Corken ZV200 Instruction manual

Installation, Operation
& Maintenance Manual
Model ZV200 External Automatic Bypass Valve
Model ZV200 External
Automatic Bypass Valve
Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products
must be made only by experienced, trained and qualied personnel. (3) Maintenance, use and installation of Corken products must comply with
Corken instructions, applicable laws and safety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia).
(4) Transfer of toxic, dangerous, ammable or explosive substances using Corken products is at user’s risk and equipment should be operated
only by qualied personnel according to applicable laws and safety standards.
ORIGINAL INSTRUCTIONS IH106E
Solutions beyond products...

Warning
Install, use and maintain this equipment according to Corken’s instructions and all applicable federal, state, local laws
and codes. Periodic inspection and maintenance is essential.
Corken One Year Warranty
CORKEN, INC. warrants that its products will be free from defects in material and workmanship for a period of one
year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) months from the date
of shipment from CORKEN. If a warranty dispute occurs, the DISTRIBUTOR may be required to provide CORKEN
with proof of date of sale. The minimum requirement would be a copy of the DISTRIBUTOR’S invoice to the customer.
CORKEN products which fail within the warrant period due to defects in material or workmanship will be repaired
or replaced at CORKEN’s option, when returned, freight prepaid to CORKEN, INC., 9201 North I-35 Service Road,
Oklahoma City, OK. 73131.
Parts subject to wear or abuse, such as mechanical seals, blades, piston rings, valves and packing, and other parts
showing signs of abuse, neglect or failure to be properly maintained are not covered by this limited warranty. Also,
equipment, parts and accessories not manufactured by CORKEN but furnished with CORKEN products are not
covered by this limited warranty and the purchaser must look to the original manufacturer’s warranty, if any. This limited
warranty is void if the CORKEN product has been altered or repaired without the consent of CORKEN.
All implied warranties, including any implied warranty of merchantability or tness for a particular purpose, are
expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warrantee period.
CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR
IMPLIED WARRANTY ON CORKEN PRODUCTS. Transfer of toxic, dangerous, ammable or explosive substances
using CORKEN products is at the user’s risk. Experienced, trained personnel in compliance with governmental and
industrial safety standards should handle such substances.
Contacting the Factory
Before you contact the factory, note the model number and serial number of your pump. The serial number directs
us to a le containing all information on material specications and test data applying to your specic pump. When
ordering parts, the Corken service manual or Operations, Installation and Maintenance (IOM) manual should be
consulted for the proper part numbers. ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN
ORDERING PARTS.
The model and serial numbers are shown on the nameplate of the unit. Record this information for future reference.
Model No.
Serial No.
Date Purchased
Date Installed
Purchased From
Installed By
2

Table of Contents
APPLICABLE NOTICES FOR ATEX 2014/34/EU CONFORMITY........................................4
FEATURES OF THE ZV200 EXTERNAL AUTOMATIC BYPASS VALVE ..................................5
INSTALLATION OF THE ZV200 EXTERNAL AUTOMATIC BYPASS VALVE ..............................5
Operation of the ZV200 External Automatic Bypass Valve .............................................5
APPENDICES
A. Model Number Identication Code and Available Options ...........................................8
B. Specications .............................................................................9
C. Performance ..............................................................................9
D. Outline Dimensions ........................................................................10
E. Parts Details .............................................................................11
F. Troubleshooting Guide ......................................................................12
G. Extended Storage .........................................................................12
3

Applicable Notices for ATEX
2014/34/EU Conformity
Product Type:
Corken Liquid Transfer Bypass Valves
Model Covered:
ZV200
Intended Application:
The bypass valve models covered by this manual conform to
the European Union ATEX 2014/34/EU Directive for explosive
gas atmospheres and transfer of liqueed gases such as
Liqueed Petroleum Gas, anhydrous ammonia, freons, etc.
Possible Misuse Warning:
The designated bypass valve models must only be
installed in systems designed for its intended use, similar
to the examples presented in this manual.
ATEX Classication:
Group II; Category 2; G; Temperature Class T4 – T5
These products are classied under the ATEX directive
as Equipment – Group II – Category 2 – equipment is
intended for use in areas where explosive atmospheres
caused by gases or vapors (G) may be present. The
surface Temperature Class rating is a range between T4
275°F (135°C) and T5 212°F (100°C).
Nameplate:
Training Instructions:
Instructions for the safe application and use of this product
are provided in this manual. Read this manual completely
prior to installation and use of this product. Only qualied
and properly trained personnel should be allowed to install,
operate, and maintain this equipment.
Mechanical Ignition Sources:
The bypass valve is installed as part of an assembly including
the pump and the entire system must be grounded to prevent
possible electrostatic discharge. Installation and adjustment
guidelines are provided in this manual and are to be followed
for the proper operation and performance of the valve.
Sound Levels:
These products are reactionary devices used in pumping
systems. Sound levels are highly dependent upon the
application, product being pumped, and installation. When
operating in the system the valves should have a noise
level no higher than 80 dBA.
Piping Forces and Moments:
Maximum Allowable Nozzle Forces and Moments
Note: Piping systems should be designed according to
standard engineering practice and applicable national
and local codes. NO piping induced forces or moments
are recommended for Corken ZV200 bypass valves.
X—Horizontal (perpendicular to valve discharge port)
Y—Vertical
Z—Horizontal (parallel to valve discharge port)
Fx = Fy = Fz = 42 lb (19 kg)
Mx = My = Mz = 70 ft•lb (10 kg•m)
Notice!
Corken bypass valves should only be installed in LPG
& NH3systems that have been designed by qualied
engineering personnel and operated and maintained
by qualied technicians. The system must conform to
all applicable local and national regulations and safety
standards (specically, LPG systems must conform to
NFPA 58). This manual must be kept with the bypass
valves and be reviewed before installing, operating or
performing any maintenance work.
Warning!
Do not attempt to open the pump or bypass valve until you
have bled off the pressure. High pressure in the system
can cause personal injury and/or property damage.
Please note: if the system contains a meter, the differential
valve will keep liquid under pressure in the pump, meter
and piping even after the hose has been emptied.
File number ATEX
directive
Explosion
protection
ATEX Directive
2014/34/EU marking
Equipment classified
as Group II—Catagory 2
Explosion gas
atmosphere high level
Surface temperature
range T4
(135°C) 275°F
4

Features of the ZV200 External
Automatic Bypass Valve
The ZV200 is a low-pressure build-up external bypass
valve designed to protect piping systems and sliding vane
pumps from being over pressurized. It is suitable for ows
up to 250 gpm (946 L/min). The continuous internal bleed
assists with the operation of piping systems containing air
or electric operated internal valves.
It is typically used for loading and unloading in both truck
and stationary applications.
Installation of the ZV200 External
Automatic Bypass Valve
An external bypass valve is an essential component of
any pump application. It plays a key role in maximizing the
performance and life of the pump by preventing excessive
pressure resulting from accidental pump over-speed, a
closed discharge line, or highly restrictive receiving systems.
Proper installation is critical to the performance of
the bypass valve. Always install the bypass valve on
the discharge side of the pump in either a vertical or
horizontal position. The discharge line of the pump
connects to the inlet of the bypass valve while the outlet
of the valve runs back to the liquid or vapor section of the
supply tank. NOTE: Do not connect the outlet piping
of the external bypass valve to the inlet piping of the
pump. To conrm the inlet and outlet of the bypass valve,
a ow direction arrow can be found on the side.
The external bypass valve and piping system should
be sized to accommodate the full ow of the pump at a
normal operating speed with the discharge line closed.
The piping sizes should match the sizes of the inlet and
outlet of the bypass valve. NOTE: If these guidelines are
not followed, the actual operating pressures of the
piping system can be higher than the bypass valve
setting causing it to open prematurely and reduce the
efficiency of the delivery.
Operation of the ZV200 External
Automatic Bypass Valve
The standard ZV200 external bypass valves are not preset
at the factory. For optional spring ranges and settings,
refer to the model identication table and part details in
this manual.
Cold Temperature Operation: Impact strength is reduced
at temperatures below -20°F (-28.9°C). Use extreme caution
when working on the external bypass valve and prevent
tools and other objects from impacting the pressurized
components of the pumping system.
NOTE: After the external bypass valve has been
installed in the piping system, the pressure setting
must be veried.
Adjust the external bypass valve as follows:
The differential pressure setting of the ZV200 external
bypass valve is adjustable; however, the range depends
on the spring size supplied with the bypass valve. The tag
attached to the cap of the bypass valve shows the spring
range. The table below shows the part number for each
spring size. NOTE: All spring sizes are interchangeable.
Flange Sizes Spring Number Differential
Pressure (psig)
1-1/4", 1-1/2",
2", 2-1/2"
5513 41–70
5515 71–90
5511 (standard) 91–125
5512 126–150
Truck Applications:
1. Install liquid-lled pressure gauges equipped with a
needle valve or snubber in the following locations:
a. Pump discharge gauge port or inlet side of the
bypass valve.
b. Supply tank and/or pump suction.
2. Connect the delivery hose to the receiving/storage
tank or delivery tank port for recirculation.
3. All shut-off valves on the pump discharge line and
bypass return line should be open.
4. Fully open the outlet valve of the supply tank and start
pumping at a normal delivery rate. Make sure the
direction of the rotating shaft follows the directional
arrow located on the pump casing.
5. If the pump has an internal relief valve, check the
pressure setting by slowly closing the shut-off valve on
the bypass return line.
6. Slowly close the shut-off valve located on the
pump’s discharge line while observing the pressure
gauge on the pump’s discharge port. As the internal
relief valve begins to open, the differential pressure
typically drops. It is important to record the peak
differential pressure (the difference between inlet
and outlet pressure) before the internal relief valve
opens. After circulation starts to ow through
the internal relief valve, the pressure will drop
signicantly due to vaporization.
NOTE: The internal relief valve on the Z-Series
truck pumps is pre-set at the factory and not
adjustable in the eld.
5

7. After the setting of the internal relief valve is conrmed,
open the shut-off valves located on the pump discharge
line and the bypass return line and resume normal
operation of the pump.
8. To conrm the setting for the ZV200 external bypass
valve, slowly close the shut-off valve in the pump’s
discharge line and record the pressure shown on the
gauge. The difference between the pump’s discharge
pressure and the tank pressure (before pumping) is
the setting of the external bypass valve.
8. If the pump is equipped with an internal relief valve,
the ZV200 external bypass valve should be set 20–25
psi (1.38 to 1.72 bar) below the setting of the pump’s
internal relief valve. Following this guideline ensures
the liquid does not recirculate through the internal
relief valve and eliminates the possibility of erratic
“hunting” between the two valves.
9. Reopen the shut-off valve in the pump’s discharge line
and resume normal operation of the pump. Record the
pressure shown on the gauge. The difference between
the pump’s discharge pressure and the tank pressure
(before pumping) is the normal operating pressure of
the system.
10.If possible the setting of the ZV200 external bypass
valve should be 15 psi (1.03 bar) higher than the normal
operating pressure of the piping system. An operating
pressure near the external bypass valve setting may
cause the liquid to recirculate unnecessarily.
11. Adjust the pressure setting of the ZV200 external
bypass valve if necessary. The external bypass valve
can be adjusted by removing the valve cap and
loosening the locknut.
WARNING: Use caution when removing the valve
cap and follow the procedures below.
a. To increase the pressure setting, loosen the
locknut and turn the adjusting screw clockwise.
b. To decrease the pressure setting, loosen the locknut
and turn the adjusting screw counterclockwise.
12.Once a satisfactory pressure adjustment has
been achieved, attach the “tamper-proof” seal
furnished with the external bypass valve to prevent
unauthorized adjustments.
Notice!
1. If the external automatic bypass valve is sized and set
correctly, a manual or hand operated bypass valve–
if applicable–should remain in the closed position
during normal operation. Keeping the manual or hand
operated bypass valve closed ensures the external
automatic bypass valve operates in a normal capacity.
2. Annual inspection and testing of the internal relief
valve–if applicable–and the external automatic bypass
valve are recommended. For testing procedures refer
to the adjustment procedures listed in this manual.
Stationary applications equipped with an electric
motor drive:
1. Install liquid-lled pressure gauges equipped with a
needle valve or snubber in the following locations:
a. Pump discharge gauge port or inlet side of the
bypass valve.
b. Supply tank and/or pump suction.
2. Attach an ammeter to a motor lead of the electric motor.
3. Remove the valve cap on the ZV200 external bypass
valve and adjust to the lowest pressure setting by
turning the adjusting screw counterclockwise until
spring tension is no longer present. Note: Do not
remove the adjusting screw.
4. Make sure the shut-off valves on the pump discharge
line and bypass return line are in a fully open position.
5. Start the pump and circulate the liquid back to the
supply tank using the discharge line.
6. Slowly close the shut-off valve located on pump
discharge line so all of the liquid ows through the
external bypass valve.
7. Slowly increase the setting of the ZV200 external bypass
valve by turning the adjustment screw clockwise until
the ammeter indicates the full-load current indicated on
the motor nameplate or required differential pressure is
reached. Record the pressure on the gauge mounted
on the inlet side of the bypass valve.
9. If the pump has an internal relief valve, the ZV200
external bypass valve should be set at least 20–25 psi
(1.38 to 1.72 bar) below the setting of the pump’s built
in relief valve. Following this guideline ensures the
liquid does not recirculate through the internal relief
valve and eliminates the possibility of erratic “hunting”
between the two valves.
10.If possible the setting of the ZV200 external bypass
valve should be 15 psi (1.03 bar) higher than the normal
operating pressure of the piping system. An operating
pressure near the external bypass valve setting may
cause the liquid to recirculate unnecessarily.
11. Adjust the pressure setting of the ZV200 external
bypass valve if necessary. The external bypass valve
can be adjusted by turning the adjust screw clockwise
to increase pressure and counterclockwise to
decrease pressure.
6

12.Once a satisfactory pressure adjustment has
been achieved, attach the “tamper-proof” seal
furnished with the external bypass valve to prevent
unauthorized adjustments.
13.Open the shut-off valve located on the pump discharge
line downstream of the external bypass valve and
continue pumping as needed.
WARNING: Do not adjust the external bypass
valve beyond the range of the spring being used.
NOTE: On Anhydrous Ammonia and LP-Gas
installations, follow the guidelines provided
by Underwriter’s Laboratories, Inc. and NFPA
Pamphlet # 58.
Notice!
1. If the external automatic bypass valve is sized and set
correctly, a manual or hand operated bypass valve–
if applicable–should remain in the closed position
during normal operation. Keeping the manual or hand
operated bypass valve closed ensures the external
automatic bypass valve operates in a normal capacity.
2. Annual inspection and testing of the internal relief
valve–if applicable–and the external automatic bypass
valve are recommended. For testing procedures refer
to the adjustment procedures listed in this manual.
7

1
Registered trademark of the DuPont company.
Base Model ZV200
Inlet 2" NPT
Outlet 2" NPT
Maximum ow rate (gpm) 250
Ship weight
lb (kg) 23 (10.4)
Springs
41–70 psig differential range No charge option A
71–90 psig differential range No charge option C
91–125 psig differential range Standard B
126–150 psig differential range No charge option D
O-ring
Material
Buna-N Standard A
Neoprene®1 No charge option B
Viton®1 Charge option D
Inlet
Flanges
1.25" NPT No charge option A
1.50" NPT No charge option C
2.00" NPT Standard E
2.50" NPT No charge option J
1.25" Slip-on weld Charge option B
1.50" Slip-on weld Charge option D
2.00" Slip-on weld Charge option F
2.50" Slip-on weld Charge option K
Outlet
Flanges
1.25" NPT No charge option A
1.50" NPT No charge option C
2.00" NPT Standard E
2.50" NPT No charge option J
1.25" Slip-on weld Charge option B
1.50" Slip-on weld Charge option D
2.00" Slip-on weld Charge option F
2.50" Slip-on weld Charge option K
Appendix A—ZV200 Model Number and Identication Code
Appendices
A. Model Number Identication Code and Available Options
8
Model Number
Base X X X X

Appendix B—Specications
Maximum differential pressure 150 psid (10.34 bar)
Operating temperature range Up to 225°F (107°C)1
Maximum working pressure 400 psi (27.6 bar)
Spring ranges 91–125 psi (6.3–8.6 bar) standard
41–70 psi (2.8–4.8 bar) optional
71–90 psi (4.9–6.2 bar) optional
126–150 psi (9.0–10.3 bar) optional
Differential Pressure psi (bar) 70 (4.82) 120 (8.27)
Maximum Rated Flow for Propane gpm (L/min) 180 (681) 250 (946)
The continuous internal bleed will assist in the operation of systems with air or electric operated internal valves.
Part Standard Material Optional Material
Adjustment nut cap ASTM A536 65-45-12
Adjusting screw Steel
Valve body Ductile iron: ASTM 536, 60-40-18
Valve cap Ductile iron: ASTM 536, 60-40-18
Gasket 1010 hot rolled steel
Flanges Ductile iron: ASTM 536, 65-45-12 (NPT) Plate steel: ASTM A516 (weld ange)
O-rings Buna-N Neoprene®2, Viton®2
Spring Music wire/chrome silicon
Spring guide 8620 A322 ASTM steel
Relief valve 17-4 PH stainless steel
A low pressure build-up bypass valve. Used with truck and stationary pumps for loading
and uploading.
1
Fitted with Buna-N O-rings.
2
Registered trademark of the DuPont company.
Material Specications
Operating Specications
Features & Benets
Equipment Type Applications
B. Specications
C. Performance
Appendix C—Model ZV200 Performance
9

Appendix D—Outline Dimensions for Model ZV200
D. Outline Dimensions
8.52
(21.60)
2.38
(6.00)
2.75
(6.99)
1.04
(2.63)
1.04
(2.63)
5.16
(13.09)
4.06
(10.32)
Discharge
2" NPT
Inlet
2" NPT
1/4" pipe plug
Flush plug
1/16" x 27 NPT
All dimensions are in inches (centimeters).
10

Appendix E—Parts Details for Model ZV200
a
Registered trademark of the DuPont company.
b
_ denotes O-ring code. See chart above.
E. Parts Details
Ref.
No. Part No. Description Qty
1. 5457 Adjustment nut cap 1
2. 7101-037NC01A Hex nut 1
3. 2732 Gasket 1
4. 2911 Adjusting screw 1
5. 5507 Bypass valve cap (2") 1
6. 2-235_bO-ring 1
7. 2-223_bO-ring 1
8. 5516 Spring guide (2") 1
9.
5512 Valve spring (126–150 psi) 1
5513 Valve spring (41–70 psi) 1
5515 Valve spring (71–90 psi) 1
10. 5509 Relief valve (2") 1
5511 Valve spring (91–125 psi) 1
Ref.
No. Part No. Description Qty
11. 7001-050NC175A Hex head bolt 8
12.
5363-1.25 Flange (1.25" NPT) 2
5363-1.5 Flange (1.5" NPT) 2
5363-2 Flange (2" NPT) 2
5363-2.5 Flange (2.5" NPT) 2
5363-1.25S Flange (1.25" slip weld) 1
5363-1.5S Flange (1.5" slip weld) 1
5363-2S Flange (2" slip weld) 2
5363-2.5S Flange (2.5" slip weld) 2
13. 2-234_bO-ring 2
14. 5506 Bypass valve body 1
15. 1629 Flush plug 1/16" x 27 NPT 2
16. 5510 Nameplate 1
17. 7012-006SF019E Pan hd. Phillip 6-32 x 3/16" 2
18. 3442 Pipe plug 1/4" NPT 4
O-ring Code
ABuna-N
BNeoprene®a
DViton®a
16
18
1
2
11
12
13
17
15
14
3
4
5
6
7
8
9
10 12
13
11
11

Appendix F—Troubleshooting Guide for the ZV200 Bypass Valve
F. Troubleshooting Guide
G. Extended Storage
Appendix G—Extended Storage of the ZV200 Bypass Valve
If your bypass valve is to be removed from service for some time, it must be protected as propane, butane and
anhydrous ammonia all leave the metal “bare” and open to corrosion. Piping and tanks not in service should also be
protected as the rust particles can destroy the pump’s seals almost immediately after startup.
1. Fill or thoroughly ush the bypass valve with a light rust inhibiting oil. (If the bypass valve is ushed with oil, placing
some desiccant packets inside the bypass valve will provide added protection.)
2. Plug all bypass valve openings.
3. Store in a dry location.
4. Before placing the bypass valve back into service, drain the oil and remove any desiccant packets.
5. Refer to pages 5–7.
Problem Cause Solution
Low capacity Valve set too low.
Note: After all potential causes from
the pump and system have been
investigated
Adjust valve as demonstrated in this IOM manual on
pages 5 –7.
Adjusting screw
will not turn
Screw adjusted full in Adjustment too high—back out adjustment and
adjust valve per instructions in this IOM manual on
pages 5 –7.
Noise from valve
during system
operation
Spring broken Depressurize system. Open valve and inspect.
Replace spring if necessary.
Adjustment screw set too far out Adjust valve per instructions in this IOM manual on
pages 5 –7.
Excessive restriction in return line Remove restrictions.
Valve leaking
product
O-ring failure Depressurize system. Open valve and inspect.
Replace O-ring.
Fitting loose Identify and tighten tting.
Valve will not
adjust to
desired pressure
Spring guide or O-ring failure Depressurize system. Open valve and inspect
O-ring and spring guide.
12

13

14

15

Printed in the U.S.A.
July 2020
CORKEN, INC. • A Unit of IDEX Corporation
9201 North I-35 Service Road, Oklahoma City, OK. 73131
Phone [phone] • Fax [phone]
Visit our website at http://www.corken.com
or e-mail us at [e-mail]
Solutions beyond products...
@CorkenInc