T.M.

C327845

TECHNICAL MANUAL

OPERATION AND
MAINTENANCE INSTRUCTIONS

GAS ISOLATION VALVE

[CLASS 600 – 2-INCH – 20-28 VDC]

MODEL NUMBER C327845

THIS DOCUMENT SUPERSEDES T.M. C327845 DATED NOVEMBER 1/96.

PROPRIETARY INFORMATION NOTICE: – THE INFORMATION CONTAINED HEREIN

IS THE PROPERTY OF WHITTAKER CONTROLS, A UNIT OF WHITTAKER CORPORATION,
AND DISCLOSURE OF THE CONTENTS TO OTHERS IS GIVEN IN CONFIDENCE. THIS
MATERIAL MUST NOT BE REPRODUCED OR COPIED, OR OTHERWISE DISCLOSED IN
WHOLE OR IN PART WITHOUT THE APPROVAL OF WHITTAKER CONTROLS, NORTH
HOLLYWOOD, CALIFORNIA, U.S.A.

1 MAY 1998
 T.M. C327845
1 MAY 1998

Reproduction of the information or illustrations contained in this publication is not permitted, without written
permission from the publisher: Whittaker Controls, 12838 Saticoy Street, North Hollywood, California
90605, U.S.A.

LIST OF EFFECTIVE PAGES

Insert latest changed pages; dispose of superseded pages.

NOTE: On a changed page, the portion of text affected by the change is indicated by a vertical line or
other change symbol in the outer margin of the page. Changes to illustrations are indicated by miniature
pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are as follows:

Original 1 . . . . . . . . . . . . 1 MAY 1998

Total number of pages in this manual is 17 consisting of the following:

Page #Change Page #Change Page #Change Page #Change

No. No. No. No. No. No. No. No.

Title . . . . . . . . . . . . . 0 i – iii . . . . . . . . . . . . 0 2-1 . . . . . . . . . . . . . 0 4-1 – 4-2 . . . . . . . . 0

A ...............0 1-1 – 1-5 . . . . . . . . . 0 3-1 – 3-2 . . . . . . . . . 0 5-1 – 5-2 . . . . . . . . . 0

#Zero in this column indicates an original page.

A
T.M. C327845
1 MAY 1998

TABLE OF CONTENTS

Section Paragraph/Title Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

I DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-6. Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-8. Valve Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-10. Closed Position Indicating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

II INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

III FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3. Fault Isolation – Valve Reported Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-4. Position Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-5. Position Indicator Moves Normally – Possible Position Indicating Switch Fault . . . . . 3-1
3-6. Position Indicator Will Not Move – Possible Solenoid Fault . . . . . . . . . . . . . . . . . . . . 3-1
3-7. Visual Position Indicator Moves Normally – No Significant Gas Flow When Open . . 3-2

IV REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-4. Inlet Filter Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-5. Closed Position Indicating Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-6. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-7. Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

V MAINTENANCE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-3. Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

i
 T.M. C327845
1 MAY 1998

LIST OF ILLUSTRATIONS
Figure Title Page

1-1. Gas Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2. Electrical Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

LIST OF TABLES
Table Title Page

1-1. Gas Isolation Valve Characteristics/Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

5-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ii
T.M. C327845
1 MAY 1998

SAFETY SUMMARY

GENERAL

The following are general safety precautions that are not related to specific procedures and therefore
do not appear elsewhere in this publication. These are recommended precautions that personnel must
understand and apply during many phases of maintenance.

WEAR PROTECTIVE CLOTHING

Wear protective clothing (gloves, apron, etc.) approved for the materials and tools being used.

USE APPROVED SAFETY EQUIPMENT

When cleaners and primers are being applied, approved explosion-proof lights, blowers, and other
equipment shall be used. Make sure that fire fighting equipment is readily available and in working order.

GIVE CLEANERS SPECIAL CARE

Keep cleaners in special polyethylene bottles or in safety cans and in minimum quantities. Discard soil-
ed cleaning rags into safety cans.

ELECTRICAL SYSTEM PRECAUTIONS

The equipment contains a 28 (20-28) VDC electrical system. Prior to performing electrical repairs after
testing, make sure that the 28 VDC power source is disconnected prior to attempting removal or dis-
assembly of any electrical components. This will protect personnel from possible electric shock as well
as protecting the equipment from possible damage.

iii
T.M. C327845
1 MAY 1998

SECTION I

DESCRIPTION AND OPERATION

1-1. DESCRIPTION.

1-2. The Gas Isolation Valve (see Figure 1) is an angle poppet shutoff valve in a straight flow through
body. The valve shutoff poppet is servo operated by line pressure. The valve is normally spring-loaded
in the closed position, and gas pressure is used in the actuator to open the valve when the solenoid is
energized. The actuator and solenoid-pilot assembly work together to open and close the valve. The valve
is designed and certified to be explosion proof. The valve incorporates a position indicating switch circuit
and a mechanical position indicator (in the top of the actuator).

1-3. OPERATION (Refer to Figures 1 and 2.)

1-4. GENERAL.

1-5. Gas flow is controlled by a flat-faced poppet with a polymer seal which shuts off flow. The valve is
normally closed when the solenoid is deenergized. To open the valve, the solenoid-pilot valve is energized
to provide actuation pressure to the valve actuator. The valve actuator opens the valve.

1-6. Valve Opening.

1-7. When solenoid is energized, the pilot valve plunger is pulled upward against the core and the lower
pilot valve ball allows high pressure gas to flow into the actuator. The upper pilot seat is closed to ambient.
When the gas pressure force in the actuator exceeds the actuator spring force, the valve opens.

1-8. Valve Closing.

1-9. When solenoid is deenergized, the pilot valve plunger is pushed downward by spring force and the
lower pilot valve ball is held against its seat. The upper pilot seat is open and the actuation pressure is
vented to ambient. When the gas pressure in the actuator vents, the actuator spring force closes the
valve.

1-10. Closed Position Indicating Switch.

1-11. When the valve is not in the fully closed position, the switch normally open contacts are open.
When the valve is in the fully closed position, the switch normally open contacts are closed. The switch
is adjusted to close when the valve reaches 85 to 95 percent of its fully closed position.

1-1
 T.M. C327845
1 MAY 1998

ELECTRICAL
ACCESS
PORT
SOLENOID

FILTER AND
VENT PORT
ACTUATOR (FAR SIDE)

INLET
PORT

C327845

FLOW OUTLET
BODY PORT

Figure 1-1. Gas Isolation Valve

1-2
T.M. C327845
1 MAY 1998

Figure 1-2. Electrical Schematic/Wiring Diagram

1-3
 T.M. C327845
1 MAY 1998

Table 1-1. Gas Isolation Valve Specifications/Characteristics

Valve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Flow Shutoff, Solenoid Pilot Operated,

Gas Actuated, Fail Safe Closed

Service Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Gas

Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 inches

Pressures
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 to 1000 psig
Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1440 psig

Actuation Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 psig

Flow (air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 4.0 pounds/second

Pressure Drop (air) (fully open) (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 11 psid at 300 psig,

4.0 pounds/second, and 60(F

Operating Times (maximum) (150 psig)

Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 milliseconds
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 milliseconds

Internal Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . per ANSI Class V

Electrical Data
Solenoid
Voltage
Nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volts dc
Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 28 volts dc
Current (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 amperes steady state

Closed Position Indicating Switch

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-wire, SPDT
Rated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts dc
Rated Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 amperes

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ½-14 NPT port

Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . Flanges per ANSI B16.5, 2-inch pipe, Class 600

1-4
T.M. C327845
1 MAY 1998

Table 1-1. Gas Isolation Valve Specifications/Characteristics (continued)

Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ½-14 NPT port

Temperatures
Normal Ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –65 to 150(F
High Ambient (one hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350(F
Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 to 150(F

Weight (dry) (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 pounds

1-5
T.M. C327845
1 MAY 1998

SECTION II

INSTALLATION

2-1. GENERAL.

2-2. This section contains information on installation of the valve in the system.

2-3. INSTALLATION.

a. The tightening torque for the flange attaching nuts/studs should be within 70 to 90 foot-pounds.

WARNING: BE SURE THAT POWER IS OFF PRIOR TO REMOVING THE ACCESS PLATE OR
TOUCHING THE ELECTRICAL WIRES!

b. To gain access to the terminal block for connection of the solenoid and closed position indicating
switch electrical wires, remove the screws and the access plate.

c. Connect the electrical conduit to the conduit port (1/2-14 NPT).

d. Feed the electrical lead wires through the conduit and connect each to its assigned terminal of
the terminal block. (Refer to Figure 1-2 for electrical schematic/wiring diagram). Tighten the terminal
screws to within 7 to 10 inch-pounds torque.

e. Install the access plate and secure with the screws. Tighten the terminal block access plate
screws to within 70 to 90 inch-pounds torque.

WARNING: PROPER GAS VENTING IS CRITICAL TO AVOID HAZARDOUS CONDITIONS.

f. Vent Port. The VENT port is on the side of the valve actuator, under the solenoid. This port
must be plumbed to a vented ambient line, such as a flue stack for expelling gas from the surrounding
enclosure. Each time the valve is closed, a small burst of gas will be expelled at high velocity through the
vent line.

2-1
T.M. C327845
1 MAY 1998

SECTION III

FAULT ISOLATION

3-1. GENERAL.

3-2. This section contains specific checks required to fault isolate an installed valve during service. Refer
to Figure 1-2 for electrical schematic/wiring diagram.

3-3. FAULT ISOLATION – VALVE REPORTED INOPERATIVE

3-4. POSITION INDICATION.

a. Pressurize the valve inlet port with gas or air to 200 psig minimum.

NOTE: To cycle the valve open, apply 24 (±2) volts dc electrical power between terminals 1 and
2. To cycle the valve closed, remove the electrical power.

b. Visually check for valve actuation by observing the position indicator at the top of the valve when
the valve is cycled (energized and deenergized).

c. If the position indicator moves normally(between the OPEN and CLOSED positions), proceed
to paragraph 3-5 below. If the position indicator does not move normally, proceed to paragraph C below.

3-5. POSITION INDICATOR MOVES NORMALLY – POSSIBLE POSITION INDICATING SWITCH

FAULT.

a. Remove the four screws and washers securing the access plate to the switch cover, to gain
access to the terminal block.

b. With the valve deenergized and the position indicator in the valve fully closed position, use an
ohmmeter to check for continuity between terminals 4 and 5 of the terminal block. If there is no continuity
(open circuit), manually actuate the closed position indicating switch while observing the ohmmeter
indication.

c. If the switch functions normally (opens and closes), adjust the switch to close when the position
indicator is within 0.050 inch maximum from the fully closed valve position. If the switch will not function
or cannot be adjusted, replace the switch (refer to the REPAIR section).

3-6. POSITION INDICATOR WILL NOT MOVE – POSSIBLE SOLENOID FAULT

a. Pressurize the valve inlet port with gas or air to 200 psig minimum.

3-1
 T.M. C327845
1 MAY 1998

b. Energize and deenergize the valve using 24 volts dc. If the valve does not actuate open and
closed, check for presence of 24 volts dc on terminals 1 and 2 of the terminal block. If voltage is present,
check the solenoid lead wire connections to the terminal block. If voltage is not present, locate and correct
the external power circuit.

c. If voltage is present but the valve will not actuate, return the valve to Whittaker Controls for
repair.

3-7. VISUAL POSITION INDICATOR MOVES NORMALLY – NO SIGNIFICANT GAS FLOW WHEN
OPEN

a. With the actuator energized, the position indicator shows the valve is in the fully open position,
but there is no measurable gas flow.

b. With the actuator energized, if there is no measurable gas flow greater than the permitted
leakage flow (0.10 pound/minute), return the valve to Whittaker Controls for repair.

3-2
T.M. C327845
1 MAY 1998

SECTION IV

REPAIR

4-1. GENERAL.

4-2. This section outlines specific repair tasks which may be required, as determined by the results of
performing fault isolation procedures. Prior to any repair action, perform the fault isolation procedures
(refer to the FAULT ISOLATION section).

4-3. Refer to Figure 1-2 for electrical schematic/wiring diagram.

4-4. INLET FILTER ELEMENT CLEANING.

NOTE: An inlet gas filter is located on the side of the actuator housing, under the solenoid. The
filter should be cleaned annually or more frequently, as follows:

a. Using a screwdriver, remove the filter retainer (P/N C325770).

b. Remove the filter element (P/N 200747-6-070).

c. Replace the filter element with a new element if available. Or, clean the filter element ultra-
sonically in alcohol. Purge with high pressure clean air.

d. Install the filter element in the actuator housing.

e. Make sure that the packing in the groove of the filter retainer is not damaged. Replace the
packing if necessary (P/N CM83485/1-020).

f. Apply retaining compound (Loctite 242) to the threads of the filter retainer. Install the filter
retainer and tighten to within 37 to 47 foot-pounds torque. Remove any excess retaining compound.

4-5. CLOSED POSITION INDICATING SWITCH REPLACEMENT.

4-6. REMOVAL.

a. Remove the four screws (P/N 200750D62) and washers (P/N CNAS620C416) securing the
access plate (P/N C325771) to the switch cover (P/N C325748), and remove the access plate.

b. Remove the four screws and washers securing the switch cover to the valve housing and
remove the cover.

4-1
 T.M. C327845
1 MAY 1998

c. Disconnect the red and black electrical wires from the switch terminals.

d. Remove the two screws (P/N CNAS1352C02H7) and washers (P/N CNAS620C2) securing the
switch and the switch actuator (P/N 200621-10) to the switch bracket (P/N C326540). Remove the switch
(P/N 100138-44) and the switch actuator (P/N 200621-10).

e. Loosen but do not remove the two screws (P/N CNAS1352C08-6) and washers (P/N
CAN960C8) securing the switch bracket (P/N C326540) to the valve housing, to allow adjustment of the
bracket/switch/actuator position.

4-7. INSTALLATION AND ADJUSTMENT.

a. Install the new switch and the switch actuator on the switch bracket and secure with the two
screws and washers. Tighten the screws to within 1.5 to 1.9 inch-pounds torque. Safety wire the screws
with lockwire (MS20995C20).

b. Solder the switch electrical wires (red and black) to the switch terminals.

c. Adjust the position of the switch/bracket to actuate the switch contacts closed when the valve
is within 0.050 inch from the fully closed position.

NOTE: To facilitate adjustment of the switch, the solenoid may be left energized and the inlet port
pressure may be increased or decreased slowly to open and close the valve. The valve
requires approximately 90 psig inlet port pressure to begin to open.

d. Following switch adjustment, tighten the two switch bracket attaching screws to within 15 to 19
inch-pounds torque. Recheck to ensure that the switch actuation point has not changed.

e. Install the switch cover on the valve housing and secure with the four screws and washers.
Tighten the screws to within 70 to 90 inch-pounds torque.

f. Install the access plate on the switch cover and secure with the four screws and washers.
Tighten the screws to within 70 to 90 inch-pounds torque.

4-2
T.M. C327845
1 MAY 1998

SECTION V

MAINTENANCE PARTS LIST

5-1. GENERAL.

5-2. This section identifies parts recommended for on-site maintenance of the Gas Isolation Valve. All
of the recommended items may be ordered from Whittaker Controls.

5-3. MAINTENANCE PARTS.

5-4. Table 5-1 comprises a listing of spare parts recommended for on-site maintenance support of the
fuel metering valve. All of the parts listed in Table 5-1 may be ordered as a kit (request Gas Isolation
Valve Repair Kit, P/N C80199.)

Table 5-1. Recommended Spare Parts

ITEM RECOMMENDED
NUMBER PART NUMBER DESCRIPTION QUANTITY

GAS ISOLATION VALVE

1 C325770 Filter Retainer 1

2 200747-6-070 Filter Element 2

3 CM83485/1-020 Packing (Filter Retainer) 2

4 C325771 Access Plate 1

5 200750D62 Screw (Access Plate) 4

6 CNAS620C416 Flat Washer (Access Plate) 4

7 C325748 Switch Cover 1

8 100138-44 Switch 1

9 200621-10 Switch Actuator 1

10 CNAS1352C02H7 Socket Head Cap Screw (Switch) 2

5-1
 T.M. C327845
1 MAY 1998

Table 5-1. Recommended Spare Parts (continued)

ITEM RECOMMENDED
NUMBER PART NUMBER DESCRIPTION QUANTITY

GAS ISOLATION VALVE

12 C326540 Switch Mounting Bracket 1

13 CNAS1352C08-6 Socket Head Cap Screw (Switch Mounting 2

Bracket)

14 CAN960C8 Flat Washer (Switch Mounting Bracket) 2

5-2