Hansen HA4A - User Manual

ADDITIONAL FEATURES
Tolerant of Dry Systems
For Ammonia, R22, R134a and other Hansen-
Approved Refrigerants
Wide Range of Options
Inlet, Outlet, or Differential Pressure
Wide Pressure Ranges
Electric Shut-Off, Dual, or Wide-Opening Available
Safe Working Pressure: 400 psig (28 bar g)
CSA Certified, CRN for Canada
Weld-In-Line Available; Contact Factory
INTRODUCTION
These advanced-design, strong-bodied, precision-
manufactured MODULAR regulators are superior in their
ability to overcome dirt and sticky oil during opening
and tight closing. Models are available for nearly every
control function requirement of industrial ammonia and
commercial halocarbon refrigeration. These regulators
are ideal for cold storage plants, poultry plants, meat
packing, fish processing, freezers, ice plants, breweries,
bottling plants, heat recovery units, petrochemical
plants, pharmaceutical plants, supermarkets, and many
others.
APPLICATIONS
Evaporator Pressure Control
Defrost Pressure Control
Condensing Pressure Regulation
Receiver Pressure Control
Hot Gas Bypass Capacity Regulation
Suction Pressure Control
Air or Liquid Temperature Regulation
Internal System Pressure Relief
V-PORT
MODULATION
IRON BODY
DUCTILE
DIRT WIPING
DISC-PISTON
MANUAL OPENING
STEM
RELIABLE
TEFLON SEAT
MODULAR PI
LOTS
HERE
SPRING
STAINLESS STEEL
DUCTILE
STRONG
GAUGE PORT
1/4'' NPT
KEY FEATURES
Contents Page
Regulator Variations 3
Capacities 4–5
Control Modules (Pilots) 6
Main Regulators Only (AR1, AR3) 7
Operation and Adjustment 8–11
Installation Dimensions 12–13
Parts List 14–18
Service and Maintenance, Abbreviations 19
Ordering Information, Conversions 20
Specifications, Applications,
Service Instructions & Parts
HA4A MODULAR
PRESSURE REGULATORS
¾" THROUGH 6" PORT
(20MM THROUGH 150MM)
Bulletin R429d
AUG 2015
Various Connection
Styles and Sizes
for Refrigerants
HA4AB Regulator with Electric Wide Opening

Summary

INTRODUCTION

KEY FEATURES

Highlights the modular pilots, durable construction, and key functional components of the regulators.

APPLICATIONS

Lists the diverse industrial and commercial refrigeration applications for these regulators.

ADDITIONAL FEATURES

Details refrigerant compatibility, operational options, and safety certifications.

MATERIAL SPECIFICATIONS

ADVANTAGES

Explains the benefits of modern design, advanced materials, and manufacturing techniques.

SIZING

Emphasizes the importance of proper valve sizing for optimal performance and longevity.

INSTALLATION

Provides essential guidelines for correct installation, system preparation, and leak testing.

REGULATOR VARIATIONS

HA4 A STANDARD REGULATOR

Modulates to control evaporator, condensing, or vessel pressure.

HA4 AO OUTLET PRESSURE REGULATOR

Controls outlet pressure by opening as downstream pressure falls below set point.

HA4 AS REGULATOR WITH ELECTRIC SHUT-OFF

Regulates at set pressure when energized; closes when de-energized.

CONTROL MODULES (PILOTS) FOR ANY REGULATOR

INLET PRESSURE PILOTS

Control modules that open as inlet pressure rises.

RESEATING RELIEF PILOTS

Modules that open when pressure exceeds setting and reseat after operation.

SOLENOID PILOTS

Solenoid valve pilots that are normally closed and open when energized.

MAIN REGULATORS ONLY (AR1, AR3)

OPERATION OF REGULATORS

Explains how the regulator body and pilot modules interact to control flow.

HA4 A STANDARD REGULATOR

OPERATION AND ADJUSTMENT

Details how the standard regulator works and how to adjust its settings.

HA4 AO OUTLET PRESSURE REGULATOR

OPERATION AND ADJUSTMENT

Explains how the outlet pressure regulator functions and is adjusted.

HA4 AP PNEUMATICALLY COMPENSATED REGULATOR

OPERATION AND ADJUSTMENT

Details how pneumatic compensation affects operation and adjustment.

HA4 AM ELECTRIC MOTOR COMPENSATED REGULATOR

OPERATION AND ADJUSTMENT

Explains motor compensation operation and how to adjust the regulator.

INSTALLATION DIMENSIONS (mm)

DIMENSIONS FOR 3;4 THROUGH 11;4 REGULATORS

Provides measurement data for smaller regulator sizes.

P DIMENSION FOR CONTROL MODULES (mm)

Specifies dimensions for various control modules.

INSTALLATION DIMENSIONS (mm)

DIMENSIONS FOR 5 AND 6 REGULATORS

Provides measurement data for large regulator sizes.

WELD END DIMENSIONS

Specifies dimensions for weld end connections.

PARTS LIST CONTROL MODULES

M3, M3 K, M3 L, M3 P MODULE PARTS

Lists parts for various common control modules.

M3 O MODULE PARTS

Lists parts for the M3O outlet pressure control module.

PARTS LIST 3;4 THROUGH 11;4 (20 mm THROUGH 32 mm)

AR1 AND AR3 REGULATOR PARTS

Lists components for AR1 and AR3 regulators in small sizes.

PARTS LIST 11;2 THROUGH 4 (40 mm THROUGH 100 mm)

PISTON KITS AND GASKET KITS

Lists components for piston and gasket kits for medium sizes.

V-PORT;SEAT KITS

Lists V-port/seat components for medium regulator sizes.

PARTS LIST 5 AND 6 (125 mm AND 150 mm)

PISTON KITS AND V-PORT;SEAT KITS

Lists components for piston and V-port/seat kits for large sizes.

GASKET KITS AND MODULE PARTS

Lists gasket kits, module parts, and related components for large sizes.

SERVICE AND MAINTENANCE

TROUBLESHOOTING

Lists common problems and their likely causes or solutions.

DISASSEMBLY AND CLEANING PROCEDURES

Step-by-step guide for servicing regulators and pilots.

ORDERING INFORMATION, HA4 A MODULAR PRESSURE REGULATORS

REGULATOR ACCESSORIES

Lists optional components like strainers, gauges, and pilot lights.

CONVERSIONS

Provides conversion factors for units and refrigeration tons.

Overview

1. Function Description
2. Key Features
3. Technical Specifications
4. Usage Features
5. Maintenance Features

The HA4A Modular Pressure Regulators, manufactured by Hansen Technologies Corporation, are advanced-design, strong-bodied, precision-manufactured devices designed for various control functions in industrial ammonia and commercial halocarbon refrigeration systems. These regulators are available in port sizes ranging from 3/4" through 6" (20mm through 150mm) and offer various connection styles and sizes.

Function Description:

The HA4A regulators are pilot-operated, modulating valves that control pressure by opening or closing a main valve seat. They are designed to overcome issues related to dirt and sticky oil during operation, ensuring reliable opening and tight closing. The modular design allows for different control functions to be achieved by interchanging various control modules (pilots).

Key Features:

• Modular Pilots: The regulators utilize screw-on control modules (pilots) that are easy to change and can be used across all valve sizes. These modules are interchangeable with Danfoss PM Series, size permitting.
• Strong Ductile Iron Body: The bodies of 3/4" through 4" regulators are made of ductile iron (ASTM A536), while 5" and 6" valves use cast steel (ASTM A352 LCB), providing superior strength and ruggedness compared to common cast iron or semi-steel valves.
• Reliable Teflon Seat: All regulators incorporate Teflon seating for the main valve seat and energized Teflon dirt-wiping piston seals, which ensure reliable operation even under dry, oil-free conditions.
• Manual Opening Stem: A manual opening stem is located on top of the valve, away from dirt and rust particles, to prevent thread jamming and allow for manual valve operation for servicing or system equalization.
• Dirt Wiping Disc-Piston: The piston design includes a dirt-wiping feature to maintain clean operation.
• V-Port Modulation: The V-port design allows for precise modulation of flow.
• Stainless Steel Spring: A stainless steel spring is used for closing the main valve.
• Tolerant of Dry Systems: The design is robust enough to operate effectively in systems with minimal oil.
• Wide Range of Options: Regulators can be configured for inlet, outlet, or differential pressure control, and are available with wide pressure ranges.
• Electric Shut-Off, Dual, or Wide-Opening Available: Specific control modules enable electric shut-off, dual pressure settings, or wide-opening capabilities.
• Safe Working Pressure: The regulators have a safe working pressure of 400 psig (28 bar g), with 600 PSIG (41 bar g) available upon contact with the factory.
• CSA Certified, CRN for Canada: The regulators are certified by CSA and registered with CRN for use in Canada.
• Weld-In-Line Available: Weld-in-line connections are available; contact the factory for details.

Technical Specifications:

• Body Material: Ductile iron (ASTM A536) for 3/4" through 4"; Cast steel (ASTM A352 LCB) for 5" & 6".
• Adapter Material: Ductile iron (ASTM A536).
• Piston Material: Steel, disc type, with Teflon piston seal.
• V-Port/Seat Material: Ductile iron with Teflon seat.
• Main Seat Material: Integral ductile iron for 3/4" through 1-1/4"; removable stainless steel for 1-1/2" through 6".
• Gaskets: Nonasbestos, graphite composite.
• Manual Opening Stem Material: Steel, plated.
• Pilots: Stainless steel trim.
• Pilot Orifice: Stainless steel.
• Flanges: Forged steel, ASTM A105.
• Operating Temperature: -60°F to +240°F (-50°C to +115°C).
• Coil Voltages (for solenoid pilots): Standard 115V, 208/230V, or 24V at 50/60Hz. Other voltages available. Coils operate between 85% and 110% of rated voltage.

Usage Features:

• Applications: Ideal for cold storage plants, poultry plants, meat packing, fish processing, freezers, ice plants, breweries, bottling plants, heat recovery units, petrochemical plants, pharmaceutical plants, supermarkets, and more.
• Control Functions:
  • HA4A Standard Regulator (Inlet Pressure): Modulates to control evaporator pressure, condensing pressure, or pressure in a vessel/system. Opens on rising inlet pressure.
  • HA4AO Outlet Pressure Regulator: Controls outlet pressure by opening as downstream pressure falls below the set point. Used for hot gas bypass, condenser/receiver pressure control, or compressor suction pressure limitation.
  • HA4AS Regulator with Electric Shut-Off: Regulates at set pressure when energized; closes tight when de-energized. Commonly used for temperature control or defrost.
  • HA4AB Regulator with Electric Wide Opening: Regulates at set pressure when de-energized; opens wide for maximum cooling when energized. Commonly used for defrost or temperature control.
  • HA4AD Dual Pressure Regulator: Regulates at one setting when energized, and a higher setting when de-energized. Used for defrost, temperature control, or pressure relief.
  • HA4AL Differential Pressure Regulator: Maintains a set differential between inlet and outlet pressure. Commonly used for liquid pump relief, condenser-receiver pressure difference control, or discharge pressure boosting.
  • HA4AK Reseating Relief Regulator: Opens when upstream pressure exceeds set point and repeatedly reseats. Used for defrost, high-to-low side, or non-atmosphere relief.
  • HA4AP Pneumatically Compensated Regulator: Used for precise air or liquid temperature control via pneumatic controller. An air, vapor, or liquid pressure signal increases inlet pressure at a 1:1 ratio.
  • HA4AT Temperature Operated Regulator: Opens as temperature rises to control air or liquid temperature.
  • HA4AJ Electronically Controlled Regulator: Electronic pilot and controller provide precise temperature control under fluctuating load conditions.
  • HA4AM Electric Motor Compensated Regulator: Alters pressure setting based on a signal from a temperature controller. Used for precise room or liquid chiller control.
• Sizing: Proper sizing is crucial for smooth operation and long life. Regulators operate satisfactorily down to approximately 15% of maximum capacity. Downsizing or parallel regulators may be needed for extreme cases. Special construction may be required for pressure drops exceeding 45 psi (3.1 bar g).
• Installation: Regulators should be protected from dirt and moisture. The arrow on the body indicates normal refrigerant flow direction. Check valves are needed for reverse flow prevention. Normally installed in horizontal pipe lines with pilots and manual-opening stems on top. System must be free of dirt, weld slag, and rust. Gauges and gauge valves should be installed for diagnosis. Nameplates should be checked against piping drawings. Coil voltage should be checked before wiring for solenoid control modules. Pipe sizing, anchoring, valve rating, and system design must consider "liquid hammer."
• Welding (for 5" and 6" valves): These steel-bodied valves are directly welded into the pipeline. During welding, the manual-opening stem should be opened downward several turns to protect the Teflon seat from weld heat. Welds should be annealed as necessary and painted for corrosion protection. Pipe covering should have a proper moisture barrier. All pipe connections, valve seats, cover seals, and stem seals must be tested for leaks before service.
• Electrical (for solenoid pilots): Hansen low-wattage, molded electrical coils are included. Standard coils come with a 1/2" fitting for conduit. Watertight solenoid coils with pigtail leads and steel frame housing are standard. Optional DIN Plug Coils are available for grounded cord connections.
• Beacon Pilot Lights: Long-life Beacon Pilot Lights (green, red, or amber) are available for AC voltage coils, featuring an encapsulated secondary wound coil and LED light, requiring no additional wiring.

Maintenance Features:

• Serviceability: Pilots are normally factory installed but can be retrofitted or interchanged in the field.
• Troubleshooting (Failure to Open): Possible causes include wrong coil/control module pilot, low line voltage, faulty switch/thermostat, burned-out coil, closed shut-off valve, misaligned adapter gasket, dirt in passages, or jammed main valve seat.
• Troubleshooting (Failure to Close): Possible causes include faulty switch/thermostat, manual-opening stem turned in, wrong installation direction, damaged main/pilot seat, or plugged piston bleed hole.
• Pre-Service Procedures: Before opening or disassembling the regulator, ensure it is isolated from the system and all refrigerant is removed (pumped out to zero pressure). Follow standard refrigeration system safe servicing procedures and refer to the CAUTION section in the manual.
• Solenoid Pilot Section Service: Disconnect electrical coil, unscrew coil nut, and remove washer. Lift coil housing and remove solenoid tube. Inspect for dirt and damage to Teflon seat and stainless steel pilot orifice. Clean, polish, or replace parts as necessary.
• 3/4" through 1-1/4" (20mm through 32mm) Service: Loosen adapter bolts slowly. Remove bottom cap to separate V-port/seat from disc piston. Inspect piston and bore for burrs, nicks, and damage. Clean or replace disc piston and Teflon seal ring (ensure seal is installed with edge up, not twisted). Inspect V-port/seat and main valve seat for nicks, marks. Lap or recondition main valve seat if necessary (up to 0.04" (1mm) of Teflon can be removed). Lubricate all parts and gaskets with refrigerant oil. Align holes and check for leaks after reassembly.
• 1-1/2" through 6" (40mm through 150mm) Service: Loosen adapter bolts. Use a threaded screw to lift out the piston if difficult to remove. Inspect piston and bore for burrs, nicks, and damage. Clean or replace disc piston and Teflon seal ring (ensure seal is installed with edge up, not twisted). These valves have a removable stainless steel main valve seat. Remove small hex head seat screw and turn seat ring counterclockwise to remove. Inspect V-port/seat and main valve seat for nicks, marks, and divots. Lap or recondition main valve seat if necessary (up to 0.04" (1mm) of Teflon can be removed). Grease and replace seat seal O-ring. Lubricate all parts and gaskets with refrigerant oil. Align holes and check for leaks after reassembly.
• Manual Opening Stem Use: The manual-opening stem allows upstream and downstream pressures to equalize for servicing but not necessarily full-flow. Located on top of the adapter cover. Slowly remove seal cap. Turn stem in (clockwise) to open manually; counterclockwise to return to automatic operation. Do not leave the stem partially open as it may be dynamically damaged.

Hansen HA4A Specifications