to Emergency Fixtures This I M ...

Page 2: ...9 Only to be operated by persons trained in this equipmentís use and safety 10 Always return the hose to its holder after use 11 Always release the water pressure in the hose after use 12 Always close shut off the inlet supply controls after use 13 Only use this equipment for its intended industrial purpose washdowns vessel filling and process applications 14 Do Not substitute any component part o...

Page 3: ...ation purposes This Installation and Maintenance Guide covers the following Steamix production generations Classic 1990 1999 Serial Numbers A1000 A10000 Millennium 1999 2003 Serial Numbers A L10000 A L13300 Infinity 2004 to present Serial Numbers A L13300 and Above Product modifications and non compatible replacement parts make Steamix generation identification mandatory prior to valve servicing o...

Page 4: ...f a cross connection in the event that Steamix flow controls are left open and an outlet flow control spray nozzle is closed In addition under certain circumstances backflow may create a pressure differential across the diaphragm great enough to allow the poppet valve to open and steam to flow Without inlet flow being present this becomes a potentially dangerous condition 7 Steamix 203 uses the su...

Page 5: ...ater pressures on either side of the diaphragm are equal This allows the spring to hold the poppet valve on its seat thereby preventing steam flow Figure 5 2 Opening the outlet allows water to begin to flow When a minimum differential pressure of 7 psi 5 bar develops across the diaphragm the diaphragm lifts from its resting position and pushes the poppet valve off the steam seat allowing steam to ...

Page 6: ...ume of water Do not use this product with superheated steam Failure to heed this warning may result in serious injury Temperature Pressure Warning This product is designed to heat water for industrial washdown vessel filling and process applications only Access to extreme water temperatures and flash steam is a possibility To avoid serious injury use extreme care and wear protective gloves garment...

Page 7: ... C Temperature Rise 100 F 56 C Temperature Rise Flow Rates Temperature The following capacity charts indicate Steamix 203 flow rates at steam and water pressures commonly available in the average manufacturing plant The mixing valve can handle a wide diversity of pressures and temperatures The three typical outlet temperatures shown in the tables demonstrate the mixing valves flow rate at 1 User S...

Page 8: ... control spray nozzle is closed In addition under certain circumstances backflow may create a pressure differential across the diaphragm great enough to allow the poppet valve to open and steam to flow Without inlet flow being present this becomes a potentially dangerous condition 5 Install unions on each inlet supply factory supplied on specific models 6 If the unit is to be hard piped from its o...

Page 9: ...arameters as specified by plant management The available temperature range of the mixing valve is from ambient inlet water temperature to almost boiling To set the mixing valve to the required temperature 1 Turn the temperature regulating lever clockwise as far as it will go to close the steam inlet This may take several revolutions 2 Remove the water flow regulator locking cap using a 3 32 Hex Ke...

Page 10: ...application is unsafe wastes energy and may lead to inefficient clean up 3 Always shut off steam water flow at the tandem valves 4 Do Not leave the outlet hose under pressure Bleed pressure by opening the outlet hose nozzle briefly 5 Check the inlet supply shut offs regularly 6 Report any malfunction immediately to appropriate maintenance personnel Safety Check 1 Set the mixing valve for normal op...

Page 11: ...ong Diaphragm Service Life 1 Cool Down Do not use a spray nozzle as a long term flow control device Turn the Steamix off at its inlet flow control when it is not in use and let the valve cool Itís good for the nozzle itís good for the hose itís good for the diaphragm 2 Steam Quality Maintain your steam system efficiently and watch the condensate chemistry Highly acidic carbonic acid is not good an...

Page 12: ...re of 50 psi 3 3 bar the calculation for PLR would be 100 45 55 psi and 50 45 5 psi Thus the pressure loss ratio is 55 5 or 11 1 6 6 bar 3 bar 3 6 bar and 3 3 bar 3 bar 3 bar Thus the pressure loss ratio is 55 5 or 11 1 This unit will not operate effectively Do not confuse the Pressure Loss Ratio with the Inlet Pressure Differential Ratio which is the ratio of inlet pressures only 100 50 or 2 1 an...

Page 13: ...e any inlet pressure differentials greater than 2 1 ratio 2 Remove primary outlet restriction remove spray nozzle for example 3 Uncoil hose completely and ensure that there are no kinks or blockages 4 Operate Hose Station and record performance Correcting high PLR 1 Install Pressure regulator s and reduce inlet pressure differential 2 Permanently reduce back pressure restriction by a using shorter...

Page 14: ... body assembly and begin with the letters A L The serial numbers will be 13 300 or higher 2 The Infinity edition has the number D4352 cast in raised digits on the underside of the steam inlet left Note Millennium and Infinity valves share common replacement parts Product Maintenance Millennium Infinity The Steamix 203 s Millennium Infinity design incorporates simple and rugged construction so that...

Page 15: ...disassembling 6 Remove the bonnet and spindle assembly 7 Unscrew the spindle in a clockwise direction and remove from the bonnet Caution Do Not twist the poppet when removing or damage to the diaphragm may occur Note Replace the poppet valve and spring as a single unit when damaged 8 Carefully push out the gland seal packing 9 Carefully remove the spring and poppet valve from body 10 Using a 1 1 2...

Page 16: ...agonally opposite Press the triangular spindle that is visible in the top of the valve body to check for free and even movement of the diaphragm assembly Water Flow Regulator Disassembly Water Flow Regulator 1 Shut off the steam and water supplies 2 Open the outlet shut off valve and nozzle if equipped 3 Remove the water flow regulator cap using 3 32 hex key on set screw 4 Using a 1 wrench remove ...

Page 17: ... refer to pages 9 10 Start Up Procedure Once adjusted and operating satisfactorily remove and store the temperature control lever Figure 4 Install the locking device and secure the 1 4 20 Hex Socket Head Bolt with the 3 16 Hex Key provided Once the Steamix has been set on site and the locking device has been installed the user will only be able to operate the on off flow control lever The installa...

Page 18: ...ining Screw 2 M2 4 Gland Plate 036 203 535 M3 5 Gland Packing M5 M3 6 Temperature Control Spindle 036 203 590 M3 7 Bonnet Retaining Screw 6 M2 8 Bonnet 036 203 630 M3 9 Upper Gasket M5 M3 M4 M7 M8 10 Return Spring M4 11 Poppet Valve M4 12 Steam Diffuser M4 13 Diffuser Copper Gasket M4 M5 M7 M8 14 Cover Screw 8 036 203 570 15 Body Consult Factory 16 Water Flow Regulator Assembly M6 17 Diaphragm Ass...

Page 19: ...g Screw Lock Washer Flat Washer 1 Bonnet Assembly Retrofit M4 Part 036 203 540 Diffuser Poppet Valve Pack M5 Part 036 203 520 Service Kit 203 Upper Screw Pack M3 Part 203 937 85 Lever Handle Assembly 203 M1 Part 036 203 525 M2 Part 036 203 560 1 Temperature Control Retaining Screw Lock Washer Flat Washer 16 Water Flow Regulator Assembly 24 Water Flow Regulator Copper Gasket Kit includes fully asse...

Page 20: ...ast two of the three valve identifiers before ordering spares The Steamix 203 s Classic design incorporated simple and rugged construction so that with minimal routine care and operation within the specified limits it should operate trouble free for long periods of time All the mixing valve parts are field replaceable using standard tools However some internal components have been superceded by pa...

Page 21: ...completes the disassembly of the upper section of the Mixing Valve To clean or inspect the lower section of the Mixing Valve or if the Diaphragm requires replacement continue with the disassembly procedure in the next section Diaphragm Replacement Replace worn or damaged parts as required Always replace O rings and gaskets with new ones after disassembly Use Service Pack 203 937 52 Diaphragm Repla...

Page 22: ...ith locking cap M6 Part 036 203 580 1 Bonnet Assembly M3 Part 203 937 58 1 Gland plate with screw 1 Gland packing When a Tamper Resistant Locking Set is used it is essential that the water flow regulator locking cap be installed If only the Temperature Regulating Locking Device is installed unauthorized persons may attempt to adjust the temperature by tampering with the water flow regulator Instal...

Page 23: ...Socket Head Bolt with the 3 16 Hex Key provided Once the Steamix has been set on site and the locking device has been installed the user will only be able to operate the on off flow control lever The installation is now complete and the steamix 203 must be tested for acceptable temperature and flow prior to being placed into service The Hex Keys provided are not commonly available to plant cleanup...

Page 24: ...ription Component Part Number Suggested Kit 003 21 Base Consult Factory 012 03 Bonnet Assembly M3 236 10 Gland Plate M3 801 31 Body Consult Factory 856 26 Handle temperature control lever M3 196 07 Flow Regulator Cap M6 937 50 Diffuser Pack M4 937 51 Poppet Valve Pack A M4 937 52 Service Pack B 203 937 52 937 53 Upper Screw Pack C 203 937 53 937 54 Lower Screw Pack D 203 937 54 937 55 Diaphragm As...

Page 25: ...Gasket Water Flow Regulator Spindle O Seals 2 Cover O Seal Connecting Tube O Seal Connecting Tube Kit M1Part 203 937 57 M2Part 203 937 82 Diaphragm Assembly M4Part 203 937 52 Service Kit 203 Diaphragm M3Part 203 937 55 Temperature Control Retaining Screw Lock Washer Flat Washer Temperature Control Lever Gland Plate Retaining Screw 2 Upper Gasket Gland Plate Gland Packing Temperature Control Spindl...

Page 26: ...Standards and Approvals Armstrong International Inc is an ISO 9001 certified manufacturer Armstrong International Inc maintains Canadian Registration Numbers specific to Steamix 203 on file ...

Page 27: ...use 12 Always close shut off the inlet supply controls after use 13 Only use this equipment for its intended industrial purpose washdowns vessel filling and process applications 14 Do not substitute any component part on this assembly 15 Use only performance matched parts for replacement from the Armstrong Hot Water Group 16 Use of incorrect parts could cause serious personal injury 17 Do not use ...

Page 28: ...SS FOR A PARTICULAR PURPOSE The sole and exclusive remedy with respect to the above limited warranty or with respect to any other claim relating to the products or to defects or any condition or use of the products supplied by Armstrong however caused and whether such claim is based upon warranty contract negligence strict liability or any other basis or theory is limited to Armstrongís repair or ...

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