PVA FCS300 Series User manual

FCS300-ES-ND
FCS300-ES-UF
FCS300-ES
FCS300-F FCS300-R
WHERE
PRECISION
DRIVES
PRODUCTIO
Front Closing Spray Valve
FCS300 Series Operation Manual
Rev D

FCS300 Series Manual
Revision D /June 2020 Page 2 of 34
This document is based on information available at the time of its publication. While efforts
have been made to ensure the contents of this manual are accurate, the information
contained herein does not purport to cover all specific details or variations in hardware, or
to provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve and Automation, Inc. assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
Precision Valve and Automation, Inc. makes no representation or warranty, expressed,
implied, or statutory with respect to, and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the information contained herein. No warranties
of merchantability or fitness for purpose shall apply.
This document, including the information contained herein, is the property of
Precision Valve and Automation, Inc. and is considered confidential and proprietary
information. It is delivered on the express condition that it not be used, disclosed, or
reproduced, in whole or in part, for any reason without prior written consent of
Precision Valve and Automation, Inc.
Copyright © 2020
Precision Valve and Automation, Inc.
All Rights Reserved.

FCS300 Series Manual
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Table of Contents
Introduction .......................................................................................................................................5
PVA Contact Information........................................................................................................5
Document History.....................................................................................................................5
System Description ..................................................................................................................6
Theory of Operation .................................................................................................................6
Air Section ..............................................................................................................................6
Fluid Section ......................................................................................................................6
Safety ..................................................................................................................................................7
Setup ...................................................................................................................................................7
Tool Kit........................................................................................................................................11
FCS300-F and FCS300-R Tool Kit ...................................................................................11
FCS300-ES Tool Kit ........................................................................................................12
FCS300-ES-ND Tool Kit.................................................................................................13
FCS300-ES-UF Tool Kit.....................................................................................................14
Part Reference Numbers.......................................................................................................15
Operation ..................................................................................................................................15
Periodic Maintenance ............................................................................................................16
Routine Cleaning and Disassembly.....................................................................................16
Assembly Instructions...........................................................................................................18
General ..............................................................................................................................18
Air Section ........................................................................................................................18
Fluid Section ....................................................................................................................19
Assemble Section ...........................................................................................................19
Setting Micrometer to Zero...........................................................................................19
Spare Parts.............................................................................................................................. 20
FCS300-F and FCS300-R Spare Parts Kit ............................................................... 20
FCS300-ES Spare Parts Kit .......................................................................................... 21
FCS300-ES-ND Spare Parts Kit...................................................................................21
FCS300-ES-UF Spare Parts Kit .................................................................................. 22
Micrometer Adjustment Breakdown.................................................................................. 22
Drawings.................................................................................................................................. 23

FCS300 Series Manual
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Bill of Materials ....................................................................................................................... 28
FCS300-F (112-5955) and FSC300-R (112-2195) ................................................... 28
FCS300-ES (112-2190) ................................................................................................. 29
FCS300-ES-ND (112-2398) ......................................................................................... 30
FCS300-ES-UF (612-9338-1) ......................................................................................31
Troubleshooting............................................................................................................................. 32
PVA Warranty Policy...................................................................................................................... 33
Table of Figures.............................................................................................................................. 34

FCS300 Series Manual
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Introduction
Before you operate this valve, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
If any questions or problems arise, contact PVA’s Technical Support department.
PVA Contact Information
Main Office PVA
One Mustang Drive
Cohoes, NY 12047
Tel [phone]
Fax [phone]
Website: http://www.pva.net
Email: [email protected]
Technical Support
Tel [phone]
Email: [e-mail]
Document History
Revision
Revision
Date
Reason for Changes
A
2012
Initial Release
B
2019
Combined FCS300-F, FCS300-R, FCS300-ES, FCS300-ES-ND Manuals
C
March 2020
Added FCS300-ES-UF Manual
D
June 2020
Added Cleaning Bit to FCS300-ES-UF Bill of Materials
Note: All photographs and CAD model representations in this document are a
“general representation” of the system and its components. The actual appearance
of the system and its components can differ based upon customer specific
configuration.

FCS300 Series Manual
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System Description
This manual applies to the following Precision Valve & Automation, Inc. valves:
FCS300-F
FCS300-R
Front Closing Stainless Steel Spray Valve, Flat Cap
Front Closing Stainless Steel Spray Valve, Round Cp
FCS300-ES
Front Closing Stainless Steel Spray Valve, Extended Cap
FCS300-ES-ND
FCS300-ES-UF
Front Closing Stainless Steel Spray Valve, Narrow Cap
Front Closing Stainless Steel Spray Valve, Ultra Fine Cap
The valves above will be referred to as the FCS300 Series for the purpose of this manual.
Any information relevant to a specific valve will be indicated.
Theory of Operation
The FCS300 Series is a low pressure, low volume, front closing stainless steel spray valve
that uses air pressure to atomize fluids and transfer them to a substrate. This valve can be
used in a wide variety of coating applications applying low to high viscosity fluids. The
FCS300 Series has a divorced design comprising of two major sections. These include:
•Air section (red anodized portion)
•Fluid section (stainless steel portion)
Air Section
The air section is an aluminum body with a simple piston/cylinder combination used to
open and close the valve. A micrometer adjustment in the upper air body controls how far
the piston and needle assembly can retract thus regulating the rate of fluid flow. The
micrometer will display a distance that the piston and needle will travel.
Fluid Section
The fluid section is a stainless steel body, which includes a needle and seat combination
located at the end of the valve inside the atomizing air cap. Fluid flows through the seat
orifice as the needle retracts out of the seat, then stops as the needle moves back into the
seat. Atomizing air is applied when the needle is retracted to spray all fluid from the air cap.
The micrometer adjustment regulates the distance that the needle can retract out of the
seat thus controlling the orifice size and rate of fluid flow. A precision air regulator is used
to control a precise amount of atomizing air. Fluids can include but are not limited to
solvents, conformal coatings, grease, etc. Wetted parts on the FCS300 Series include: 303,
304 stainless steel, Teflon®, and Kalrez®.

FCS300 Series Manual
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Safety
Due to material contents being under pressure, eye protection is required for operators. All
spray valves should be used in a well-ventilated area. For additional precautions, refer to
the MSDS sheet for the dispensed material.
Setup
The FCS300 Series requires a 2-position, 4-way air solenoid valve to actuate the air
section. The valve should be operated with clean, dry air between 60-100psi. Two #10-32
threaded air ports are located on the air section of the valve. The port located furthest from
the midsection of the valve is air to close the valve. The port located closest to the mid-
section of the valve is air to open the valve. Quick connect air fittings are typically supplied
with the FCS300 Series to fit 5/32” tubing.
Note: The valve should normally be in the closed position.
Atomizing air is connected to the #10-32 threaded port located on the fluid section. Quick
connect air fittings are typically supplied to fit 5/32” tubing. Atomizing air should be
connected such that it turns on only when the valve is cycled to the open position. There
are two configurations that can be used to connect atomizing air. The first configuration
uses a Single Solenoid with a one output used to simultaneously open the valve and
pressurize the atomizing air regulator. The second option uses a Dual Solenoid
configuration to allow independent control of the atomizing air.
Fluid is supplied to the FCS300 Series through the 1/8”fnpt port located on the stainless
steel fluid section of the valve.

FCS300 Series Manual
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Figure 1: FCS300-F Diagram
Figure 2: FCS300-R Diagram

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Figure 3: FCS300-ES Diagram
Figure 4: FCS300-ES-ND Diagram

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Figure 5: FCS300-ES-UF Diagram

FCS300 Series Manual
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Tool Kit
PVA offers standard tool kits for all dispensing valves.
FCS300-F and FCS300-R Tool Kit
The tool kit for the FCS300-F and FCS300-R is part number B12-1989, which includes all
necessary tools and lubricating grease to perform maintenance on this spray valve.
B12-1989 Includes:
Qty Part Number Description
1 0266244 8” Adjustable wrench
2 26563 3/32” Allen Key
1 26561 5/64” Allen Key
1 26559 1/16” Allen Key
1 5516A18 Tweezers
1 B62-0752 Mineral Oil Lubrication Kit, 2.5cc
1 B62-2048 Silicone Lubricant for o-ring, 2.5cc
1 9570K71 Hook and Pick Set
1 0266255 Pliers
2 53085A61 Optional soft plastic covers for pliers
1 PB135/2 Flat Head Screw Driver for Micrometer
1 PT17184 Micrometer Adjustment Wrench
1 V319 Seat Wrench
1 MM115 Removable Threadlocker
Figure 6: FCS300-F and FCS300-R Tool Kit

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FCS300-ES Tool Kit
The tool kit for the FCS300-ES is part number B12-2011, which includes all necessary tools
and lubricating grease to perform maintenance on this spray valve.
B12-2011 Includes:
Qty Part Number Description
1 0266244 8” Adjustable wrench
2 26563 3/32” Allen Key
1 26561 5/64” Allen Key
1 26559 1/16” Allen Key
1 5516A18 Tweezers
1 B62-0752 Mineral Oil Lubrication Kit, 2.5cc
1 B62-2048 Silicone Lubricant for o-rings, 2.5cc
1 9570K71 Hook and Pick Set
1 0266255 Pliers
2 53085A61 Optional soft plastic covers for pliers
1 PB135/2 Flat Head Screw Driver for Micrometer
1 PT17184 Micrometer Adjustment Wrench
1 0216173 M7 Wrench
1 MM115 Removable Thread Locker
Figure 7: FCS300-ES Tool Kit

FCS300 Series Manual
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FCS300-ES-ND Tool Kit
The tool kit for the FCS300-ES-ND is part number B12-1986, which includes all necessary
tools and lubricating grease to perform maintenance on this spray valve.
B12-1986 Includes:
Qty Part Number Description
2 0266244 8” Adjustable Wrench
2 26563 3/32” Allen Key
1 26561 5/64” Allen Key
1 26559 1/16” Allen Key
1 5516A18 Tweezers
1 B62-0752 2.5cc Mineral Oil Lubrication Kit
1 B62-2048 2.5cc Silicone Lubricant
1 9570K71 Hook and Pick Set
1 0266255 Pliers
2 53085A61 Soft Plastic Covers for Pliers
1 PB135/2 Micrometer Screw Driver, #2
1 PT17184 Micrometer Adjustment Wrench
1 MM115 Removable Thread Locker
Figure 8: FCS300-ES-ND Tool Kit

FCS300 Series Manual
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FCS300-ES-UF Tool Kit
The tool kit for the FCS300-ES-UF is part number B12-1986, which includes all necessary
tools and lubricating grease to perform maintenance on this spray valve.
B12-1986 Includes:
Qty Part Number Description
2 0266244 8” Adjustable Wrench
2 26563 3/32” Allen Key
1 26561 5/64” Allen Key
1 26559 1/16” Allen Key
1 5516A18 Tweezers
1 B62-0752 2.5cc Mineral Oil Lubrication Kit
1 B62-2048 2.5cc Silicone Lubricant
1 9570K71 Hook and Pick Set
1 0266255 Pliers
2 53085A61 Soft Plastic Covers for Pliers
1 PB135/2 Micrometer Screw Driver, #2
1 PT17184 Micrometer Adjustment Wrench
1 MM115 Removable Thread Locker
Figure 9: FCS300-ES-UF Tool Kit

FCS300 Series Manual
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Part Reference Numbers
•FCS300: Refer to Drawing #112-2195 for part reference numbers.
•FCS300-ES: Refer to Drawing #112-2190 for part reference numbers.
•FCS300-ES-ND: Refer to Drawing #112-2398 for part reference numbers.
•FCS300-ES-ND: Refer to Drawing #612-9338-1 for part reference numbers.
Please refer to the part number reference key below when reviewing the operation
instructions.
Bracket Used
Drawing and Valve Indicated
( )
Drawing #112-5955 FCS300-F
Drawing #112-2195
FCS300-R
{ }
Drawing #112-2190 FCS300-ES
[ ]
Drawing #612-9338-1 FCS300-ES-UF
< >
Drawing #112-2398 FC300-ES-ND
Figure 10: Part Number Reference Key
Operation
1. Plumb up the valve as outlined above in the setup procedures.
2. Regulate the air pressure operating the valve between 60-100 psi.
3. Make sure that the valve is not aimed toward anyone. Cycle the valve several times.
When the valve is cycling, the piston can be heard hitting the micrometer
adjustment and the needle (1){1}[1]<3> can be seen going up and down in the center.
4. Adjust the atomizing air pressure regulator. Air should be felt flowing from the end
of the valve when the valve cycles open. If the valve is not cycling properly, refer to
the Troubleshooting section.
5. When the fluid delivery system is connected to the valve, pressurize the material to
be dispensed.
6. Cycle the valve open to purge. Fluid should begin to spray from the tip of the air cap,
continue cycling the valve until all air is removed from the fluid line and a steady
spray pattern of material can be seen.
7. Adjust the atomizing air pressure to achieve proper spray of material. This pressure
will vary due to the viscosity of the fluid.

FCS300 Series Manual
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8. Check the fluid connection and packing nut (15){15}[17]<16> for leaks. If the valve is
leaking, refer to the Troubleshooting section.
9. Turn the micrometer adjustment (5){5}[7]<6> until the desired flow rate is achieved.
Turning the adjustment clockwise toward zero will decrease the material flow rate
and counterclockwise will increase the material flow rate. If the micrometer
adjustment is turned all the way down to zero, it will stop fluid flow entirely.
10. Once the micrometer setting is determined, the collar (E) on the micrometer can be
turned clockwise to lock the adjustment.
Note: Refer to Troubleshooting section for any problems.
Periodic Maintenance
1. Lubricate the packing (14){14}[16]<15> on the FCS300 Series valve every 200 hours
by placing a few drops of mineral oil or other light oil inside the packing nut.
Note: PVA offers a 10cc mineral oil lubrication kit; Part#: B62-0752
2. The packing nut (15){15}[17]<16> will require occasional tightening, as wear occurs in
order to prevent leaks through the packing.
Routine Cleaning and Disassembly
Cleaning and rebuilding the valve will be required from time to time. A spare
parts kit is available with all the normal wear parts included.
•FCS300: Part #FCS3-SP
•FCS300-ES: Part #FCS3-ES-SP
•FCS300-ES-ND: Part #FCS3-ES-ND-SP
•FCS300-ES-UF: Part #FCS3-ES-UF-SP
1. Begin disassembly by removing air and fluid pressure from the valve.
2. Remove all pneumatic tubing and fluid delivery fittings, hoses, etc. from the valve.
3. Using the tip of a 3/32” Allen key, loosen the packing nut (15){15}[17]<16>.
4. Using the same 3/32” Allen key, evenly remove the two machine screws
(8){8}[10]<9> that are located on the same corners as the fluid section standoffs
(3){3}[3]<5>.
Note: During removal that there is a spring (10){10}[11]<11> forcing the air section
away from the fluid section.

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5. Pull the air section (red anodized portion) away from the fluid section (stainless
steel portion).
6. Clean off the tip of the stainless-steel needle (1){1}[1]<3>.
7. From the fluid section of the valve, unthread and remove the packing nut, and the
packing (14){14}[16]<15>.
8. Unthread and remove the collar ring (16){16}[18]<17> followed by the air cap
(17){18}[6]<2>.
9. Using the seat wrench, unthread and remove the seat (4){4}[4]<1> followed by the
007 Kalrez o-ring (20){21}[21]<20>.
Note: The teeth of the seat wrench are tapered so the wrench will only fit on one
side.
10. Clean all of the wetted parts thoroughly with an appropriate solvent.
11. On the air section, use a standard 3/32” Allen key to evenly remove the two
machine screws (7){7}[9]<8> that thread into the end cap (11){11}[13]<12>.
Note: During removal, the spring will force the air section apart.
12. Separate the upper air body (2){2}[2]<4> from the lower air body (12){12}[14]<13> to
remove the spring then slide the end cap off the needle.
13. Holding the lower air body in one hand, grab the needle and push the needle and
piston (13){13}[15]<14> assembly out of the lower air body.
14. Remove the 004 Buna o-ring (18){19}[19]<18> from the lower air body.
15. Hold the piston with an adjustable wrench then use a 5/64” Allen key to unthread
and remove the set screw (9){9}[11]<10> to remove the needle then remove the 014
Buna o-ring (20){21}[22]<20> from the piston.
16. Remove the 014 Buna o-ring from the upper air body then use a 1/16” Allen key to
remove the set screw.
17. Using soft tip pliers grip the collar (E) or midsection (D) of the micrometer
(5){5}[7]<6> and turn counterclockwise to loosen then unthread and remove from
the upper air body by hand.
18. Remove the 007 Buna o-ring (19){20}[20]<19> from the micrometer.
19. Replace components with spares provided in the spare parts kit.

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Assembly Instructions
General
•All o-rings must be lubricated with a small amount of silicone grease.
•A small amount of removable thread locker should be applied to the set screw
(9){9}[11]<10>.
•Assemble the air section and fluid section separately prior to connecting the
assemblies.
Air Section
1. Mount one 007 Buna o-ring (19){20}[20]<19> on the end (F) of the micrometer
(5){5}[7]<6> and slide it up to the threads.
2. Thread the micrometer into the upper air body (2){2}[2]<4> hand tight.
3. Holding the collar (E) of the micrometer turn the dial (C) counterclockwise until “5”
can be seen on the midsection (D).
4. Using soft tip pliers grab the midsection (D) section of the micrometer and turn
clockwise to snug it onto the upper air body.
5. Use a 1/16” Allen key to assemble the set screw (9){9}[11]<10> into the upper air body
securing the micrometer in place.
6. Mount one 014 Buna o-ring (20){21}[22]<20> on the end of the upper air body.
7. Drop the needle into the piston (13){13}[15]<14> and assemble with the set screw
using an adjustable wrench and 5/64” Allen key to tighten.
8. Mount the 014 Buna o-ring onto the piston.
9. Apply a small amount of silicone grease to the inside of the lower air body
(12){12}[14]<13> then drop in the piston and needle assembly.
10. Mount the 004 Buna o-ring (18){19}[19]<18> on the end of the needle and slide it
down into the groove in the end of the lower air body.
11. Slide the end cap (11){11}[13]<12> onto the needle up to the lower air body, place the
spring (10){10}[11]<11> on top of the piston, and assemble the two air bodies using
two machine screws (8){8}[9]<9> tightening with a 3/32” Allen key.
Note: Be sure the air holes are lined up on the same face and will align with the air
hole on the fluid section (3){3}[3]<5>.

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Fluid Section
1. Drop the packing (14){14}[16]<15> into the fluid section (3){3}[3]<5>, and screw in the
packing nut (15){15}[17]<16> but leave finger tight until assembled with the air
section.
2. Mount the 007 Kalrez o-ring (20){21}[21] on the seat (4){4}[4] and thread the seat
into the fluid section. Tighten the two parts using an adjustable wrench on the fluid
section and soft tip pliers on the seat.
•FCS300-ES-UF Only: Thread the seat<4> into the fluid body[3] by installing
the 007 Kalrez O-Ring[20] on the end of the seat[1]. Tighten into the fluid
body with an adjustable wrench.
3. Place the air cap (17){18}[6]<2> onto the fluid section over the seat then secure it by
threading the collar in place.
4. FCS300-ES-UF Only: Thread the atomizing air tips <5> on the air cap<6>.
Assemble Section
1. Be sure the micrometer adjustment {11}[12]<7> is backed out far enough so at least
the number 1 can be seen on the midsection (D).
2. Apply a small amount of silicone grease to the end of the needle then insert it into
the packing nut {6}[7]<16> and slide the two sections together.
3. Align the air holes of the air section on the same face as the atomizing air hole of
the fluid section then connect the sections using the two machine screws,
{21}[22]<10> tightening them down evenly using a 3/32” Allen key.
4. Using the tip of a 3/32” Allen key, tighten the packing nut.
Setting Micrometer to Zero
When assembling the valve it will be necessary to re-calibrate the micrometer adjust back
to the zero position.
1. Using the micrometer wrench (A), insert the inside tip of the small end into the
orifice of the midsection (D) and rotate it clockwise until the numbered centerline is
displayed on a side that can most easily be viewed by an operator.
Note: Valves are supplied from the factory with the center line located 90’ left of
the fluid inlet.

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2. Turn the dial (C) clockwise until the end (F) hits the piston {9}[10].
3. Using soft tip pliers, hold the knurled end of the dial (C) tightly and loosen the screw
(B) using a flat head screwdriver.
Note: Loosen the screw 3-4 turns only. It is not necessary to fully remove the
screw.
4. Using a soft dead blow hammer, tap the dial (C) of the micrometer adjust to unlock it
from the midsection (D). The dial will now spin freely.
5. Rotate the dial (C) to align the zero mark of the dial with the numbered centerline of
the midsection (D) and press down firmly to secure the dial in place.
6. Hold the dial (C) securely in one hand maintaining alignment with the zero mark and
numbered centerline, then carefully tighten the screw (B) using the flat head
screwdriver to lock the micrometer in the zero position.
Spare Parts
PVA offers standard spare parts kits for all dispensing valves. These kits are stocked for
immediate shipment and allow replacement of all wearable parts of the valve.
FCS300-F and FCS300-R Spare Parts Kit
The spare parts kit for this valve, product number FCS3-SP, includes the following
components.
Qty
Part Number
Description
1
114-6997
Seat
1
114-5248
Needle
1
V305
Packing, Teflon
2
VLV-014B
O-ring, Buna
1 VLV-007B O-ring, Buna
1
VLV-007K
O-ring, Kalrez
1
VLV-004B
O-ring, Buna
1
V319
Seat Wrench
1 PT17184 Micrometer Wrench
Figure 11: Contents of FCS300-F and FCS300-R Spare Parts Kit