Vindum CV Series User manual

CV Series
High-Pressure Valves
Copyright 2005-2006 Vindum Engineering, Inc. All rights reserved. Reproduction or use of contents in any manner is prohibited without
express permission from Vindum Engineering. While every precaution has been taken in the preparation of this manual, the publisher assumes
no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from use of the information contained herein.

This page is intentionally blank.

________________________________________________________________________
i
Table of Contents
Chapter 1 General Overview.......................................................................................................1
1.1 Configuration.............................................................................................................................1
1.2 Main O-Ring Seal Material........................................................................................................1
1.3 Pressure Rating ..........................................................................................................................1
1.4 Solenoid Pilot Valve..................................................................................................................1
1.5 Valve Temperature Rating.........................................................................................................2
1.6 Wetted Parts...............................................................................................................................2
1.7 Everything is included with your CV Valve..............................................................................2
2.1 Principles of Operation for the 2-Way Valve............................................................................5
Chapter 2 Understanding Your Valve....................................................................................5
2.1.1 Possible Configurations of the 2-Way Valve..................................................................5
2.1.2 Direction of Flow............................................................................................................5
2.2 Principles of Operation for the 3-Way Valve............................................................................5
2.2.1 Possible Configurations of the 3-Way Valve..................................................................6
2.2.1.1 Open / Closed Position (A1 / B2)......................................................................6
2.2.1.2 Closed / Open Position (B1 / A2)......................................................................6
2.2.1.3 Open / Open Position (A1 / A2) ........................................................................6
2.2.1.4 Closed / Closed Position (B1 / B2)....................................................................7
Chapter 3 Solenoid Pilot Valves & Manifolds....................................................................9
3.1 Air Supply Requirements...........................................................................................................9
3.2 Electrical Power.........................................................................................................................9
3.3 Air Input and Output................................................................................................................10
3.4 High Temperature CV Valves .................................................................................................11
Chapter 4 CV-200 Series & CV-400 Series Valve Maintentance.............................13
4.1 Tools You Will Need...............................................................................................................13
4.2 Disassembling the 2-Way Valve..............................................................................................13
4.3 Disassembling the Piston Assembly........................................................................................14
4.4 Disassembling the Sleeve Assembly .......................................................................................15
4.5 Inspecting the Sleeve and Cone...............................................................................................16
4.6 Reassembling the Sleeve Assembly.........................................................................................17

________________________________________________________________________
ii
4.7 Reassembling the Piston Assembly.........................................................................................17
4.8 Reassembling the 2-Way Valve...............................................................................................18
Chapter 5 CV-300 Series & CV-500 Series Valve Maintenance.............................19
5.1 Differences Between the CV 2-Way and 3-Way Valves.........................................................19
5.2 Disassembling the 3-Way Valve..............................................................................................19
5.3 Disassembling the Piston Assembly........................................................................................20
5.4 Disassembling the Sleeve Assembly .......................................................................................20
5.5 Reassembling the Sleeve Assembly.........................................................................................20
5.6 Reassembling the Piston Assembly.........................................................................................20
5.7 Reassembling the 3-Way Valve...............................................................................................20
Chapter 6 Maintenance & Troubleshooting......................................................................23
6.1 Air Supply Problems................................................................................................................23
6.1.1 Solenoid Pilot Valve Visual Check...............................................................................23
6.1.1.1 If the Light Goes On and Off for a Different Solenoid Pilot Valve ................24
6.1.1.2 If No Light Goes On or Off .............................................................................24
6.1.2 Solenoid Pilot Valve Audio Check...............................................................................24
6.1.2.1 No “Air Escaping” Sound When CV Valves Are Opened & Closed..............24
6.1.2.2 The Air Supply is Not Dry...............................................................................25
6.1.2.3 The Air Pressure is Too Low...........................................................................25
6.1.2.4 The Air Pressure is Too High ..........................................................................25
6.1.2.5 Constant “Air Escaping” Sound.......................................................................25
6.1.2.6 Compressed Air Supply Runs Out Quickly.....................................................27
6.2 Fluid Supply Problems.............................................................................................................27
6.2.1 Fluid Leaks from the CV Valve Bleed Port..................................................................27
6.2.2 Fluid Leaks Across a “Closed” Valve ..........................................................................27
6.2.3 Fluid Leaks Into Air Tubes...........................................................................................28
6.2.4 Fluid is Not Traveling Properly....................................................................................28
Appendix 1: Removal & Replacement of the Cone.........................................................29
Appendix 2: CV-210 & CV-310 Valve Components.......................................................31
Appendix 3: CV-405 & CV-505 Valve Components.......................................................33
Appendix 4: CV-410 & CV-510 Valve Components.......................................................35

________________________________________________________________________
iii
Appendix 5: CV-420 & CV-520 Valve Components.......................................................37
Appendix 6: Commercially Available Parts........................................................................39
Appendix 7: O-Ring Compatibility Chart...........................................................................41
Appendix 8: Quote Request / Order Form..........................................................................43

________________________________________________________________________
iv
This page is intentionally blank.

________________________________________________________________________
1
Chapter 1
1. General Overview
The Vindum Engineering CV High Pressure Valves are available in two configurations;
either as a 2-position, on/off valve, or a 3-way, 4-position valve. The CV Valves are air-
actuated, constant-volume valves with a switching time of less than .1 second. They are
typically used as switching devices in high-pressure fluid flow systems. The valves are
designed so that no fluid is displaced when they are opened or closed. This allows them
to be useful in systems requiring constant volumes or constant pressures during the
switching cycle.
All CV Valves utilize either 316 stainless steel, which is corrosion resistant, or Hastelloy
C-276, which is used for brine applications or highly corrosive fluids. Our standard
valves have a temperature rating of 180°F (80°C). Valves with our high temperature
option have a temperature rating of 320°F (160°C).
1.1 Configuration
Each CV Valve is customized to the needs of the user by utilizing the following options:
The CV Valve can be built as either:
•2-Way, on/off valve which is supplied with a single solenoid pilot valve
•3-Way, 4 position valve which is supplied with 2 solenoid pilot valves. The 3-way, 4-
position valve contains two independently operated valves that are connected with a
tee.
1.2 Main O-Ring Seal Material
The following materials are available for the main o-ring seal. The o-ring seal material
needs to agree with the fluid used.
•Aflas
•Buna
•Teflon
•UHMW
•Viton
1.3 Pressure Rating
The CV-Valve can have a pressure rating of either 5,000; 10,000; or 20,000 psi.
1.4 Solenoid Pilot Valve
The solenoid pilot valves for the 85 to 1,000 psi air supply can be operated by either:
•12 VDC
•24 VDC

________________________________________________________________________
2
1.5 Valve Temperature Rating
•Standard Ambient Temperature: 180°F (80°C) with push-in type air line fittings.
•Optional High Temperature: 320°F (160°C) with compression type air line fittings
1.6 Wetted Parts
There are two options of materials for the valves wetted parts. (The parts of the valve that
will come in contact with the fluid:
•316 Stainless Steel for inert materials, or
•Hastelloy C-276 for corrosive materials or brine
1.7 Everything is included with your CV Valve
•Valve
•High Pressure Fittings
•Solenoid Pilot Valves
•Pneumatic fittings
•1/8” air tubing
The following tables show additional Valve information.
CV VALVE MODELS
Valve
Model
a)
Maximum
Pressure
Rating [PSI (Bar)]
Internal
Volume (cc)
Approximate
Flow
Coefficient (CP)
2-Way On-Off Valves
CV-210 10,000 (700) 0.11 .06
CV-405 5,000 (350) 0.44 .24
CV-410 10,000 (700) 0,44 .12
CV-420 20,000 (1400) 0.22 .03
3-Way 4 Position Valves
CV-310 10,000 (700) 0.31 .06
CV-505 5,000 (350) 1.08 .24
CV-510 10,000 (700) 0.74 .12
CV-520 20,000 (1400) 0.62 .03
Table 1-1

________________________________________________________________________
3
Valve Size
Valve
Model Fittings (Autoclave Engineers) Valve Dimensions
2-Way On-Off Valves
CV-210 W125 - 1/8” Speedbite 2” diameter x 1.695”
(5.0 cm diameter x 4.3 cm
CV-405 SW250 - 1/4” Speedbite 2.25” diameter x 1.95”
(5.7 cm x 4.9 cm)
CV-410 SW250 - 1/4” Speedbite 2.25” diameter x 1.95”
(5.7 cm x 4.9 cm)
CV-420 F250C - 1/4” High Pressure 2.25” diameter x 1.95”
(5.7 cm x 4.9 cm)
3-Way 4 Position Valves
CV-310 W125 - 1/8” Speedbite 2” diameter x 3.645”
(5.0 cm x 9.2 cm)
CV-505 SW250 - 1/4” Speedbite 2.25” diameter x 4.435”
(57 cm x 11.3 cm)
CV-510 SW250 - 1/4” Speedbite 2.25” diameter x 4.435”
(57 cm x 11.3 cm)
CV-520
F250C - 1/4” High Pressure 2.25” diameter x 4.435”
(57 cm x 11.3 cm)
Table 1-2

________________________________________________________________________
4
This page is intentionally blank.

________________________________________________________________________
5
Chapter 2
2. UNDERSTANDING YOUR VALVE
2.1 Principles of Operation for the 2-Way Valve
Each CV 2-Way Valve contains two air supply tubes, which
are connected to one solenoid-operated pilot valve. Pressurized
air passes from the solenoid pilot valve through one of the air
supply tubes into the 2-Way valve’s piston assembly. Within
the piston assembly is a cone that serves as a “gate”, which
either opens and allows fluid to flow or closes and stops fluid
from flowing.
•Pressurized air passing through air supply tube A moves
an internal cone back towards the valve bracket. This
causes the valve to open and fluid to flow. This is
considered the “open” position.
•Pressurized air passing through air supply tube B moves
an internal cone away from the bracket. This causes the
valve to close and fluid to stop. This is considered the
“closed” position.
2.1.1 Possible Configurations of the 2-Way Valve
The 2-Way CV Valve is an on/off valve. It can be configured
in two ways, either normally open or normally closed. In case
of a power failure, it can be set to open or to close. (ADD
cross Reference) See ...Regarding the Use of the Solenoid Pilot
Valves)
2.1.2 Direction of Flow
The fluid can flow through the valve in either direction. The sketch shows the fluid
coming in from the right side.
2.2 Principles of Operation for the 3-Way Valve
The CV 3-Way Valve contains two piston assemblies, which are connected by a center
fitting (tee), and four air supply tubes. Two air supply tubes run between each piston
assembly and solenoid pilot valve. Two solenoid pilot valves are then attached to an air
manifold.
Fi
g
ure 2.1

________________________________________________________________________
6
2.2.1 Possible Configurations of the 3-Way Valve
Because the three-way CV Valve contains the equivalent of two 2-Way valves, it can be
used as two independently operated on-off valves, or as a single 3-way, 4-position
switching valve. The 3-way valve can be operated in the following four positions.
2.2.1.1 Open / Closed Position (A1 / B2)
•Air flows into air-inlet port A1, causing
the cone inside of valve 1’s piston
assembly to open.
•Air flows into air-inlet port B2 causing
the cone inside of valve 2’s piston
assembly to close.
2.2.1.2 Closed / Open Position (B1 / A2)
•Air flows into air-inlet port B1 causing
the cone inside of valve 1’s piston
assembly to close.
•Air flows into air-inlet port A2 causing
the cone inside of valve 2’s piston
assembly to open.
2.2.1.3 Open / Open Position (A1 / A2)
•Air flows into air-inlet port A1 causing
the cone inside of valve 1’s piston
assembly to open.
•Air flows into air-inlet port A2 causing
the cone inside of valve 2’s piston
assembly to open.
Figure 2.2 Open/Closed Valve
Fi
g
ure 2.3 Closed/O
p
en Valve
Fi
g
ure 2.4 O
p
en/O
p
en Valve

________________________________________________________________________
7
2.2.1.4 Closed / Closed Position (B1 / B2)
•Air flows into air inlet port B1 causing
the cone inside of valve 1’s piston
assembly to close.
•Air flows into air inlet port B2 causing
the cone inside of valve 2’s piston
assembly to close.
Figure 2.5 Closed/Closed Valve

________________________________________________________________________
8
This page intentionally left blank.

________________________________________________________________________
9
Chapter 3
3. Solenoid Pilot Valves and Manifolds
The CV-Series Valves are completely air actuated. Air is taken into the air inlet and
distributed to the solenoid pilot manifolds. The solenoid pilots then distribute and control
the air flow to the valves.
3.1 Air Supply Requirements
Because the CV Valves are completely air-actuated, 85 to 115 PSIG of filtered air must
be connected to the solenoid pilot valves at all times. Failure to maintain sufficient air
pressure at the appropriate port on the CV Valves can result in valve malfunction,
leakage and subsequent loss of control. Following are the air supply requirements for all
CV Valves.
•The air must be clean.
•The air must be dry because moisture in the air supply will cause the solenoid pilot
valves to rust and malfunction.
•The air must be oil-free.
•The air must be 85 - 115 PSI (5.95 to 8.05 bar). If air pressure exceeds this, the
solenoid pilot valves may stop working.
A standard, filtered laboratory air supply from an air compressor is adequate if it meets
the above criteria. The air compressor should be equipped with a dryer because water
vapor in the air lines will cause the pilot valves to rust and malfunction. Tanks of
compressed air should not be used as a pressurized air source.
3.2 Electrical Power
The solenoid pilot valves require electrical power to re-direct air pressure from one valve
port to another. If electrical power is lost, the solenoid pilot valves position themselves to
their default; non-energized position and valve control is lost. In this situation the “B”
port of the solenoid pilot valve becomes pressured and the “A” port has no pressure on it.
For this reason, electrical failure should be taken into consideration and the lines should
be connected so that if a power failure does occur, a dangerous situation is not created.
•Figure 3-1, below, shows the correct connections for “normally closed” operation
of the CV-210 Valve with a single solenoid pilot valve.

________________________________________________________________________
10
•Figure 3-2, below, shows the correct connections for “normally closed” operation
for the CV-310 Valve with two solenoid pilot valves. For both valves, fluid can
flow in either direction.
3.3 Air Input and Output
As previously mentioned, the CV Valves are air-actuated. Incoming air must be
connected at the solenoid pilot valves’ air inlet port, as shown in Figure 3-3. The air inlet
at the bottom of the manifold (marked with a “P”) has a ¼ inch quick-disconnect fitting.
Into this fitting the user should insert a 1/4 inch air line that is connected to a pressurized
air source, regulated at 85 - 115 PSIG. A standard, filtered laboratory air supply from an
air compressor is adequate if it is clean, dry and oil-free.
Figure 3-3
Figure 3-2
Figure 3-1

________________________________________________________________________
11
NOTE: The air compressor should be equipped with a dryer because water vapor in the
air lines will cause the solenoid pilot valves to rust and malfunction.
The air inlet fittings on the CV Valves are plastic “quick disconnects”, the same as the
outlet fittings on the solenoid pilot valves. To connect the solenoid pilot valve(s) to the
CV Valve, 1/8” nylon tubing should be used on these fittings.
•If normally-open operation is desired for a CV-210 Valve, connect the solenoid
pilot valve to the CV-210 Valve as shown in Figure 3-4
•If normally-open operation is desired for a CV-310 Valve, connect the solenoid
pilot valves to the CV-310 Valve as shown in Figure 3-5.
NOTE: Before any of the air lines connecting the solenoid pilot valves to the CV Valves
are disconnected, for any reason, some type of numbered or color-coded tags should be
placed on each air line, each solenoid pilot valve fitting, and each CV Valve fitting to
ensure the correct connections are made during reassembly.
3.4 High Temperature CV Valves
If you are connecting a high temperature CV Valve, the following two changes should be
made when installing the air lines.
Figure 3-5
Figure 3-4

________________________________________________________________________
12
•The 1/8” tubing used for the air connection between the solenoid pilot valve and the
CV Valve must be made of Teflon instead of nylon.
•The inlet air line fittings on the CV Valve will be swage-type fittings with metal
ferrules. The tubing is slid through the back side of the threaded cap. The metal
ferrule is then slid onto the end of the air line, and the threaded cap is firmly
tightened onto the fitting, compressing the ferrule onto the air line.
If using CV Valves in an application where they are placed in an oven, the solenoid pilot
valves should be placed outside of the oven and the Teflon air lines connecting them to
the CV Valves should be as short as possible.

________________________________________________________________________
13
Chapter 4
4. CV-200 Series and CV-400 Series Valve Maintenance
The information contained in Chapter 4 explains how to disassemble, reassemble and
service all of the CV-series on-off valves. Chapter 5 will explain how to service the 3-
way valves. The piston assemblies and sleeve assemblies in the 3-way valves are relative
to those used in the on-off valves, so most of the information in his chapter also pertains
to 3-way valves.
Figure 4-1 is an expanded view of the CV-210 Valve. The CV-400 Series valves are
similar, except that they are slightly larger in size. Throughout this chapter, refer to
Figure 4-1 for component numerical references, which will be shown in brackets. For
example, the two 8-32 x 1/2" socket-head cap screws shown as number “1” will be
referenced as “[1]”.
4.1 Tools You Will Need
You will need the following tools in order to maintain your valves.
•1 each - 9/64 inch Allen wrench
•1 each - 1/2 inch adjustable wrench
•2 each - 3/4 inch adjustable wrenches
•Q-Tips cotton ended ear swabs
Note: Power needs to be turned off.
4.2 Disassembling the 2-Way Valve
To disassemble the CV-200 Series or the CV-400 Series valve, refer to Figure 4-1,
above, while following the instructions below.
Figure 4-1

________________________________________________________________________
14
1. Use a 9/64” Allen wrench to remove the two 8-32 x 5/8” socket head cap screws [1]
securing the valve to the Support Bracket [3].
2. Remove the remaining six 8-32 x 1/2" socket-head cap screws [2] securing both End
Caps [4] in place.
3. Grasp the valve in one hand and slide a 1/2” adjustable wrench onto one of the end
fittings [5]. Use the wrench to rotate the End Fitting and End Cap in a clockwise
direction while simultaneously applying force away from the body of the valve.
When there is sufficient space between the End Cap and the Cylinder Shell [6], grasp
the End Cap by hand and gently separate the two parts. As the End Cap begins to
separate from the Cylinder Shell, continue to pull “straight back”, with a minimum
amount of “rocking back-and-forth”.
NOTE: The End Fitting is permanently attached to the End Cap with “Loctite® 272”.
4. Inspect the polished stem on the End Fitting to make sure that it is free of scratches. If it is
scratched, it needs to be polished using 2,000 grid paper. Polishing the stem is easiest if done
on a lathe.
5. Repeat step 3 with the other end of the End Cap/End Fitting, and set both pairs of parts aside
on a clean work surface.
6. Gently slide the Piston Assembly [8] out of the Cylinder Shell [6], and set the Cylinder Shell
aside.
Figure 4-2
4.3 Disassembling the Piston Assembly
Refer to Figure 4-2, above, for the following instructions.
1. Slide two 3/4” adjustable wrenches over the flats on the outside of both the Piston
halves [11] and [13].