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
© 2017 Emerson. All Rights Reserved.valves.emerson.com VCIOM-03339-EN 17/05
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.
OR
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!

2
A
A
L3
L2
L1
G
F
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.

3
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

4
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

5
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

6
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

7
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.

8
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

9
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.

10
11**
33
34
47
38
39
36
48
41*
43
35
43
38
39
36
41*
48
35
46/46a
3” 1½” 900 4 1”-8UNC 1
13
/
16”
1500
900
4” 2” 1500 8 ⅞”-9UNC 1⅝”
6” 2½” 900 8 1”-8UNC 1
13
/
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

11
46/46a
47
18
19
31
51*
51*
1
17
50/49 733 4 8 6
3 2 5
51
30
48
24
15
27
52
32
53 26 29
15
34
34
23
23
22
14
12
13
13
11 10 9 7
58
12
14
22
24
YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN
InstallatIon and maIntenance InstructIons
See detail E
See details C and D
See details A and B
DETAIL A
(new design)
DETAIL E
DETAIL B
(old design)
O-ring
Back-up ring
3” VALVE ONLY
(new design)
FIGURE 8

12
42
43
22
19
41
48
45
35
38
44
39
28
36
27
44
39
45
60
YARWAY 7100 SERIES ARC®VALVE NON-FILTERED DESIGN
InstallatIon and maIntenance InstructIons
DETAIL D
Spherical seat pilot tube design
(old design)
DETAIL C
Conical seat pilot tube design
(new design)
'Old design' designates parts manufactured before 1997; 'New design' designates parts manufactured after 1996.
NOTES
* Recommended spare parts for service and inspection.
∙Recommended spare parts for service overhaul.
♦ Optional on body.
❖ Must be replaced as a set for the first disc replacement made after 1996.
PARTS LIST
Item Description Item Description
1 Body 30 Bypass cover
2 Bonnet 31 Stud
3 Pipe plug 32 Nut
4 Segmented retaining ring 33∙*O-ring
5 Segmented ring retainer 34∙*O-ring
6 Spring 35∙*O-ring
7❖Disc 36∙*O-ring
8 Orifice snubber 38∙*O-ring
9 Retaining ring 39∙*O-ring
10 Washer 41∙*Seal assembly
11∙*Seal 42∙*Anti-rotation keys
12❖Disc lower guide bushing 43∙*Retainer (O-ring)
13 Switch point adjustment screw 44∙*Pilot valve seat
14 Switch point adjustment screw bushing 45∙Pilot tube seal bushing
15 Spring pin 46∙*O-ring
17 Flow element 46a∙*Back-up ring (3” valve only - new design)
18∙Bypass bushing 47∙*O-ring
19∙Piston 48∙O-ring
22∙*Pilot tube 49 Drive screws
23∙*Metering orifice 50 Nameplate
24∙*Metering orifice retainer 51♦Pipe plug
26 Spring pin 52 Stud
27 Stroke adjustment screw 53 Adjustment screw cover
28 Spring pin 58❖Retaining ring
29 Lock nut 60 Retaining ring
FIGURE 9

13