Technical Instructions
IS-P-595CD
#11 Regulator
Single Seat - Bronze Trim - Composition Disc
Valve Description ■
The Powers #11 Regulator is a self-actuating control valve
which automatically controls the temperature of a fl uid
without the use of external power. Adjust the set point and
the rugged self-operating #11 Regulator controls the fl ow
of heating medium (water or steam) to maintain a constant
temperature.
The instrument has a vapor pressure thermal system containing a thermally responsive fl uid. This thermal system rapidly
senses temperature changes at the bulb and controls the
fl ow of heating medium through the valve to maintain the
desired temperature. The thermal system features a two-ply
brass bellows with six reinforcing ribs on the bellows head
and thick capillary tubing walls to ensure long operating life.
The Powers #11 CD Regulator features:
• Tight shutoff when the valve is closed
• A valve stem of highly polished corrosion resistant grade
316L stainless steel to decrease friction and reduce
hysteresis
• An adjusting nut mounted on ball bearings and a removable
set point adjusting rod to ease set point adjustments
• A set point reference scale to aid temperature adjustments
Table of Contents ■
Valve Description ..............................................................1
Operation ............................................................................1
Specifi cations ....................................................................2
Applications .......................................................................2
Sizing and Selection .........................................................3
Water Capacities .............................................................3
Steam Capacities .............................................................4
Product Identifi cation ......................................................5
Installation ..........................................................................5
Maintenance ......................................................................6
Dimensions .........................................................................8
Parts .................................................................................. 10
Accessories ................................................................... 12
Temp. Ranges/Bulb Sizes ............................................ 12
Order Code ...................................................................... 13
Preventive Maintenance.............................................. 14
Troubleshooting ............................................................. 14
Warranty Information ................................................... 16
Operation ■
A bulb is connected to a bellows containing a thermally
responsive fl uid. The bulb is inserted into the fl uid you are
trying to control (process fl uid) to sense its temperature.
The Regulator set point is adjusted to allow suffi cient fl ow of
heating medium (water or steam) through the valve to keep
the process fl uid at the desired temperature.
(A) When the termperature of the process fl uid drops below
the set point, the temperature of the thermally responsive
liquid decreases, which decreases the vapor pressure in the
bulb/bellows. The force of the resulting vapor pressure is less
than the spring force, so the bellows contract and the spring
extends, which raises the valve plug up from its seat. This
increases the fl ow of the heating medium (water or steam),
which raises the temperture of the process fl uid.
(B) As the process fl uid temperature increases toward or
beyond the desired set point, the temperature of the thermally responsive fl uid in the bulb increases, which causes the
vapor pressure to increase. This expands the bellows, compresses the spring, and moves the valve plug down towards
its seat, to reduce or stop the fl ow of the heating medium.
VALVE
PLUG
BELLOWS
SPRING
CAPILLARY
TUBING
LIQUID
VAPOR
Temp .
Below
Set Point
LIQUID
BULB
VALVE SEAT VALVE SEAT
Temp.
Above
Set Point
(A) (B)
VALVE
PLUG
1
Specifi cations ■
Physical
Valve Sizes: ............................................1/2" to 1-1/2" (NPT)
Body Material: ......................................Bronze
Body Rating: ...........................................ANSI Class 250
Connections: .......................................... Double Female Unions
with pipe thread
Style: ........................................................ Single Seat with
Composition Disc
Valve Plug Travel: ................................ See Dimensional Data
on pages 8 & 9
Effective Bellows Area: ......................7.8 in
2
(50.3 cm2)
Maximum Body
Temperature: .................................400°F (204°C)
Applications ■
Powers #11 Regulators are used to automatically control the
temperature of a fl uid. The self-actuated regulator can easily be
installed in any convenient location. Among its applications are:
hot water and steam systems, fuel oil heaters, heat exchangers,
air drying rooms, and many industrial processes. Below are two
typical applications.
#11 CD valves are well suited to heating applications where
the steam inlet pressure is under 50 psig and good shutoff is
required.
Operating
Temperature Range: ....................See table on page 12
Controlled Medium: ..................... Steam or Water
Max. Differential
Pressure: ......................................... See Tables on pages 3 & 4
Max. Allowable
Overheat Temperature: ............... 25°F (14°C) above
temperature range
Max. Well
Safe Pressures: .............................See Table on page 9
Shipping Weight: .......................... See Table on page 8
Flow Characteristics: .................. Quick Opening
Shutoff Class Rating: ................... ANSI Class IV (leakage 0.01%
of rated valve capacity)
Bulb in Well
Oil Inlet
Fuel Oil Heater
Fuel Oil Heater Application
#11 Regulator
Single Seat CD
Steam SupplyOil Outlet
Condensate
Hot Water
#11 Regulator
Single Seat CD
Steam Supply
Condensate
Water Heater Application
2
Water Heater
Bulb in Well
Cold Water
Sizing and Selection ■
Proper sizing of the Regulator is essential for correct system
operation. An undersized regulator will not allow suffi cient fl ow
at maximum load. An oversized regulator may cycle and will not
utilize the full valve stroke for effi cient modulation of fl ow. This
results in poor control and shortened valve life (quicker deterioration of valve disc and seat). For these resasons, the correct
sizing of the regulator for actual expected conditions is considered essential for good control.
NOTE: Select a bulb (see page 12) that has the desired set point
in the upper third of the temperature range for best valve performance.
Size the #11 Regulator for actual rather than maximum conditions. Do not size according to pipe size; piping systems are
designed for different criteria than process controls. Refer to
Powers Form #AE-1, Valve Selection and Sizing for further recommendations.
Maximum Operating Pressure Differential (differential for fl uid
fl ow): In order for the process medium to fl ow, a pressure drop
must exist across the valve. “Pressure differential” is the difference in valve pressure between the inlet and outlet under fl ow
conditions. The greater the differential, the greater the fl ow at
any given plug position.
Though the regulator should be sized for actual conditions, you
need to know the available differential at maximum fl ow. For
optimum control, take as much differential as possible across
the valve.
Water Capacities ■
Use a pressure drop of at least 25% of inlet pressure when sizing valves for water applications.
Caution: Do not exceed maxi-
mum pressure differentials for
given valve sizes. The maximum
differential is the pressure the
valve has against it at shutoff. Too
large a differential can cause valve
chatter and/or prevent shutoff.
3
Caution: Do not exceed maximum pressure differentials for the given valve sizes. The maximum differential is the pressure the valve has against it at shutoff.
Steam Capacities ■
Use a pressure drop of 50% of absolute inlet pressure (gauge pressure + 15 psi) for steam applications.
Too large a differential can cause valve chatter and/or prevent shutoff.
4
Product Identifi cation ■
1. Product Label
A red label should be on the front face of the thermal system.
Figure 1. This label contains information required to properly
maintain, service and order parts for this product. If there is no
label, look for a white label on the inside of the thermal system
legs (Figure 2A) or the valve body vertical yoke (Figure 2B)
When replacing the original thermal assembly or valve body,
secure the old red label onto the valve or thermal system or ink
the number onto the body.
2
A. Thermal System Label
2B. Valve Body Label
Installation ■
Tools Needed
• Straight slot screwdriver • 5/16" open end wrench
• 3/8" open end wrench • 7/16" open end wrench
• 1-3/8" open end wrench • Pliers
Position Valve
1. To insure proper system operation, thoroughly fl ush all piping
and valves to rid them of all scale, dirt and debris.
2. Select valve location with suffi cient clearance to allow
maintenance. Install valve in line. The direction of the arrows
on the valve body must match the direction of the water or
steam fl ow.
For best results, we recommend installing the valve in a
horizontal line, and in the upright position with bellows head
above valve. The valve may also be installed in any position
within 90° of upright.
Install Bulb
3. Figure 3a shows proper bulb orientation. Figure 3b shows the
special bulb needed for upwards vertcial positioning.
4. Figure 4. For any position, fully immerse the bulb in the fl ow
of the medium.
These instructions are for D style bulbs - for installation of other
styles, refer to tag attached to bulb.
5. Without a well: Remove bushing from the bulb and screw it
into the tank. Insert the thermostatic bulb through the bushing and tighten the union nut.
With a well: Do not use bushing. Screw well into tank, insert
bulb directly into well, and tighten union nut.
TOP
Correct: Bulb in flow of medium
Standard Bulb
Downward Vertical (left)
Horizontal (below)
Only
WORD "TOP" ON FLAT SURFACE FACING UP
HEAD END
A. Bulb Orientation
3
or
Incorrect: Bulb not in flow of medium
4. Bulb Positions
Special Bulb
Upward Vertical
Only (right)
B. Special Bulb
3
Adjust Capillary Tubing
6. Coil the extra capillary, and position away from regulator
operation where it is subjected to room temperature only.
WARNING: DO NOT kink, cut, sever or fi le the tubing.
DO NOT disconnect tubing from bulb or bellows assembly.
This can render the thermal system inoperable and result in
severe process overheating.
Adjust set point
All regulators are factory set to control near mid-range
operating temperature.
7. When adjusting the set point, make certain the heating
medium is fl owing through the valve and is at the operating
pressure of the system.
8. Figure 5. Make all set point temperature changes by inserting
the temperature adjustment rod into one of the holes of the
adjusting nut assembly. (Use the temperature adjustment
setting scale only for reference)
To Raise the set point:
Turn rod left to right
(counterclockwise
from top).
To Lower the set point:
Turn rod right to left
(clockwise from top).
5. Adjusting Set Point
5
Maintenance ■
Number in brackets [#] refer to part numbers on pp. 10 & 11.
To replace the composition disc only
1. Before disassembly, the bulb must be cooled 30°F (16°C)
below the lowest point on the thermal system range,
and fl ow through the valve must be stopped.
2. Figure 5. Relieve all pressure on the spring by turning adjust-
ing nut assembly [31]fully right to left (clockwise from top).
3. Figure 6. Loosen lock nut [11] with 1-3/8" open end wrench.
Use the 1-3/8" wrench to unscrew bonnet [20] from valve
body [26]. DO NOT ALLOW the regulator top to rotate.
Lift up regulator top.
3. Figure 7. Remove housing bolts [6] and nuts [7] and tempera-
ture adjustment setting scale [8] and lift off thermal system
[1] (housing, bellows, capillary, and bulb).
7. Remove Housing and Thermal System
Lock Nut
Bonnet
Disc
Disc Retainer
Nut
Body
6. Lift off Regulator from valve
4. Remove disc retainer nut [25] and replace disc [24].
5. Assemble in reverse order.
To fully disassemble regulator from valve
1. Before disassembly, the bulb must be cooled 30°F (16°C)
below the lowest point on the thermal system range,
and fl ow through the valve must be stopped.
2. Figure 5. Relieve all pressure on the spring by turning adjusting nut assembly [31]fully right to left (clockwise from top).
Figure 8. Using one 3/8" wrench and one 5/16" wrench, carefully
loosen and remove piston plate assembly [2,3] from the stem
extension [4]. Lift off spring [19].
3/8" Nut
Piston Plate Assembly
Spring
5/16" Nut
8. Remove Piston Plate/Spring
4. Figure 9. Use 1-3/8" wrench to unscrew lock nut [11] and lift
off the yoke and bridge assembly [9].
Locknut
Yoke and Bridge
9. Lift off yoke and bridge
6
Maintenance, cont. ■
To replace packing
Follow To fully disassemble regulator from valve steps 1-5.
5. Figure 10. Use a 5/16" wrench on the fl ats of the stem extension [4] and a 7/16" wrench on the hex nut [12] to loosen and
remove them.
6. Use the 1-3/8" wrench to loosen and remove bonnet [20].
5/16" Stem
Extension
7/16"
Hex Nut
Stem Assembly
10. remove stem extension and hex nut
7. Carefully pull out stem assembly [30]. Check the stem. It must
have a polished surface that is free of roughness and pitting.
Replace any parts if necessary.
8. Figure 11. Remove packing gland [14], and all packing
components [15a-15e].
Packing
Packing Kit
(15a-e)
Disc
Stem
Gland
Spacer
Packing
Gland
15. Thread the packing gland assembly [14] into the bonnet.
TIghten the gland assembly against the spacer.
16. With valve plug fi rmly seated, screw stem extension [4] to the
dimension shown in Figure 12 and tighten into place with hex
nut [12].
17. Assemble the remaining parts in reverse order.
Top of Stem
Extension
Hex Nut
Top of Bonnet
12. Stem extension Reassembly dimension
10-1/8"
[257mm ]
+1/32"
- 0"
+.79mm
- 0mm
Testing the Thermal System ■
If the valve is not responding to temperature change, test the
thermal system.
1. Stop the fl ow of fl uid through the line.
2. Raise the temperature of the the bulb above the set point
temperature by placing it a container of hot water. This will
cause the plug to fully seat.
3. Figure 13. With the valve plug seated, use a felt tip pen to
mark where the position of the packing gland assembly on
the stem.
Bonnet
11. Packing Components, bonnet and stem
9. Clean packing chamber, taking care not to scratch seating
surfaces. Be sure chamber is free of dirt and grease.
10. For 1-1/2" Valves: Place O-ring [21] on body before bonnet.
11. Replace bonnet [20] and stem [30] into valve body.
NOTE: You must replace the bonnet and stem before attempting to insert the packing. The rings will slide over the stem.
Otherwise, you may tear the packing rings.
12. For standard packing kits, installed the parts as shown in
Figure 11.
Slide part(s) [15e], followed by [15d] and [15c] over the stem.
Gently push them into the packing chamber.
NOTE: Some kits do not include all the listed packing parts (see
page 12), but the order for part installation is the same.
13. For EP V-rings, lubricate the rings fi rst.
Slide each V-ring [15b] over the stem and carefully
push it into the packing chamber.
14. Place the packing gland spacer [15a] on top of the bonnet.
Distance between two
marks = Valve Travel
13. valve travel measurement
4. Place the bulb in a pan of cool water. Cool the bulb 30°F
(16°C) below set point so the valve is fully open.
5. Use the pen to mark the new position of the packing gland
assembly on the stem.
6. The distance between the marks is the valve plug travel.
This should correspond with the TRAVEL value in the
VALVE DIMENSIONS table on page 8. No movement or
only partial movement indicates the thermal system is
defective and should be replaced with a new system.
WARNING: Failure of the #11's thermal system will cause a heat-
ing valve to full open and a cooling valve to full close. If either of these
valve states results in an unsafe process condition, a high-limit shutdown device, such as a Powers Aqua Sentry, should be used.
7
Dimensions ■
11-5/8"
[296mm]
C
D
5" DIA.
[127mm]
CAPILLARY TUBING
8' [2.4m]
15' [4.6m]
30' [9.1m]
4-1/8
[108]
3-5/8" DIA
[87]
Optional Indicating Style Head
NPT Pipe Thread
D Style Bulbs
E
BB
J Style Bulbs
BB
NPT Pipe Thread
JD Style Bulbs
BB
S Style Wells
1" NPT Pipe Thread
F
G
H
K
(outer dim. of taper)
A
A
A
J
8
Dimensions ■
BULB DIMENSIONS
Bulb Style Size Material A (in.) B (in.) Shock Non-Shock
D
Fixed Union
(& V-Vertical
Fixed Union)
J
Plain Bulb
JD
Adjustable
Bulb Style Size Material A (mm) B (mm) Shock Non-Shock
D
Fixed Union
(& V-Vertical
Fixed Union
J
Plain Bulb
JD
Adjustable
1 x 9
1 x 20
1 x 9 347 Stainless 15/16 8 3/4 – –
1 x 20 347 Stainless 15/16 20 1/2 – –
1 x 9 347 Stainless 15/16 8 3/4 500 725
1 x 20 347 Stainless 15/16 20 1/2 500 725
1 x 9
1 x 20
1 x 9 347 Stainless 24 222 – –
1 x 20 347 Stainless 24 521 – –
1 x 9 347 Stainless 24 222 12700 18415
1 x 20 347 Stainless 24 521 12700 18415
Copper 15/16 8 175 250
347 Stainless 15/16 8 1/16 500 725
Copper 15/16 19 7/8 175 250
347 Stainless 15/16 19 13/16 500 725
Copper 24 203 4445 6350
347 Stainless 24 205 12700 18415
Copper 24 505 4445 6350
347 Stainless 24 503 12700 18415
Max. Pressure - psi
Max. Pressure - kPa
WELL DIMENSIONS
Bulb Size Well Kit # Well Material F (in.) G (in.) H (in.) J (in.) K (in.) Shock Non-Shock
1 x 9
1 x 20
Bulb Size Well Kit # Well Material F (mm) G (mm) H (mm) J (mm) K (mm) Shock Non-Shock
1 x 9
1 x 20
709-193 Chrome Plated Copper 15/16 13/16 9 1/16 1 1.11 175 250
808-478 316L Stainless Steel 1 1/16 13/16 8 11/16 1 1/64 1.11 450 675
709-075 Chrome Plated Copper 15/16 13/16 21 1 1.11 175 250
808-475 316L Stainless Steel 1 1/16 13/16 20 3/8 1 1/64 1.11 450 675
709-193 Chrome Plated Copper 24 21 230 25 28 1207 1724
808-478 316L Stainless Steel 27 21 221 26 28 3103 4654
709-075 Chrome Plated Copper 24 21 533 25 28 1207 1724
808-475 316L Stainless Steel 27 21 518 26 28 3103 4654
Max. Well Pressure - psi
Max. Well Pressure - kPa
9
Parts ■10Parts ■
18
19
31
2
3
4
6
7
1a
1b
1c
1d
1e
5
10
12
1f
17
8
15
9
14
15a
15b
15c
15d
15e
28
27
30
11
20
13
22
21
29
23
26
24
25
11
Accessories ■
Packing kits can be ordered to replace parts in the packing assembly (See pages 10 & 11).
Temperature Ranges/Bulb Sizes ■
For ordering thermal systems, refer to order code on page,
Powers #11 product Specifi cation Brochure, or call Powers.
12
Order Code ■
Valve Type
Single Seat Composition Disc .......... CD
Valve Sizes
1/2" ....................................................... 050
3/4" ....................................................... 075
1" .......................................................... 100
1-1/4" .................................................... 125
1-1/2" .................................................... 150
Applications
Heating....................................................H
Bulb/Capillary Material & Length
Copper 8" ............................................C08
Copper 15" ..........................................C15
Copper 30" ..........................................C30
Stainless Steel 8" ............................... S08
Stainless Steel 15" ............................. S15
Stainless Steel 30" ............................. S30
Valve Assembly Thermal System Assembly
595-
Bulb Size
Fixed Union.............................................D
No Pipe Fittings (N/A Copper) ............. J
Adj. Union (N/A in H Head) .................A
Fixed Union (D Type) Vertical ..............V
Head Assembly
Non-Indicating...................................... N
Indicating................................................. I
Range/Bulb Size.................................... #
See Chart on page 12
Select Range with Set Point in
UPPER THIRD for best performance.
For additional information on your application or equipment, please contact a Powers application engineer.
13
Preventive Maintenance ■
Once every three months, inspect the Regulator
as follows:
1. Visually check for leaks from the valve body joints, piping-tovalve connections, packing and stem areas
2. Visually check for excessive corrosion on the regulator,
including the bellows, capillary, bulb, thermal system legs,
bridge, and yoke. Also check for excessive corrosion on the
valve body.
3. Perform the instructions in Testing the Thermal System Less
than full valve travel may indicate a leak in the bellows, capillary, or bulb, or other problems.This may result in excessive
temperature in the process.
4. Test the temperature adjusting nut assembly for freedom of
movement (see Adjust Set Point for instructions).
5. Remove bulb form the process fl uid and check for excessive
corrosion, or erosion that may weaken the bulb and/or cause
thermal system failure.
Troubleshooting ■
WARNING: Failure of the thermal system will result in a
constant rise in temperature (or constant high temperature) of the fl uid which you are trying to control.
• Erratic temperature control (valve cycles too hot/too cold)
1. Valve sized incorrectly. Verify valve selection.
2. Regulator is controlling at incorrect set point. Refer to Adjust
Set Point.
3. Bulb is poorly positioned and/or oriented, and will not control
the actual temperature of the heating/cooling medium. Refer
to Install Bulb.
4. Incorrect type of bulb is being used. See Table on page 11.
5. The valve stem is sticking. Lubricate the stem.
6. The valve stem is bent. Refer to Maintenance for disassembly instructions and replace.
7. Packing gland assembly too tight. Loosen packing
gland nut [14].
8. Faulty or incorrect steam traps. Replace with correct
steam trap.
9. Very wet steam. Install a high pressure steam trap just ahead of
the valve to drain off condensate that collects in the steam line.
• Regulator Does Not Shut Off
1. Pressure differential is greater than allowable pressure drop.
Refer to Water Capacities and Steam Capacities tables.
2. Disc is worn. Replace disc (refer to Maintenance).
3. Foreign material between the disc and the valve plug seat.
Refer to Replace only the composition disc for disassembly.
Clean.
4. Bulb is poorly positioned and/or oriented, and will not control
the actual temperature of the heating/cooling medium. Refer
to Install Bulb.
5. Incorrect type of bulb is being used. See Table on page 11.
6. Valve sized incorrectly, causing wire drawing and leakage.
Refer to Sizing Information.
7. Packing gland assembly is too tight, locking valve stem.
Loosen packing gland assembly and lubricate if desired.
8. Bent valve stem; need to replace. Refer to Maintenance
for disassembly.
9. Thermal system failure. Refer to Testing the Thermal System.
10. Temperature adjusting nut assembly raised too high. Refer to
Adjust Set Point.
• Valve "chatters"
1. Regulator installed with the fl ow of the control medium in
reverse of arrow direction on valve body.
2. Pressure differential too high, refer to Tables on pages 3 and
4 for correct pressure differential range.
3. Trapped condensate in line. Install a steam trap just ahead
of the regulator to drain off condensate that collects in the
steam line.
• Constant rise in process fl uid temperature
1. A constant rise in temperature may indicate the thermal system is leaking charge and/or the valve has failed in a partially
or fully open position. This would allow a constant fl ow of
heating medium, which would overheat the fl uid which you
are trying to control.
14
Notes ■
15
Warranty ■
The Seller warrants that the equipment manufactured by it and covered by this order or contract is free from defects in material and workmanship and, without
charge, equipment found to be defective in material or workmanship will be repaired, or at Seller’s option replaced F.O.B. original point of shipment, if written
notice of failure is received by Seller within one (1) year after date of shipment (unless specifically noted elsewhere), provided said equipment has been properly
installed, operated in accordance with the Seller’s instructions, and provided such defects are not due to abuse or decomposition by chemical or galvanic action.
THIS EXPRESS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, GUARANTEES, OR REPRESENTATIONS, EXPRESS OF IMPLIED. THERE ARE
NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. The Seller assumes no responsibility for repairs made on the
Seller’s equipment unless done by the Seller’s authorized personnel, or by written authority from the Seller. The Seller makes no guarantee with respect to material
not manufactured by it.
USA: Phone: 1.800.669.5430 • Fax 1.847. 229. 0526 • www.powerscontrols.com
Canada: Phone: 1.888.208.8927 • Fax 1. 888. 479.2887
IS-P-595CD 0844 6509030 © 2008 Powers
• www.powerscontrols.ca
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