MOTORIZED CONTROL VALVE INSTALLATION

INSTALLATION OVERVIEW MANUAL CONTROL TOOL (MCT)

Protect the interior of valve from dirt and moisture during The V-port can be manually actuated by using the Manual
storage and installation. Valve should be installed so Control Tool (MCT), see Figure 14. To utilize the MCT, the
that the arrow on the valve body is in direction of normal actuator would need to be removed from the valve. This
refrigerant flow. System should be free from dirt, weld slag can be done by first removing the cables plugged into
and rust particles. A 60 mesh, close-coupled strainer is the actuator, power (red) cable followed by the signal
available for installation at inlet of valve for 3/4˝, 1˝ and (green) cable. The valve v-port will remain in the same
1-1/4˝. Do not close-couple strainers to 1-1/2 ˝ through 2 ˝ position it was at when cable was unplugged. Remove
Motorized Control Valves. the actuator by loosening the three set screws at the
base. DO NOT REMOVE THE BONNET. Place the MCT
Please note: Valve will not backflow if in closed position. over the cartridge and turn the MCT clockwise to open or
Do not install check valves upstream of the Motorized counterclockwise to close. Before re-installing rotate the
Control Valve without hydrostatic pressure relief. Do not MCT counterclockwise until the V-port is closed. Refer
close the hand valve on inlet or outlet without making sure to TABLE 25 for the number of turns to fully actuate the
valve is in the open position. valve. MCT is required to install V-port fully onto cartridge
1/4˝ NPT Gauge/Purge port connections are provided on or remove V-port from cartridge (this includes during
the inlet and outlet of the 3/4˝ thru 2˝ valves standard. converting from SMV to MCV).
Pipe sizing, valve placement, rating, anchoring, and similar To reinstall the actuator, follow the instructions on page 21.
prudent precautions should be taken to ensure “liquid
hammer” will not occur when valves open or close.
FIGURE 14
For proper flange gasket sealing, care must be taken
when threading or welding to assure flanges are parallel
to each other and perpendicular to pipe. Also, gaskets
should be lightly oiled and all bolts should be lubricated
with an anti-seize and must be tightened evenly.
Protect cables during installation.
Do not mount the valve with the motor in the down position.
The valve will only operate properly if the motor is mounted
in a horizontal or upright position. Refer to diagrams
below. Horizontal mounting of motor is satisfactory if oil
and dirt are controlled.

TABLE 25

NUMBER OF TURNS TO ACTUATE VALVE

VALVE PORT SIZE
INCH NUMBER OF TURNS
(MM)

1/16” THRU 9/32”

NO 6
YES (2 THRU 7)

3/4” THRU 1-1/4”

7
(20 THRU 32)

1-1/2” THRU 2”
12
(40 THRU 50)

3”
18
(80)

4”
20
(100)

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SEPTEMBER 2018 20
 MOTORIZED CONTROL VALVE INSTALLATION

INSTALLATION INSTRUCTIONS 6. Remove new actuator and remaining contents from

NEW COMPLETE VALVE box.

NOTE: Do not power on actuator until it is mounted to 7. Install new cartridge gasket to counter bore on top
the valve and the set screws are properly torqued. face of valve.

1. Remove valve, actuator, and remaining contents from 8. Install V-port into cartridge while fully supporting
box. the V-port and cartridge and carefully aligning the
threaded shaft of cartridge with the low friction nut
2. F o r f l a n g e d v a l v e s , a l i g n v a l v e w i t h a r r o w of V-port. Carefully thread together 6-8 turns and
pointing in direction of flow and mount per install align the anti-rotation slot on the V-port with the
protocol. For weld in line valves, it is recommended anti-rotation pin of the cartridge. Using the MCT,
to remove the cartridge/V-port assembly during fully thread the V-port into the cartridge, screwing
welding by loosening bolts and removing the V-port fully into the cartridge by turning the rotor
bonnet. Replace cartridge/V-port assembly after clockwise.
valve body is installed and ensure o-ring in installed
onto cartridge. 9. Install new rotor cartridge/V-port assembly into valve.

3. Install bonnet onto cartridge assembly and tighten 10. Install new bonnet over cartridge assembly and
four bonnet bolts. tighten bonnet bolts.

4. P l a c e M a n u a l C o n t r o l To o l ( M C T ) o n t o t h e 11. Ensure O-ring is installed onto cartridge assembly.

top of magnetic car tridge assembly. Continue 12. Place Manual Control Tool (MCT) onto the top of
to rot ate the tool counterclock wise until the magnetic cartridge assembly. Continue to rotate
valve is closed and the V-port will no longer move. the tool counterclockwise until the valve is closed
5. Grease exterior of car tridge above the O -ring and the V-port will no longer move.
with supplied low temp, high load, low RPM 13. Grease exterior of cartridge above the O-ring with
grease such as Lubriplate Aero or similar. supplied low temp, high load, low RPM grease such
6. C h e c k t h e b a s e o f t h e a c t u a t o r t o e n s u r e as Lubriplate Aero or similar.
that the set screws are not protruding past the 14. Check the base of the actuator to ensure that the set
ID of the threaded ring. If necessary back the set screws are not protruding past the ID of the threaded
screws out to prevent interference during installation. ring. If necessary back the set screws out to prevent
7. Ins t a ll ac tuator onto ca r tr idge. Pr e s s f ir mly interference during installation.
down on the top of the actuator to 15. Install new actuator onto cartridge. Press firmly down
ensure it fully seats. The gap between the base on the top of the actuator to ensure it fully seats. The
of the actuator and bonnet should be less than 1/16”. gap between the base of the actuator and bonnet/
8. Rot ate ac tuator to or ient in desir e d position cartridge should be less than 1/16”.
and torque the 3 set screws at base to 4 in-lb using 16. Rotate actuator to orient in desired position and
3/32” hex key. torque the 3 set screws at base to 4 in-lb using 3/32”
9. Wire the flying lead ends of the cable to power and hex key.
the desired input signal and feedback loop per wiring 17. For HMMR/HMMV conversion, connect the black
diagram. 7 pin dongle connector to the existing connection
10. Connect the red and green cables to the actuator already wired in place. The VPIF can be left in place
if desired.
11. Upon power-up, the valve will automatically calibrate.
NOTE: For HMSV conversion cut off black 7 pin dongle
12. Actuator is programmed for 4-20mA input signal. connector to power and input/output, per wiring
See page 40 to change if other signal is used. diagram. It is important to remove the 24VAC to the
CONVERSION FROM SMV TO MCV pink and yellow relay signal wires. Voltage to this
line will cause damage as the input should only be
NOTE: Do not power on actuator until it is mounted to a closed contact switched to ground.
the valve and the set screws are torqued.
18. Connect the red and green cables to the actuator.
1. Isolate and pump down existing valve per PSMs.
19. Upon power-up, the valve will automatically calibrate.
2. Disconnect existing powerhead connections.
20. Confirm actuator is programmed for valve size and
3. Unscrew the powerhead screws and remove the input signal through the keypad display. See page 40.
powerhead.
NOTE: Gaskets and O-rings should be replaced with new
4. Unscrew bonnet bolts and remove the bonnet. if they are removed from valve. Recommend to lubricate
5. Remove existing can and cartridge assembly. Ensure new gaskets/O-rings with oil prior to installing. Bolts
old gasket is removed from counter bore on top face should have anti-seize applied.
of valve.

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21 SEPTEMBER 2018
R649c
SEPTEMBER 2018
CUSTOMER SUPPLIED POWER SUPPLIES AND CONTROLLER
(Modulating Control with Position Feedback)

LINE VOLTAGE

DC POWER SUPPLY TR92 DC POWER

HANSEN PN 75-1327 TRANSFORMER SUPPLY
24VAC 24 VDC
24VDC OR 50 mA MIN
8 PIN SIGNAL 5 PIN POWER 0.8A MIN PER VALVE 42VA MIN PER VALVE
-V +V PER VALVE - +

ISOLATED FROM EARTH GROUND

+ +
COMPUTER
GRAY: (-)24VDC/24VAC (POWER) OR
(POWER) CONTROLLER
BLACK: (+)24VDC/24VAC
(CONTROL SIGNAL/GROUND) - -
YELLOW: (-)INPUT
GRAY: (+)4-20mA INPUT (CONTROL SIGNAL)
BROWN: (-)4-20mA OUTPUT *(VALVE POSITION FEEDBACK)
GREEN: (+)4-20mA OUTPUT *(VALVE POSITION FEEDBACK)

THE VALVE IS SUPPLIED WITH 6.5 FET OF CABLE WITH

22 AND 24 GAUGE WIRES. FOR GREATER DISTANCE
BETWEEN VALVE AND CONTROLLER, OR MULTIPLE
VALVE INSTALLATIONS, USE WIRE SIZE AS SHOWN
IN TABLE 1: 24 VAC/DC POWER WIRING

22
DO NOT RUN MOTOR VALVE WIRING
WITH OR NEAR POWER WIRING OR VFD (VARIABLE
FREQUENCY DRIVES).
FIGURE 15

* VALVE POSITION FEEDBACK WIRES

DO NOT NED TO BE CONNECTED FOR
VALVE TO WORK

TABLE 1: 24VAC/DC POWER WIRING

NUMBER OF VALVES POWERED

AWG WIRE GAUGE (DIAMETER mm)

CABLE LENGTH, ft (m) 1 2 3 4

50 (15) 20 (0.8) 17 (1.2) 15 (1.5) 14 (1.6)

100 (30) 17 (1.2) 14 (1.6) 12 (2.0) 11 (2.3)

150 (46) 15 (1.5) 12 (2.1) 11 (2.3) 9 (2.9)

200 (61) 14 (1.6) 11 (2.3) 9 (2.9) 8 (3.3)

MOTORIZED CONTROL VALVE INSTALLATION

300 (91) 12 (2.1) 9 (2.9) 8 (3.3) 6 (4.1)

(Current Input Modulating Control with Position Feedback)
CUSTOMER SUPPLIED POWER SUPPLY AND CONTROLLER

voltage power wiring or VFD Controls (Variable Frequency Drives). Do not earth or ground 24 VAC wiring.
use wire size as shown in Table 1: 24VAC/DC Power Wiring. Do not run Motorized Control Valve wiring with or near high
The valve is supplied with 6.5 feet of cable with 22 and 24 gauge wires. For greater distance between valve and controller
 CUSTOMER SUPPLIED POWER SUPPLIES AND CONTROLLER
(Modulating Control with Position Feedback)

LINE VOLTAGE

DC POWER SUPPLY TR92 DC POWER

HANSEN PN 75-1327 TRANSFORMER SUPPLY
OR 24VAC 24 VDC
24VDC 50 mA MIN
8 PIN SIGNAL 5 PIN POWER 0.8A MIN PER VALVE 42VA MIN PER VALVE
PER VALVE - +
-V +V

ISOLATED FROM EARTH GROUND

+ +

COMPUTER
GRAY: (-)24VDC/24VAC (POWER) OR
CONTROLLER
BLACK: (+)24VDC/24VAC (POWER)
- -
YELLOW: (-)INPUT (CONTROL SIGNAL/GROUND)

PINK: (+)0-5/10VDC INPUT (CONTROL SIGNAL)

BROWN: (-)4-20mA OUTPUT *(VALVE POSITION FEEDBACK)
GREEN: (+)4-20mA OUTPUT *(VALVE POSITION FEEDBACK)

THE VALVE IS SUPPLIED WITH 6.5 FET OF CABLE WITH

22 AND 24 GAUGE WIRES. FOR GREATER DISTANCE
BETWEEN VALVE AND CONTROLLER, OR MULTIPLE
VALVE INSTALLATIONS, USE WIRE SIZE AS SHOWN
IN TABLE 1: 24 VAC/DC POWER WIRING

23
DO NOT RUN MOTOR VALVE WIRING
WITH OR NEAR POWER WIRING OR VFD (VARIABLE
FREQUENCY DRIVES).
FIGURE 16

* VALVE POSITION FEEDBACK WIRES

DO NOT NEED TO BE CONNECTED FOR
VALVE TO WORK

TABLE 1: 24VAC/DC POWER WIRING

NUMBER OF VALVES POWERED

AWG WIRE GAUGE (DIAMETER mm)

CABLE LENGTH, ft (m) 1 2 3 4

50 (15) 20 (0.8) 17 (1.2) 15 (1.5) 14 (1.6)

100 (30) 17 (1.2) 14 (1.6) 12 (2.0) 11 (2.3)

MOTORIZED CONTROL VALVE INSTALLATION

150 (46) 15 (1.5) 12 (2.1) 11 (2.3) 9 (2.9)

200 (61) 14 (1.6) 11 (2.3) 9 (2.9) 8 (3.3)

(Voltage Input Modulating Control with Position Feedback)

300 (91) 12 (2.1) 9 (2.9) 8 (3.3) 6 (4.1)

CUSTOMER SUPPLIED POWER SUPPLY AND CONTROLLER

voltage power wiring or VFD Controls (Variable Frequency Drives). Do not earth or ground 24 VAC wiring.
use wire size as shown in Table 1: 24VAC/DC Power Wiring. Do not run Motorized Control Valve wiring with or near high
The valve is supplied with 6.5 feet of cable with 22 and 24 gauge wires. For greater distance between valve and controller

SEPTEMBER 2018
R649c
R649c
SEPTEMBER 2018
CUSTOMER SUPPLIED POWER SUPPLIES AND CONTROLLER
(Modulating Control with Position Feedback)
TYPICAL APPLICATIONS
LINE VOLTAGE
IDEAL FOR REPLACEMENTOF:
1. BOTH HOT GAS SOLENOID VALVE
AND SOFT GAS SOLENOID VALVE
WITH A SINGLE HANSEN MOTOR VALVE.
DC POWER SUPPLY TR92
HANSEN PN 75-1327 TRANSFORMER 2. BOTH SUCTION SOLENOID VALVE
24VDC OR 24VAC AND EQUALIZE SOLENOID VALVE
8 PIN SIGNAL 5 PIN POWER 0.8A MIN PER VALVE 42VA MIN WITH A SINGLE HANSEN MOTOR VALVE.
PER VALVE
-V +V
3. ANY OPEN/CLOSED APPLICATION
REQUIRING SLOW OPERATION TO
MINIMIZE LIQUID VELOCITY SHOCK
ISOLATED FROM EARTH GROUND AND/OR REQUIRING NO PRESSURE
DROP TO OPERATE. (VENT OR GRAVITY DRAIN)

GRAY: (-)24VDC/24VAC 4. MOST MOTORIZED BALL VALVE AND

(POWER) PLC OR BUTTERFLY VALVE APPLICATIONS THEREBY
BLACK: (+)24VDC/24VAC (POWER) CONTROLLER ELIMINATING SHAFT SEAL LEAKAGE.
RELAY
YELLOW: (-)INPUT (CONTROL SIGNAL/GROUND)

PINK: RELAY INPUT (CONTROL SIGNAL) NOTES:

1. NO EXTERNAL POWER NECESSARY

2. DEFAULT SETTING:
RELAY CLOSED = VALVE CLOSED
THE VALVE IS SUPPLIED WITH 6.5 FET OF CABLE WITH
22 AND 24 GAUGE WIRES. FOR GREATER DISTANCE
BETWEEN VALVE AND CONTROLLER, OR MULTIPLE
VALVE INSTALLATIONS, USE WIRE SIZE AS SHOWN
IN TABLE 1: 24 VAC/DC POWER WIRING

24
DO NOT RUN MOTOR VALVE WIRING
WITH OR NEAR POWER WIRING OR VFD (VARIABLE
FREQUENCY DRIVES).
FIGURE 17

TABLE 1: 24VAC/DC POWER WIRING

NUMBER OF VALVES POWERED

AWG WIRE GAUGE (DIAMETER mm)

CABLE LENGTH, ft (m) 1 2 3 4

50 (15) 20 (0.8) 17 (1.2) 15 (1.5) 14 (1.6)

100 (30) 17 (1.2) 14 (1.6) 12 (2.0) 11 (2.3)

150 (46) 15 (1.5) 12 (2.1) 11 (2.3) 9 (2.9)

200 (61) 14 (1.6) 11 (2.3) 9 (2.9) 8 (3.3)

MOTORIZED CONTROL VALVE INSTALLATION

(Relay Input Slow Open/Close Solenoid Control)

300 (91) 12 (2.1) 9 (2.9) 8 (3.3) 6 (4.1)

NOTE: Do not connect voltage to pink or yellow wires as it will damage the actuator board.
CUSTOMER SUPPLIED POWER SUPPLY AND CONTROLLER

voltage power wiring or VFD Controls (Variable Frequency Drives). Do not earth or ground 24 VAC wiring.
use wire size as shown in Table 1: 24VAC/DC Power Wiring. Do not run Motorized Control Valve wiring with or near high
The valve is supplied with 6.5 feet of cable with 22 and 24 gauge wires. For greater distance between valve and controller