Installation InstructionsIssue DateSeptember 27, 2002©2002 Johnson Controls, Inc.1Part No. 24-7664-2500, Rev. —www.johnsoncontrols.comV48 and V49 Series Valves Repair KitApplicationFollow these guidelines and procedures to repair mostV48 Series and V49 Series valves. For information onrepairing V48AF type valves (1-1/2 in. size), seeV48AF Type Valves Repair Kit Installation Instructions,Part No. 24-7664-2519.InstallationFlushing the Valve and LinesManually flush the valve and fluid piping before andafter installing, repairing, or replacing a valve toremove filings, chips, or other foreign matter. Insertscrewdrivers under both sides of the valve springguide and lift upward to flush the valve. See Figure 1.Manual flushing does not affect valve adjustment.Range AdjustmentScrewInsert screwdriversunderneath the valvespring guide.Figure 1: Manual Flushing Parts IncludedTable 1: Seat Repair Kit Contents by Valve TypeSeat Repair Kit Product Code Numbers by Valve TypeV48AB (1/2 in.)V48AC, V49AC (3/4 in.)V48AD (1 in.)V48AE (1-1/4 in.)Individual PartDescriptionSTT15A-605RSTT16A-604RSTT17A-616RSTT17A-617RSeat Guide1111Disc Stud2222Disc Cup (Retainer)2222Valve Disc2222Valve Seat2222Valve Stem1111Gasket (Body)1111Rubber Diaphragm4455Guide Plate Gasket1011Bellows Sealing Ring1011O-ring1111Seat Wrench1111Note:3/8, 1/2, and 3/4 in. valves require two diaphragms on the spring end and two diaphragms on the sensing elementend. 1 and 1-1/4 in. valves require two diaphragms on the spring end and three diaphragms on the sensingelement end.2 V48 and V49 Series Valves Repair Kit Installation InstructionsNew Construction Valves (1/2 in. to 1-1/4 in. Size)! CAUTION:Risk of Personal Injury.Contents of liquid lines could be under pressure.Shut off the liquid supply and relieve the pressurebefore servicing the valve to avoid possible personalinjury.! CAUTION:Risk of Personal Injury.Do not disassemble the Spring Housing Assembly.Disassembly could cause the spring to fly out,resulting in personal injury.! CAUTION:Risk of Equipment Damage.Using excessive force to turn the screw beyond thestop point will damage the screw thread. Do not turnthe screw beyond the stopping point.! CAUTION:Risk of Equipment Damage.Cool the temperature-sensing bulb oftemperature-actuated valves by submerging the bulbin ice water. Do not remove the bulb from ice wateruntil the sensing element is reinstalled. Failure tofollow this precaution may result in damage to thebellows when the sensing element is removed fromthe valve.Use the following procedure to install the repair kits onnew-construction valves.See Figure 2, Figure 3, and Figure 4 for partsidentification.1. Decrease the compression on the main spring byturning the range-adjusting screw clockwise until itstops. Count the number of turns until the screwstops.2. Remove the four spring housing screws.3. Remove the spring housing assembly from thevalve body assembly.4. Remove the sensing element screws and thesensing element assembly.5. Pull the lower disc cup and disc assembly awayfrom the valve body and disassemble. Remove thebellows push rod and rubber diaphragms.6. Remove the seat guide.7. Turn the disc stud counterclockwise to remove thevalve stem assembly.8. Use the seat wrench supplied with the kit toremove the old valve seat and replace the newvalve seat.9. Replace the old parts with new parts: valve discs,disc cups, disc studs, valve stem, diaphragms,bellows push rod and seat guide post.10. Remove and replace the body gasket or O-ringlocated between the valve bodies.11. Place the new valve stem assembly into the valvebody assembly and turn clockwise to tighten.12. Lightly lubricate two new rubber diaphragms withgrease and replace the old diaphragm with thenew. Use only slight lubrication on the center holeof the diaphragm to prevent puckering when theassembly is screwed together.13. Replace the old seat guidepost with the new seatguide and tighten. See Table 2.14. Reassemble the spring housing assembly and thevalve body assembly.15. Replace and tighten the spring housing screws.See Table 2.16. Turn the bellows push rod counterclockwise toremove the bellows push rod and the bottomretainer. See Figure 4.17. Lightly lubricate three new rubber diaphragms withgrease and replace the old diaphragms with thenew. Use a small amount of lubrication on thecenter hole of the diaphragm to prevent puckeringwhen the assembly is screwed together.18. Replace the bellows push rod and the bottomretainer. Turn clockwise to tighten. See Table 2.19. Replace the old guide plate gasket with the newguide plate gasket.20. Replace/reinstall the sensing element assembly.21. Replace the sensing element screws. SeeTable 2.22. To approximate the previous setting, tighten therange adjustment screw the same number of turnsused in Step 1.V48 and V49 Series Valves Repair Kit Installation Instructions 3Table 2: Torque SpecificationsValveSizeSensing ElementScrews,Spring HousingAssembly ScrewsBellows Push Rod,Valve StemAssembly,Seat Guide Post,Disc Stud3/8 in.13 lb⋅in (1.1 N⋅m)1/2 in.23 lb⋅in (2.2 N⋅m)5.5 lb⋅in (0.51 N⋅m)3/4 in.33 lb⋅in (3.4 N⋅m)8 lb⋅in (0.90 N⋅m)1 in.1-1/4 in.53 lb⋅in (5.6 N⋅m)40 lb⋅in (4.5 N⋅m)Spring Housing AssemblyValve BodyAssemblySensing ElementAssemblyRange Adjustment ScrewSpring Housing Screws (4)Figure 2: Spring Housing AssemblySeat GuideBellowsPushRod2 RubberDiaphragms2 or 3 RubberDiaphragmsDisc StudDisc StudDisc CupDisc CupValve DiscValve DiscSeat WrenchValve SeatValve StemBody Gasketor O-ringFigure 3: Valve Body Assembly4 V48 and V49 Series Valves Repair Kit Installation Instructions2 or 3 Rubber DiaphragmsGuide Plate GasketBellows SealingRingBellowsPushRodGuide PlateBottomRetainerSensingElementValve BodyRange Adjustment ScrewSensing ElementScrews (4)Figure 4: Sensing Element AssemblyOld Construction Valves (1/2 in. to 1-1/4 in. Size)! CAUTION:Risk of Personal injury.Contents of liquid lines could be under pressure.Shut off the liquid supply and relieve the pressurebefore servicing the valve to avoid possible personalinjury.Repair kits are no longer produced with oldconstruction parts. To replace old construction partswith new construction parts, disassemble the valve asindicated here, and reassemble as indicated in NewConstruction Valves, 1/2 in. to 1-1/4 in. Size.Removing the Spring Housing Assembly! CAUTION:Risk of Personal injury.Do not disassemble the Spring Housing Assembly.Disassembly could cause the spring to fly out,resulting in personal injury.! CAUTION:Risk of Equipment Damage.Using excessive force to turn the screw beyond thestop point will damage the screw thread. Do not turnthe screw beyond the stopping point.! CAUTION:Risk of Equipment Damage.Cool the temperature-sensing bulb oftemperature-actuated valves by submerging the bulbin ice water. Do not remove the bulb from ice wateruntil the sensing element is reinstalled. Failure tofollow this precaution may result in damage to thebellows when the sensing element is removed fromthe valve.! CAUTION:Risk of Personal Injury.The housing contains a compressed spring.Disassembly could cause the spring to fly outresulting in personal injury. For valve sizes 1 in. andlarger, do not remove the two screws on the sides ofthe spring housing.See Figure 2, Figure 3, Figure 4, and Figure 5 for partsidentification.1. Decrease the compression on the main spring byturning the range adjustment screw clockwise untilit stops. Count the number of turns until the screwstops.2. Remove the four housing screws.3. Remove the spring housing assembly from thevalve body assembly.4. Remove the sensing element screws and thesensing element assembly.5. Remove the valve assembly screw.6. Remove the seat guidepost, bellows push rod, andthe rubber diaphragms.V48 and V49 Series Valves Repair Kit Installation Instructions 57. Pull the disc retainers, discs, and the extensionsleeve from the body.8. Use the seat wrench supplied with the kit toremove the old valve seats and replace with thenew valve seats.9. Replace the old parts with new parts: valve discs,disc retainers, seat guide, and assembly screw.Secure in place. Refer to Figure 5 for removal ofold parts. For installation of the new constructionparts, see Figure 3. See Table 1 for information onthe number of rubber diaphragms used on eachend.10. Assemble the bellows push rod onto the assemblyscrew.11. Tighten the assembly screw in place. Ensure thatthe rubber diaphragms are properly positioned.12. Place the sensing element over the push rod andsecure in place.13. Install the spring housing over the guidepost andsecure in place with the four long screws.14. Adjust the valve to the desired opening point.2 RubberDiaphragms2 or 3 RubberDiaphragmsSeat WrenchExtension SleeveBody Gasketor O-ringValveAssemblyScrewBellows Push RodValve DiscValve SeatValve DiscDisc RetainersDisc RetainersSeat GuideFigure 5: Valve Body AssemblySetup and AdjustmentsAdjusting the Valve after ReassemblyThe opening point is the refrigerant pressure at thevalve’s bellows or temperature at the sensing bulbnecessary to just lift the valve disc off the valve seatand allow water to flow through the valve body (Port 1to Port 2). Turning the adjustment screw changes theopening point.The throttling range is the pressure/temperaturedifference between the opening point and thepressure/temperature necessary to fully open thevalve (Port 1 to Port 2) and allow maximum flow. Thethrottling range is a fixed value. Turning the rangeadjustment screw to adjust the opening point alsomoves the fixed throttling range.Use a standard service valve wrench or screwdriver toadjust the opening point.• Turn the adjustment screw counterclockwise toraise the opening point (and throttling range).• Turn the adjustment screw clockwise to lowerthe opening point (and throttling range).Pressure-actuated valves close (Port 1 to Port 2)approximately 3-7 psi (21-48 kPa) below the openingpoint.Temperature-actuated valves close (Port 1 to Port 2)approximately 3-5 Fº (1.7-2.8 Cº) below the openingpoint.Use a refrigerant pressure/temperature gauge toadjust the opening point pressure/temperature.Operate the system at normal load conditions andadjust the valve’s opening point to the desiredpressure/temperature. See Table 3 forpressure/temperature specifications.6 V48 and V49 Series Valves Repair Kit Installation InstructionsSpecial ConsiderationsIf the compressor is located in an area with highambient temperatures, refrigerant head pressures mayremain high enough during off cycles to prevent thevalve from closing completely. In such instances, theopening point of the valve should be raised justenough to cause the valve to close flow to thecondenser during compressor standby periods.If the system uses a single condenser, adjust thebalancing valve in the bypass while the compressor isshut off and the tower pump is operating. Adjust thebalancing valve so that the amount of water throughthe bypass is just sufficient to provide the minimumrecommended nozzle pressure. See Figure 6.On a multiple-condenser system, adjust the balancingvalves in the bypasses evenly while the compressorsare shut down and the tower pump is operating. Thetotal flow through the bypasses should be justsufficient to provide the minimum recommendednozzle pressure.The sensing bulb of V49 valves must be secured in thefluid or area being controlled.CondenserFrom Bellows to Pressure Connection or Temperature BulbV48 or V49 ValvePort 1Port 3Port 2Balancing ValveBypassTo Cooling TowerFrom Cooling TowerFrom Other Condensers(if used)To OtherCondensers(if used)Port 1 = InletPort 2 = CondenserPort 3 = BypassFigure 6 : Recommended Piping Arrangement for V48 or V49 ValvesV48 and V49 Series Valves Repair Kit Installation Instructions 7Table 3: Valve SpecificationsV48 SeriesV49 SeriesLow Pressure1High Pressure2V49AC-3CMaximum PermissibleRefrigerant Pressure230 psi (1585 kPa)320 psi (2206 kPa)__Maximum BulbTemperature____155°F (68°C)Opening Point AdjustmentRange85-110 psi (586-750 kPa)145-190 psi(1000-1310 kPa)75-135°F (24-57°C)Factory-SetOpening Point(Port 1 to Port 2)95 psi (655 kPa)165 psi (1138 kPa)103°F (39°C)Throttling Range35 psi (241 kPa)50 psi (345 kPa)24°F (13°C)Closing Point(Port 1 to Port 3)130 psi (896 kPa)215 psi (1482 kPa)127°F (52°C)Maximum Water Pressure150 psi (1034 kPa)Maximum WaterTemperature170°F (77°C)1. V48AB-1C, V48AC-1C, V48AD-1C, V48AE-1C, V48AF-1C2. V48AB-2C, V48AB-4C, V48AC-2C, V48AC-4C, V48AD-2C, V48AD-7C, V48AE-2C, V48AE-6C, V48AE-8CCheckoutBefore leaving the installation, observe at least onecomplete operating cycle to be sure that allcomponents are functioning correctly.8 V48 and V49 Series Valves Repair Kit Installation InstructionsRepairs and ReplacementSee Table 4 and Table 5 for information on partnumbers for replacing or repairing sensing elements.See V46, V47, V48, and V49 Sensing ElementReplacement Technical Bulletin, LIT-121700 forinformation on replacing the sensing element.Table 4: V48 Valves Sensing Element ReplacementValve Product Code NumberBellows ReplacementProduct Code NumberCapillary ReplacementProduct Code NumberV48AB-1V48AB-2V48AB-4SEP91A-602RV48AC-1V48AC-2V48AC-4SEP91A-601RV48AD-1V48AD-2V48AD-7V48AE-1V48AE-2V48AE-6V48AE-8SEP91A-603RSEC99AA-36Table 5: V49 Valves Sensing Element ReplacementValve Product Code NumberSensing Element Replacement Product Code NumberV49AC-3CSET98A-651Controls Group507 E. Michigan StreetP.O. Box 423Published in U.S.A.Milwaukee, WI 53201www.johnsoncontrols.comNext >