Jordan Valve Mark 4150 User Manual

I & M Mark 4150 and 4160 Series

3170 Wasson Road • Cincinnati, OH 45209
Phone [phone] • Fax [phone] (f)
[e-mail] • www.jordanvalve.com

Warning: Jordan Valve Control Valves must only be used, installed and repaired in accordance with these Installa­tion & Maintenance Instructions. Observe all applicable public and company codes and regulations. In the event
of leakage or other malfunction, call a qualified service person; continued operation may cause system failure or
a general hazard. Before servicing any valve, disconnect, shut off, or bypass all pressurized fluid. Before disassem­bling a valve, be sure to release all spring tension.

IntroductIon

The Mark 4150 and 4160 Series pressure controllers
are designed to provide years of reliable and accurate
service.

These instructions cover maintenance, adjustment,
and changes in mode of control.

Installation & Maintenance Instructions for the

Mark 4150 and 4160 Series Pressure Controllers

If the body is flanged, the bolts should be tightened up
evenly to reduce risk of damage to the valve body and
the flange.

A good quality thread lubricating compound should be
used on all male connections if the body has screwed
connections.

Control Line Connectors

These instructions are intended for the controllers
in general. Any instructions that apply to specific
controllers will be indicated by model number in the
instruction.

Model numbers are stamped on the nameplate locat­ed inside the cover of the controller (Key 29, Figure 4).

The connections should be made in an area of the
pipeline that is free of bends and elbows. Piping
connections should be made with 1/4” or 3/8” pipe or
tubing.

Tap the pipeline as close to the valve body as possible
allowing for these limiting factors.

Controllers

Inspect the controllers for shipping damage and for­eign debris when uncrating.

Valve

Ensure the pipeline is free of welding slag, chips and
other debris by blowing out the line prior to installation.

It is recommended that a strainer be installed up
stream of the valve to protect the valve from foreign
debris in the line. Jordan Valve recommends a stan­dard three-valve maintenance bypass be installed.
This allows isolation of the control valve without shut­ting down the pipeline system.

The valve should be positioned on the line so the flow
direction indicator corresponds to the direction of the
flow of the pipeline.

1. The tap area should be an area that is free
from abnormal velocities.

2. The ideal distance away from the body should
be 10 x the pipeline diameter.

The control pressure line is run from the tapped hole in
the side or the back of the case to the main pipeline.

Install a lock shield needle valve in the control line to
slow down the controlled pressure or to dampen out
any pulsations. While the control valve is operational,
the needle valve must never be entirely closed.

An air vent is provided on all controllers and works well
when air is used as the operating medium. When gas
is used the vent can be removed, this allows for an ad­ditional 1/4” NPT connection for gas to be piped away.

Mark 4150 and 4160 SerieS PreSSure ControllerS

Operation

Although the output for these controllers are set prior
to shipping, upon arrival the following items should be
checked.

Bellofram Mark 50 Filter Regulator

Bellofram Mark 50 Filter Regulator is a self-contained
filter regulator designed to deliver air or gas to the
pilot at a constant pressure. The Bellofram Mark 50 is
designed to handle inlet pressures up to 250 psi. The
Series 4150/4160 delivers an outlet pressure of 3 - 15
psi when the regulator is set to 20 and it will deliver 6-30
psi output when the regulator is set to 35 psi.

The filter component ensures that operation is clean and
dry.

The relief valve is geared to open when the pressure is
reduced to 1 psi above the regulator set point.

Releasing the lock nut and adjusting the adjusting screw
located on the top of the regulator can reduce pressure
setting for the regulator.

Proportional Controllers

Most of the proportional controls will be used in applica­tions that require a band set to approximately 15%. The
following steps are used to test this setting.

1. The air supply should be connected to Bello-
fram Mark 50 filter regulator.

2. Zero the pressure setting dial.

3. Set the proportional band adjustment to 15%

4. There should be no pressure sent to the mea
suring element.

5. For direct or reverse acting controllers the
range and output should be set as follows.

Range Output

3-15 psi 8-10 psi

6-30 psi 16-20 psi

Proportional-Reset Controllers

1. The reset dial should be set to maximum.

2. The air supply should be connected to Bello-
fram Mark 50 filter regulator.

3. Zero the pressure setting dial and proportioned
setting dial.

4. There should be no pressure sent to the mea-
suring element.

5. For direct or reverse acting controllers the
range and output should be as follows.

Range Output

3-15 psi 8-10 psi

6-30 psi 16-20 psi

Start Up

Proportional Controllers

1. The air supply should be connected to Bellofram
Mark 50 filter regulator.

2. Connect the control pressure line and open the
lock shield needle valve.

3. Ensure all piping and connections are free from
leaks.

4. Set the pressure to the desired control point.

5. Proportional band should be set at 15% of the
bandwidth.

6. Open the manual control valves that are up
stream and downstream, at the same time close
the by-pass valves.

7. Set the controller near the desired control point.
When it reaches that point, begin to broaden the
proportional band. Broaden the band as little
as possible. The narrowest band that
will not result in cycling provides
the best control. This band adjustment
will affect the zero. Re-zero the unit.

8. Test the bandwidth by changing the pressure
setting adjustment for a moment. If this
causes cycling, then broaden the proportional
band and test again. This procedure is
to be repeated until stability is reached.

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Mark 4150 and 4160 SerieS PreSSure ControllerS

Proportional-Reset Controllers

1. The air supply should be connected to Bellofram
Mark 50 filter regulator.

2. Connect the control pressure line and open the
lock shield needle valve.

3. Ensure all piping and connections are free from
leaks.

4. Set pressure to the desired control point.

5. Proportional band should be set at 100% of
bandwidth.

6. Maximize the setting on the reset dial.

7. Open the manual control valves that are up
stream and downstream, at the same time close
by-pass valves.

8. Set the controller near the desired control point.
When it reaches that point, begin to narrow
the proportional band until a cycling condition
exists. Broaden the band slightly until a stable
condition is reached. There is no need
to reset the zero in controllers that have reset.

9. Try to obtain the fastest reset time without intro
ducing cycling control carefully by adjusting the
reset rate.

10. Test the bandwidth and the reset rate by chang-
ing the pressure setting adjustment for
a moment. If this causes cycling, then broaden
the proportional band and test again. This
procedure is to be repeated until stability is
reached.

Example: with the proportional band set @ 1 (10%),
using a Bourdon tube of 0-1000 psi that is set @ 500 psi
on the pressure dial. The full travel of the valve would
occur between 450 psi (3 psi output) and 550 psi (15 psi
output) to try to maintain the set point.

Using this theory, an input pressure of 500 would give
you an output pressure of 9 psi. The greater the propor­tional band setting is the slower the reaction.

Figure 1: Pressure Connections for
Proportional Controller

The goal for the controller setting is to have the narrow­est proportional band and the fastest reset rate that will
not cause cycling.

Changing Controller Action

One advantage of the Mark 4150/4160 is the ease at
which you can change from one mode of control to an­other. There is a connection for both direct and reverse
action in all modes of control. There is also a screw (key
5, figure 6) provided to plug the hole opposite of the
nozzle. It will be necessary to follow INITIAL SETTINGS
after any change in mode of control.

Adjustments

Proportional Band Width Adjustments

The proportional band width adjustment determines the
change in control pressure required to cause the control
valve to travel full open or full closed.

Figure 2: Pressure Connections for
Proportional-Reset Controller

Reset Rate Adjustment

By definition the reset rate is the number of minutes that
it takes to adjust the controller to adjust the output pres­sure up or down by the same amount of proportional
change output caused by the process change.

The reset rate is calibrated in minute per repeat.

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Mark 4150 and 4160 SerieS PreSSure ControllerS

Pressure Setting Adjustment

The Mark 4150 and 4160 come with calibrated set point
adjustment. The dial is calibrated for pressure ratings
of the measurement element. If start up instructions are
followed, the pressure setting dial is correct for any set­tings on proportional-reset controllers.

Mark 4150 Pressure Controller

The theory of operation can be broken down into steps.
Refer to the schematic diagram figure 3.

I. The pressure first enters the Bourdon tube. As
the pressure increases the Bourdon tube
straightens causing the beam (B) attached to
the end of the Bourdon tube to move closer to
nozzle (C).

2. Closing the nozzle (C) will cause a build up of
pressure in chamber (D) from the constant air or
gas supply through the orifice (E).

3. The resulting pressure built up in chamber (D)
cause the diaphragm (F) to push up and
open valve (G).

4. An open Valve (G) will cause the constant air or
gas supply to flow into chamber (H).

5. The build up of pressure in chamber (H) causes
diaphragm (F) to be pushed back to its original
position and therefore closes valve (G).

6. The increase in pressure in chamber (H) sends
the supply pressure to flow to the diaphragm
of the control valve causing the control valve to
start to close.

7. At the same time, the pressure flows through the
three-way valve (K) causing an increase in pres
sure in bellows (I).

8. The increase in the pressure bellows (I) cause
the beam (B) to move away from nozzle (C). As
a result there will no longer be a build up of
pressure in (D). The control valve is now at the
desired pressure setting.

If there is a decrease in control pressure the above men­tioned steps will proceed in reverse. The control pres­sure will bleed out through the exhaust vent (J).

Please note that the changes in pressure are continuous
in nature. The process has been explained in steps for
ease of explanation.

As seen in the figure 3, schematic illustration of Mark
4150, the output pressure from relay chamber (H) goes
to both the proportional band adjustment relay three-way
valve (K) and the control valve diaphragm. The amount
of feedback to the proportional bellows (I) can be ad­justed by adjusting the orifice. If valve (K) is fully open,
then the total of the diaphragm pressure is sent to the
bellows chamber (I).

This causes the beam (B) to move away from nozzle (C)
allowing the pressure to be released from chamber (D).
The result of this is 100% proportional band based on
the rating of the Bourdon tube. Closing the three-way
valve (K) will result in a lowering of proportional band re­sponse. The proportional band would be approximately
3% when fully closed.

Figure 3: Schematic Illustration of
Mark 4150 Proportional Controller

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Schematic Illustration of Mark 4150
Proportional-Reset Controller