Akron Brass Style 8840 Datasheet

1
STYLE 8840 HI CYCLE ELECTRIC VALVE
INSTRUCTIONS AND PARTS LIST
GENERAL INFORMATION
The Style 8840 Valve utilizes a flat ball concept providing an open area greater than a typical 4” waterway. This design features a 4” long body and has
easy operation with limited friction loss.
The valve has the Swing-Out™ feature and is designed for easy service with only one seat and an aluminum bronze flat ball which will rarely need to be
changed.
The valve has a rated working pressure of 250 PSI in the flow direction, but will hold 100 PSI in the reverse direction. It is hydrostatically rated at 500
PSI.
This valve is single directional and must be installed with the 250 PSI directional arrow (cast on valve body) pointing away from the pump regardless if it
is for discharge or intake applications.
NOTE: If the valve is used as an intake, it must be installed with the 250 psi directional arrow towards the swivel intake.
The electric actuator is reduced to 25:1 and will travel from full open to full close in approximately 8-10 seconds.
INSTALLATION
1. Plumb into the pump system as usual being sure to heed the flow directional arrow cast on the body.
2. The actuators can be mounted in one of four positions.
3. Keep the piping aligned so undue stresses are not placed on the valve. Victaulic connections in lieu of pipe threads do help.
4. Be sure the white flange seal rings are in place before installing the valve. Close the flat ball before attaching flanges to body.
5. Snug up flange bolts alternately (not adjacently) when securing flanges to valve body. Tighten each to 60-70 foot pounds. (Also alternately)
6. Electric actuators should be installed in a direction where the manual override is accessible.
7. If any welding is to be done on the truck, disconnect electrical connections until welding is finished.
NOTE: If the actuators are removed for repositioning, always use Loctite 222 or Permabond LM113 on the mounting screws.
NOTE: Pressures over 100 psi in the direction opposite to the arrow cast into the body could allow a small volume of water to pass through the valve
on the upstream side. Back pressures up to 250 psi, will not affect the valve seating system or fire pump.
PRESSURE TRANSDUCER
Use a thread seal and tighten only until snug plus an extra 1/8 to 1/4 turn. Over tightening of the metal fitting may cause a slight zero shift.
CAUTION: Reverse excitation will permanently damage the unit. Follow the wiring instructions carefully.
TANK FILL CONTROLLER DIP SWITCH SETTINGS
120578

2
* Factory Default Settings
THEORY OF OPERATION
The Auto Tank Fill System uses a motor controlled valve to regulate the water height in a tank. Variable flow rates are accommodated for both the
incoming water supply and the discharge water usage. A pressure transducer is used to determine the height of the water in the tank. A microcontroller
in the logic box measures the water height in the tank and the rate of rise or fall of the water level to determine the direction that the valve must be
moved in order to maintain a constant water level in the tank.
The Auto Tank Fill System divides the tank into three regions: (1) The Water Level Dead Zone, (2) Any level above the dead zone, and (3) Any level below
the dead zone. The top of the Water Level Dead Zone is called the Set Point. The depth of the Water Level Dead Zone, i.e., the depth of the layer
descending below the Set Point is determined by Switch 4 and Switch 5 of the Printed Circuit Board (PCB) DIP switch. The factory level default for the
Water Level Dead Zone layer is 2.5 inches. The height in the tank for the Set Point, and hence the top of the Water Level Dead Zone, is set at the fac-
tory. The Set Point may be moved relative to the factory setting with the use of Switches 1-3 of the PCB DIP switch.
A software program contained in the logic box is used for regulating the depth of the water in the tank.
The logic in the program is as follows:
1. If the water level in the tank is above the set point, the controller moves the motorized valve in the closed
direction. As long as the water level stays above the set point, the controller continues to close the valve
until a micro switch is activated just shy of the hard stop at the fully closed position. If the valve activates the
micro switch for longer than 5 seconds and the water level continues to rise, the valve will fully close to the
hard stop.
2. If the water level in the tank is below the bottom of the Water Level Dead Zone, the controller moves the
valve in the open direction. As long as the water level stays below the bottom of the dead zone, the controller
continues to open the valve until a micro switch is activated just shy of the hard stop at the fully open
position. If the valve activates the micro switch for longer than 5 seconds and the water level continues to
fall, the valve will fully open to the hard stop.
3. If the water level in the tank is within the Water Level Dead Zone, the controller shuts off the motor on the
valve. This causes the valve to remain throttled at whatever position it was in just before the water level in the tank moved into the
dead zone.
SWITCH 1 SWITCH 2 SWITCH 3 RELATIVE WATER LEVEL (INCHES)
Down Down Down +2.0
Up Down Down +1.0
Down Up Down Factory Default
Up Up Down -1.0
Down Down Up -2.0
Up Down Up -3.0
Down Up Up -4.0
Up Up Up -5.0
SWITCH 4 SWITCH 5 WATER LEVEL DEAD ZONE (INCHES)
Down Down 0.5
Up Down 1.0
Down Up 1.5
Up Up 2.5*
SWITCH 6 LEVEL CHANGE SENSITIVITY
Down High
Up Moderate*
SWITCH 7 SWITCH 8 RAPID LEVEL CHANGE
COMPENSATION
Down Down Low
Up Down Moderate*
Down Up High
Up Up Very High

3 3
4. The software program is set to compensate for rapidly changing water levels. If the water level in the tank is
rising rapidly due to a high inflow and little or no discharge, the controller anticipates the need to start
closing the valve prematurely and does so to prevent overflow of the tank. In a similar fashion, if the water
level in the tank is falling rapidly due to a high discharge rate, coupled with an insufficient inflow, the
controller will begin to open the valve prematurely in an effort to keep the water level in the tank within the
dead zone.
Switch 6 of the PCB DIP switch selects the controller’s sensitivity to water level changes and affects how item 4 above modifies the basic regulation
algorithm. The High setting for this switch causes the controller to react very quickly to changing water levels. This causes more wear on the valve
components because the valve changes direction most often at this setting.
The Rapid Level Change Compensation controlled by switches 7 and 8 on the PCB DIP switch also affects the
controller’s response to changing water levels. The Rapid Level Change Compensation determines how strongly the basic algorithm is modified once
a changing water level is detected. This setting also affects the wearing of the valve components. The higher the compensation level is set, the more
tightly the water level in the tank is controlled, even with large unequal inflow and discharge rates. However, the cost of this tighter regulation is more
wear on the valve components as the controller continuously adjusts the valve to meet changing conditions within the tank.
The controller has the ability to activate an external no-voltage-input counter using the “closed” micro switch as a trigger. When the “closed” micro
switch is activated, a set of dry relay contacts will close. When the switch is deactivated, the relay contacts open back up. These contacts have no volt-
age on them and are available at the “INPUT SWITCHES AND COUNTER” connector, terminals A and E.
The PCB inside the logic box has a red and a green LED that is used to indicate the various operating conditions of the valve. External LEDs can be
plugged into the logic box at the LEDs connector and will duplicate the function of the
on-board LEDs. The current-limiting resistors are built onto the board so ordinary 2-volt LEDs should be used. The
following table describes the LED behavior during valve operation.
OPERATING INSTRUCTIONS
Please read the following instructions completely before applying power to the Auto Tank Fill System.
1. Make sure all connectors are plugged in and connected properly.
2. Place the Enable/Close switch in the Close position.
3. Apply power to the Auto Tank Fill System.
4. About 1 second after power is applied to the system, the Controller will close the Tank Fill valve. Power
to the valve motor is automatically removed when the valve reaches the closed position. If the valve is
already closed at power up, the controller will detect this condition.
5. If the Tank Fill Valve has responded correctly to item 4 above, move the Enable/Close switch to the
Enable position. This is the position for normal operation of the Auto Tank Fill System. If the tank is
empty, the controller will immediately begin to open the Tank Fill Valve. If the valve is already at the fully
open position, the controller will maintain the valve in that position. If the tank is full of water, the
controller will close the Tank Fill Valve. If the valve is already closed, the controller will maintain the valve
in this position.
TROUBLESHOOTING
The following instructions may prove helpful in troubleshooting the Auto Tank Fill System:
Tank Fill Valve Does Not Operate
1. Make sure power is applied to the Auto Tank Fill System.
2. Place the Enable/Close switch in the closed position for at least 5 seconds.
LED STATUS VALVE OPERATING CONDITION
Solid Red Valve is fully closed against the hard stop
Quickly Blinking Red at 5 times a second Valve is closing
Slowly Blinking Red at once a second Valve is stopped at the micro switch just shy of the closed hard stop
Solid Green Valve is fully open against the hard stop
Quickly Blinking Green at 5 times a second Valve is opening
Slowly Blinking Green at once a second Valve is stopped at the micro switch just shy of the open hard stop
Solid Red and Solid Green Valve is stopped somewhere between the open and closed micro switches
No Red and No Green No power to the logic box

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3. Unplug the pressure transducer cable from the logic box and plug in the Valve Switch Tester.
4. Use the Open/Close switch on the Valve Switch Tester to make sure that the valve does not operate while
the Enable/Close switch is in the Close position.
5. Change the position of the Enable/Close switch to the Enable position. Use the Open/Close switch on the
Valve Switch Tester to see if the valve operates. It takes about 5 seconds for the valve to move between
the open and closed position. The motor can be heard when it is operating the valve. If the motor runs, the
Logic Box is correctly monitoring the Enable/Close switch and sending power to the valve motor. If the
motor runs but the valve does not open and close in response to changes in the Open/Close switch on the
Valve Switch Tester, then the valve actuator is faulty and must be replaced.
6. If the valve motor does not respond to changes in the Enable/Close switch, check the connection of the
Enable/Close switch cable to the connector at the logic box.
Tank Overflows Occasionally
1. Adjust the Rapid Level Change Compensation setting from Moderate to High or Very High by changing
switches 7 and 8 of the PCB DIP switch.
2. If the Rapid Level Change Compensation is not sufficient to keep the tank from overflowing, adjust the
Relative Water Level downward to lower the overall level of water in the tank. This will cause the valve to
begin closing earlier and may be sufficient to keep the tank from overflowing.
Tank Fill Valve Does Not Shut Off - Tank Overflows
1. Make sure the Tank Fill Valve is operating properly.
2. If the Tank Fill Valve is operating properly, the problem is most likely in the pressure transducer or with
the connection of the transducer to the Logic Box.
3. Make sure the cable from the Transducer to the Logic Box is in good shape and the Transducer
connector is correctly mated with its receptacle.
4. Replace the pressure transducer if the problem persists.
Tank Fill Valve Does Not Open - Tank Remains Empty
1. Make sure the Tank Fill Valve is operating properly.
2. If the Tank Fill Valve is operating properly, the problem is most likely in the pressure transducer or with
the connection of the transducer to the Logic Box.
3. Make sure the cable from the Transducer to the Logic Box is in good shape and the Transducer
connector is correctly mated with its receptacle.
4. Replace the pressure transducer if the problem persists.
Tank Overflows When Filled Rapidly with No Discharge
1. This condition can occur when a very high inflow is accompanied with little or no discharge.
2. Adjust the Rapid Level Change Compensation setting from Moderate to High or Very High by changing
switches 7 and 8 of the PCB DIP switch.
3. If the Rapid Level Change Compensation is not sufficient to keep the tank from overflowing, adjust the
Relative Water Level downward to lower the overall level of water in the tank. This will cause the valve to
begin closing earlier and may be sufficient to keep the tank from overflowing.
4. As a last resort, move the Level Change Sensitivity to High with switch 6 of the PCB DIP switch.
Water Level in the Tank Varies Too Much
1. The water level in the tank can be expected to vary by more than the Water Level Dead Zone height.
This is because the valve motor only starts to change the valve position when the water level is either
above or below the boundaries of the Water Level Dead Zone. In the time it takes the valve to move to a
position to compensate for the rising or falling level, additional water enters or leaves the tank.
2. Adjust the Water Level Dead Zone height using switches 4 and 5 of the PCB DIP switch. The factory
default was chosen to minimize wear on the valve components. As the dead zone depth is made
smaller, the valve will work harder since the water level in the tank will only be in the dead zone for a
short time.

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Test Procedure for Checking Switch Operation in Akron Brass Tank Fill Valve
Tools Required
 • #2Phillipsheadscrewdriverforremovingandsecuringthelidofthelogicbox
 • Voltmeterformeasuringsystemvoltages
 • ValveSwitchTester
Setup
1. Make sure that the logic box is powered down.
2. Remove the lid of the logic box. If the gasket becomes separated from the lid, carefully press the gasket
back into the lid.
3. Unplug the pressure transducer from the logic box.
4. Plug the tester into the logic box at the PRESSURE TRANSDUCER Connector.
5. Position the switch on the tester to the “CLOSE” position.
Testing
 • Note:whenmeasuringvoltagesatterminalblockTB3,properlylocateTB3asthesectionofthegreen
terminal blocks that faces the black terminal block TB2 where the incoming power is connected.
Reference the wiring diagram on the inside of the lid of the logic box.
 • SwitchSourceVoltage
1. Power up the logic box. If not already closed, the valve will move towards the closed position.
2. Measure the voltage at terminal TB3-28 with respect to system ground (terminal TB2-3). It should be
about 1 volt below the incoming system voltage at TB2-2. Note: the voltage at this terminal is 2 diode
drops below the incoming system voltage.
 • “Opened”Switch
1. Move the switch on the tester to the “OPEN” position.
2. The green LED on the circuit board will blink rapidly at 5 times a second, indicating that the valve is
opening. When the “Opened” switch is activated by the sector gear, the LED will blink slowly at once a
second. Normally, the valve will stay in this position but after 5 seconds, the valve may open to the hard
stop, depending on the accuracy of the analog-to-digital converter in converting the least significant bit.
3. Measure the voltage at terminal TB3-27. It should be about 16 volts indicating that the “Opened” switch
is activated. Note: the voltage at this terminal is about 60% of the voltage at terminal TB3-28. This is
due to a voltage divider formed by the external 1kΩresistor and a 1.5kΩresistor on the board.
4. Measure the voltage at terminal TB3-26. It should be 0 volts indicating that the “Closed” switch is not
activated.
 • “Closed”Switch
1. Move the switch on the tester to the “CLOSE” position.
2. The red LED on the circuit board will blink rapidly at 5 times a second, indicating that the valve is
closing. When the “Closed” switch is activated by the sector gear, the LED will blink slowly at once a
second. Normally, the valve will stay in this position but after 5 seconds, the valve may close to the hard
stop, depending on the accuracy of the analog-to-digital converter in converting the least significant bit.
3. Measure the voltage at terminal TB3-26. It should be about 16 volts indicating that the “Closed” switch
is activated. Note: the voltage at this terminal is about 60% of the voltage at terminal TB3-28. This is
due to a voltage divider formed by the external 1kΩresistor and a 1.5kΩresistor on the board.
4. Measure the voltage at terminal TB3-27. It should be 0 volts indicating that the “Opened” switch Is not
activated.

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Troubleshooting
 • Switchsourcevoltageisnotclosetoincomingsystemvoltage(within1-2volts)
1. Switch source voltage may be shorted to ground either directly or indirectly. Remove the cable from
the TANK FILL VALVE SWITCHES Connector and check the voltage again. If the voltage is still incorrect,
remove the cable from the INPUT SWITCHES AND COUNTER Connector and check the voltage again.
If the voltage is still incorrect, remove the cable from the PRESSURE TRANSDUCER Connector and
check the voltage again. If it is still incorrect, replace the circuit board.
2. If unplugging one of the cables corrected the voltage reading, then trace out the wiring for that cable and
attempt to find the short circuit. If the cable from the TANK FILL VALVE SWITCHES Connector seems to
be at fault, also check to make sure that the wires inside the logic box between the TANK FILL VALVE
SWITCHES Connector and terminal block TB3 are wired Correctly
 • “Opened”switchdoesnotappeartobeworking
1. Check the wiring to make sure that voltage is going out to the switch and that the return from the switch
is going into terminal TB3-27. Make sure that the wiring has not been crossed with the “Closed” switch
wiring, either in the external cable or in the logic box.
2. Make sure that the switch is being activated by the sector gear.
 • “Closed”switchdoesnotappeartobeworking
1. Check the wiring to make sure that voltage is going out to the switch and that the return from the switch
is going into terminal TB3-26. Make sure that the wiring has not been crossed with the “Opened” switch
wiring, either in the external cable or in the logic box.
2. Make sure that the switch is being activated by the sector gear.
MAINTENANCE
After 80,000 cycles or every 56 weeks, whichever comes first, the following Maintenance needs to be performed:
An Akron Style 9167 must be used to rebuild the valve. Complete instructions are included with each kit.
WARRANTY
All components of the Hi Cycle Valve carry a one (1) year Akron Brass warranty provided the maintenance instructions outlined above are followed.

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Logic Box Assembly
A
A
E
E
(CUSTOMER SUPPLIED)
PRESSURE TRANSDUCER ASSEMBLY
TANK-TO-PUMP
VALVE
A
BCD
E
A
B
C
D
E
VIEW E-E
TYPICAL (1)
TANK-TO-PUMP
TANK FILL
D
D
POWER
IN
TANK FILL
VALVE
PRESSURE
TRANSDUCER
TANK FILL
HEATSHRINK
WITH GLUE
F
CONNECTOR: HD16-5-16S SOCKET: 0462-201-16141 SEALING PLUG: 114017
1 2
CLOSE OPEN
VIEW F-F
TYPICAL (3)
VALVE
CONNECTOR: HD16-3-96S SOCKET: 0462-209-16141 STRAIN RELIEF: HD18-003 SEALING PLUG: 114017
INPUT SWITCHES
C
VALVE MOTOR CABLE ASSEMBLY (CUSTOMER SUPPLIED)
F
C
HEATSHRINK
WITH GLUE
POWER CABLE ASSEMBLY (CUSTOMER SUPPLIED)
GND
B
B
AB
C
A
B
C
VIEW B-B
TYPICAL (1)
SEALING PLUG
GND
POWER
AB
C
A
B
C
VIEW C-C
TYPICAL (3)
SEALING PLUG
OPEN
VALVE
CLOSE
3-POSITION DEUTSCH
2-POSITION DEUTSCH
5-POSITION DEUTSCH
+SYSTEM VDC
+SYSTEM VDC
+SYSTEM VDC OUT TO SWITCHES OR SEALING PLUG
+SYSTEM VDC
INPUT SWITCHES CABLE ASSEMBLY
TANK FILL
VA
LVE SWITCHES
PROG
RUN
DIP
SWITCHES
CONNECTOR: DT06-2S-E008 SOCKET: 0462-209-16141 WEDGE LOCK: W2S
NOTE - VERIFY THAT SWITCH HAS BEEN SET TO THIS POSITION AND
NOTE - VERIFY THAT DIP SWITCHES HAVE BEEN SET TO PROPER POSITIONS AS SHOWN ON THE LABEL DRAWING (SHT. 2)
INPUT
SWITCHES
AND
COUNTER
TANK-TO-PUMP
COUNTER
NO-VOLTA GE
INPUTS
OUT TO NO-VOLTAGE COUNTER
OUT TO NO-VOLTAGE COUNTER
LEDs
RED GRN
PRESSURE TRANSDUCER WITH CABLE SUPPLIED BY AKRON BRASS. CONNECTOR NOT INCLUDED.

8
Logic Box Assembly
VIEW A-A
G
G
VIEW G-G
H
H
HEATSHRINK
WITH GLUE
(CUSTOMER SUPPLIED)
HEATSHRINK
WITH GLUE
TANK FILL VALVE SWITCHES
CABLE ASSEMBLY
A
BCD
E
A
B
C
D
E+ SYSTEM VDC
OUT TO SWITCHES
+ SYSTEM VDC
OUT TO SWITCHES
SEALING PLUG
"CLOSED"
"OPENED"
VIEW H-H
TANK FILL VALVE SWITCHES
4-POSITION DEUTSCH
1
2
4
3
+ SYSTEM VDC
"CLOSED" "OPENED"
+ SYSTEM VDC
CONNECTOR: DTM06-4S-E007
SOCKET: 0462-201-20141
WEDGE LOCK: WM-4S
A
BCD
E
A
B
C
D
E
GREEN
RED
VIEW D-D
TYPICAL (1)
WHITE
BLACK
DRAIN
PRESSURE TRANSDUCER
I
I
LED CABLE ASSEMBLY (CUSTOMER SUPPLIED)
TYPICAL-
DATA DISPLAY PRODUCTS
PMRL200W-NWR2-WT
TYPICAL-
DATA DISPLAY PRODUCTS
PMRL200W-NWG2-WT
RED
(CLOSE)
GRN
(OPEN)
AB
C
A
B
C
VIEW I-I
LEDs
RED LED
CATHODE
(CLOSE)
GREEN LED
CATHODE
(OPEN)
+SYSTEM VDC
TO LED ANODES
TYPICAL (1)

9
Wiring Diagram
LEDs
TANK-TO-PUMP VALVE
TANK FILL
VALVE
SWITCHES
INPUT
SWITCHES
AND COUNTER
PRESSURE
TRANSDUCER
TANK FILL
VALVE
POWER IN
SYSTEM VDC
RED LED CATHODE(YEL)
GREEN LED CATHODE
(GRN)
(WHT)+SYSTEM VDC OUT TO SWITCHES
(WHT)+EXITATION
(GRN)+SIGNAL
ALGORITHM SELECTOR JUMPER (WHITE)
OUT TO NO-VOLTAGE COUNTER (GRY) OUT TO NO-VOLTAGE COUNTER (GRY)
VEHICLE GROUND (-) (BLK)
+SYSTEM VDC VEHICLE BATTERY (+) (RED)
+SYSTEM VDC OUT TO LED ANODES (WHT) SIGNAL COMMON (BLK)
EXITATION COMMON (BLK) SHIELD (BLK)
OPEN (BRN) CLOSE (ORG) OPEN (BRN) CLOSE (ORG)
(VIO) TANK FILL
(GRY) CLOSED
(BLU) OPENED
(WHT) +SYSTEM VDC OUT TO SWITCHES (WHT) +SYSTEM VDC OUT TO SWITCHES
DWG D-43534 LABEL REV. 04
GRN RED
(BLU) TANK-TO-PUMP

10
Electric Valve Diagram
2 2
2
2 2
2
2
1
1
22 17 18 17 20 33 21 17 1718 23 24 25 36 34
26
27
35
32
52
50
53 41
19
2
29
40
5 5
1
54
6
39
48
44 45
42
48
46
47
43
4
3
1
25:
14
15
16 10
13
7
3
9
*1
*2
3
46
9
12
5
8
11
25:
~
56
49
55
51
30
37
38 39
1
1
2
2
2
2
USE TRIBOLUBE 23.
USE PERMABOND LM113 OR LOCTITE 222
USE PARKER-O-LUBE ON ALL O-RINGS AND
ALL MATING SURFACES.
ASSEMBLY NOTES:
1
2
5OIL DIP
USE LOCTITE 680
6
3USE PRIMER-T
USE PERMABOND HH120 OR LOCTITE 227
4
* GREASE TOP & BOTTOM OF TRUNNION SHAFT AND
MATING BODY SURFACES. USE TRIBOLUBE 23