Hansen HA4AB - User Manual

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Summary

Technical Specifications and Installation

Installation and Electrical Considerations

Explains installation procedures and electrical requirements for the regulators.

Control Module (Pilot) Functions

Main Regulator Bodies and Operation

AR1 and AR3 Regulator Configurations

Regulator Internal Operation Principles

Explains the internal operation of the regulators based on control module input.

Standard and Relief Regulator Operation

HA4 A Standard & HA4 AK Reseating Operation

Covers the operation and adjustment for HA4A Standard and HA4AK Reseating Relief regulators.

HA4 AL Differential Pressure Operation

Details the operation and adjustment procedures for the HA4AL Differential Pressure Regulator.

Specialized Regulator Operations

HA4 AO Outlet & HA4 AB Wide Opening

Describes the operation of HA4AO Outlet and HA4AB Electric Wide Opening regulators.

HA4 AS Shut-Off & HA4 AD Dual Pressure

Explains the operation for HA4AS Electric Shut-Off and HA4AD Dual Pressure regulators.

Advanced Control Regulator Operations

HA4 AP Pneumatic & HA4 AT Temperature

Details the operation of HA4AP Pneumatically Compensated and HA4AT Temperature Operated regulators.

HA4 AJ Electronic Control

Covers the operation of the HA4AJ Electronically Controlled Regulator.

Electric Motor Compensated Regulator

HA4 AM Operation and Adjustment

Installation Dimensions (3;4 to 4)

Installation Dimensions (5 & 6)

Dimensions for Larger Regulators

Service, Maintenance, and Safety

Troubleshooting and Disassembly

Guides on troubleshooting common failures and procedures for disassembly and reassembly.

Manual Opening and Abbreviations

Ordering, Accessories, and Warranty

Ordering, Accessories, and Conversions

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.