TECHNICAL INSTRUCTIONS

Series 440 Fotopanel & Fotoguard Model 6

Form MV440-2

OPERATION After first passing through the strainer checkstops, hot and cold water enter the Fotoguard mixer through their respective inlet ports. The right hand strainer checkstop is fitted with a stem extension to facilitate volume control (see Figure 10). Rotating the volume valve counter- clockwise will increase capacity. Both supplies mix in the chamber containing the valve assembly, and the mixture flows over the thermostatic motor. The thermostatic motor positions the valve assembly to maintain the desired temperature.

DESCRIPTION Color film manufacturers have long recognized the importance of maintaining proper water temperatures during film p roc essing. Bec ause valuab le negat ives have b een destroyed by erratic water temperatures, film manufacturers often specify that temperatures be maintained to 1/2F (1/4C) during film processing. Only a thermostatic mixing device can protect against varying water temperatures and water pressuresand assure stable water temperatures for all types of film processing. The 440 Fotopanel mixes hot and cold water thermostatically to deliver tempered water at precisely the temperature selected. The adjustments permit accurate selection of temperature and volume. Once the temperature and flow rate have been preset, you need only to turn an on-off switch to start or stop your process. The 440 Fotopanel assures better quality negatives and at the same time avoids expensive waste of time and materials. SPECIFICATION Maximum Hot Water Supply Temperature . . .190F (88F) Maximum Static Pressure . . . . . . . . . . . .125 psi (862 kPa) Temperature Range (Std) . . . . . . . . . . .65125F (1852C) (Hi-Temp) 120175F (4979C) NOTE: To obtain maximum temperature, hot water inlet temperature must be 15F (8C) or more above setpoint temperature for the standard temperature models and 30F (17C) or more for the high temperature models.
Figure 1. Top view of Fotopanel & Fotoguard Mixer from Strainer Checkstop

If the temperature of the mixer is higher than the control point, the thermostatic motor expands and decreases the flow of hot water by moving the valve assembly toward the hot water seat. An increase in cold water flow and decrease in hot water flow will adjust the delivery temperature to the desired level. The process is reversed if the mixture temperature is lower than the desired control point. Upon cold water failure, the hot water will shut off because of expansion of the thermostatic motor and seating of the hot water disc. By rotating the handle, any desired temperature within the range of the Fotoguard can be obtained. The temperature setting requires one complete rotation over the full range of the instrument. Clockwise rotation will lower delivery temperature, and counterclockwise will raise delivery temperature. Rotating the handle fully clockwise seats the shutoff disc and stops the flow. At the same time, the hot water disc seats, preventing interchange of water supplies. In addition to the mixer and volume control, the Fotopanel is supplied with a shutoff valve which requires only 67 rotation to shut off the supply of mixed water to the process. In this case, interchange of water supplies is prevented by the inlet check valves. The vacuum breaker, also supplied with the Fotopanel, prevents siphoning of solutions in the event of a pressure failure. A dial thermometer indicates discharge temperature.

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Page 2 volume control inlet. These instructions are also found in the installation instruction forms. 4. Discharge temperature is erratic or variable. a. THERMOSTATIC MOTOR failure. Test motor as shown in Figures 14 or 15. b. Accumulation of deposits in VALVE ASSEMBLY. c. Ruptured diaphragm in balance chamber of PRESSURE EQUALIZER (440-20 Fotopanel). Replace with new cartridge assembly. 5. Flow of water continues when mixer is shut off. a. Worn SHUTOFF DISC. Replace disc. 6. Maximum temperature specified cannot be obtained. a. Accumulation of deposits in hot water pipes, which restricts the flow of hot water. b. Hot water inlet temperature is not 15F (8C) or more above setpoint temperature. 30F (17C) for the high capacity models.
Figure 2. Repair items: Refer to the following pages for the desired item letter.

OPERATION (contd.) The Model 440-2000 Fotopanel is equipped with a pressureequalizing section. Hot and cold water is fed into separate sides of a pressure-equalizing valve and act on a force balance diaphragm assembly, The highest supply pressure will cause the diaphragm to close off on that inlet port. This is done by means of a poppet valve assembly, thus allowing more supply water to enter from the other port. This process continues until fluctuations diminish and a balanced condition is obtained. The hot and cold water supplies are now fed into the water mixer at equal pressures. GENERAL SERVICING PROCEDURE 1. Remove on-off knob, temperature adjustment knob, and volume control knob as shown in Figure 2. 2. Remove six bracket screws and remove stainless steel box assembly, exposing mounting bracket and piping assembly as shown in Figure 2. Do not remove front panel from box or mixer assembly from bracket. 3. The mixer can be serviced entirely from the front. This is also true of the combination strainer checkstops. 4. Refer to Figures 2 through 18 when servicing or troubleshooting the Fotopanel. Be sure to shut off water supplies to mixer at strainer checkstops before disassembling mixer. See page 5 on how to shut off volume control (R.H.) strainer checkstop (section G, paragraph 1). 5. The procedure of servicing and disassembly of Fotopanel also apply to the Fotoguard. 6. See page 3 for procedures involved in servicing and disassembly of the high capacity models. MAINTENANCE & TROUBLESHOOTING 1. The flow of water is less than desired. a. Left hand CHECKSTOP not fully open or right hand VOLUME CONTROL not adjusted properly. (Counterclockwise rotation opens checkstop and volume control). b. Valves upstream from supply not fully open. c. Low supply pressures. d. Accumulation of deposits in strainer CHECKSTOPS, VOLUME CONTROL, VALVE ASSEMBLY, or hot water pipes. 2. No flow of water. a. CHECKSTOP and VOLUME CONTROL closed. b. Valves closed upstream from supply. c. Failure of cold water supply pressure. The Foto-guard and Fotopanel are constructed to shut off on a cold water supply failure. 3. Flow is untempered hot or cold water. a. Accumulation of lime deposits in hot water pipes which restricts the hot water flow b. THERMOSTATIC MOTOR failure. Replace with new motor. See Figures 14 or 15 for testing. c. The water supplies are connected to the wrong ports. As you face the mixer, connect hot to the left hand strainer checkstop inlet, and cold to the right hand

REPAIR ITEMS
A

through

(Refers to Figure 2) 400-1000 440-175 440-174 440-155 440-2000 440-182 440-181 440-186 440-3000 440-176 440-174 440-146

Item A B C

Name Cabinet Cover plate Back plate

MV440-2 HIGH CAPACITY VALVES: MAINTENANCE & TROUBLESHOOTING (Refer to Figures 3, 4 and 5) Troubleshooting of the mixer involves the same steps found above, except for the following variations: 1. Discharge temperature is erratic or variable. A. In the high capacity mixer, lime deposits can build up around the PISTON causing it to bind in the PISTON CYLINDER. To replace or remove PISTON CYLINDER, use Cylinder Removal Kit No. 225-350. This kit contains the following items: a. 1/4-20 x 1 lg. (M6.35 x 1.272.54 cm) Fil. Hd. Brass Screw (2). b. Guide Plate. c. Special Seat Removal Wrench. Also enclosed is Instruction M-1287 on the use of the above items. 2. Maximum temperature specified cannot be obtained. A. Hot water inlet temperature is not 30F (17C) or more above the set point temperature. B. The mixer has a concealed maximum temperature adjustment in the temperature adjustment stem. See Figure 3 for setting maximum adjustment screws. a. Turn handle completely counterclockwise to deliver water at maximum temperature. b. Remove handle parts and lock screw located inside t he t emp erat ure ad just ment st em w it h 3/ 16 (4.8mm) hex wrench. c. Using the same hex wrench, turn the maximum temperature limit screw clockwise for a lower temperature, and counterclockwise for a higher temperature. d. Setting the maximum temperature limit screw for a temperature greater than 15F (8C) above the standard limit of 125F (52C) may render the mixer inoperative.
Note: Figures 3, 4 and 5 refer to high capacity valves only.

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Figure 4. To begin disassembly of high capacity mixer for servicing, remove four bonnet screws, bonnet and stem assembly, and bonnet gasket. Be sure to shut off volume control and left hand strainer checkstop before disassembly.

Figure 5. Thermostatic motor and valve assembly can be easily pulled out for servicing parts. Valve assembly can be separated from thermostatic motor. This exposes piston cylinder.

NAMEPLATE FOR MODEL IDENTIFICATION

MODEL YEAR
Figure 3.

MONTH

MIXER KNOB PART NUMBERS D (Items refer to Figure 6)

Fotopanel Item 1 2 3 4 5 6 Part Name Knob Knob insert W asher R etaining screw Plug button Sleeve Dial 440-1000 and -2000 440-3000 440-169 420-213 (2) 440-173 440-224(8) 440-167 440-168 440-1500 *227-354 *420-125 *227-197 *034-510G *227-198 440-041 Fotoguard 440-1510 227-354A 440-173 440-224(8) 440-168 *227-430 225-282A 440-1550 *227-354 *420-125 *227-197 *034-510G Figure 6. *227-196 420-145

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VACUUM BREAKERS D (Items refer to Figure 6)

Fotopanel Product No. 440-1000, -2000 and -3000 (singleoutlet) 131-1575 131-1813 Contact for Product # Manufacturer replacement parts 043-834 W atts No. 288A W atts No. 288A-C W R Co. atts eg. Lawrence, Mass. W R Co. atts eg. Lawrence, Mass.
1 2

2. The strainers (screens) can now be removed and cleaned as shown in Figure 9. Screen Replacement Kit No. 230133 can be used if needed. This kit contains the following: a. 38 x 12 x 116 (10 x 13 x 1.6mm) O-ring (2) b. Bonnet Gasket (2) c. Stem Gasket (2) d. Screen (2) If only the gaskets need to be replaced, use Gasket Replacement Kit No. 230-131. Gasket kit contains the following: a. 38 x 12 x 116 (10 x 13 x 1.6mm) O-ring (2) b. Bonnet Gasket (2) c. Stem Gasket (2) d. Screen (2) 3. The poppets of the strainer checkstop and volume control can be checked if necessary. The water supplies must be shut off. The stem must be then screwed out and the poppet removed. 4. The right hand volume stem extension can be removed as shown in Figure 8. 5. See Figure 10 for the internal construction of the right hand volume control. 6. Use Check Valve Replacement Kit No. 23C-132. This kit contains the following: a. b. c. d. e. 8 x 12 x 116 (10 x 13 x 1.6mm) O-ring (2) Bonnet Gasket (2) Stem Gasket (2) Poppet Assembly (2) Spring (2)
3

Vacuum Breakers

043-834A

See figures 10 and 18 for part numbers of volume control and on-off valve knobs and screws. MAINTENANCE OF THERMOMETER SECTION F (Items refer to Figure 7) If leakage occurs where the manifold (4) enters the shutoff switch body, disconnect outlet piping from the vacuum breaker. Do not exert excessive torque on the pipe since the vacuum breaker is supported by the plastic manifold. Remove two mounting screws (1). Pull manifold out of switch body. Replace O-ring (2). If manifold should break, replace it by following the above procedure. When reassembling, do not use pipe dope on any plastic threads. Use teflon pipe tape.

Figure 8. To remove volume stem extension, loosen flat head screw inside stem extension and pull extension off. CAUTION: Do not remove nuts, item 5, figures 8 and 9. These are factory set for minimum fee.

Figure 7.

MAINTENANCE OF STRAINER CHECKSTOPS AND VOLUME CONTROL 1. Before disassembling the checkstop or volume control, turn each clockwise to its closed position. On the left checkstop, use a screwdriver. On the right hand checkstop, loosen screw inside of volume stem. Stop can now be turned off.

Figure 9. Unscrew bonnet and pull out screen for cleaning.

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Figure 10

Figure 11. Remove four cap screws and pull out cap assembly. The motor and shutoff disc assembly and stem sleeve should come out with the cap assembly. If not, they can be easily pulled out. When reassembling, the portion of the stem sleeve with the hole should be projecting out of the motor.

Figure 12. Pull out the combination seat with two pliers, pulling on two opposite lugs. One plier can be used by alternatively pulling on the two opposite lugs until the seat can be removed by hand. Pull out the valve assembly with the attached return spring as shown above. The hot water seat can be easily removed with a 7/8 (22mm) socket wrench.

THERMOSTATIC MOTOR TESTING 1. Remove motor assembly as shown in Figure 11. Motor bellows should offer a firm, not spongy, resistance to a rigid object inserted inside the bellows. If motor bellows does not offer firm resistance, it is not fully charged and should be replaced. 2. Insert stem sleeve in the motor and immerse into water at 75F (24C) and 100F (38C) as shown in Figure 14. The motor should cause a 1/32 (0.8mm) outward travel of the stem sleeve for a 25F (14C) temperature rise. If stem sleeve travel is considerably less, the motor has lost its charge and should be replaced.

Figure 13. A new motor and shutoff disc assembly can be substituted. If only a shutoff disc is to be replaced, disassemble as shown above. Use a plier and 13/16 (21mm) hex wrench to separate parts. Locate the plier near the disc. Be sure you do not press motor too firmly.

Figure 11.

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Thermostatic Valve (Standard)

PARTS LIST
Item 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18A Part No. 227-430 227-166 440-059 420-217 (20) 440-207 440-041 410-284 * 227-189 420-124 227-190 420-214 (12) 420-200 * * Description Plug button Seefigure3, page3 Seefigure3, page3 Seefigure3, page3 R etainer Dial insert Screw(8-32 x 112) Dial plate(concealed oval) Dial (exposed round) G asket Handleadapter T emp. stop models 4, 5, 6 T emp. stop model 7 Spacer sleeve Identification tag Screws (10-24 x 916) Bonnet Bonnet gasket** Bonnet O -ring Material C.P Steel . Item 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part No. 227-188 * 420-221 (5) 227-234 420-122 * * * * * 227-233 * * * * * * 227-258 227-375 Description Packing gland Packing rings Packing stop ring Adjustablestemmodels 4, 5, 6 Adjustablestemmodel 7 Motor quad ring Shut-off disc nut Shut-off disc retainer Shut-off disc Thermal motor Spacer ring Combination seat O -ring Motor sleeve Combination seat Valveassembly Valvereturn spring Hot water seat Body 3-port (concealed) Body 3-port (exposed) Material Brass T eflon-asbestos Brass Brass Brass Buna-N Brass Brass Buna-N Delrin Buna-N Brass Inconel Bronze Bronze Bronze

C.P Steel . Aluminum Stainless steel C.P brass . Neophrene C.P Zinc . Stainless steel Stainless steel Brass Stainless steel Brass R ubber Buna-N

( ) Number of items per kit. * Items available in kits on page 6. **Use either 18 or 18A, depending on existing bonnet seal.

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H

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Thermostatic Valve (Standard) - Repair and Modification Kits Troubleshooting 1.W leak at stem and/or bonnet ater 2.Flow of water continues after mixer is turned off. 3.Variable or untempered discharge temperature. Recommended Repair Kit 227-338 Includes items: 18, 18A, 20, 23, 26, 29 (65115F) 227-339 (120175F) 227-342 Includes items: 18, 18A, 2327, 30 227-340 (Models 5, 6 and 7) Includes items: 18, 18A, 29, 30, 3234 227-351 Includes items: 18, 18A, 29, 3134 227-445 (Models 5, 6, and 7) Includes items 18, 18A, 29, 3134 227-445 (Models 5, 6, and 7) Includes items 18, 18A, 29, 3134

Gasket and Disc Replacement Motor Replacement

Valve and Hot Water Seat Replacement

Combination Seat Replacement Standard Capacity High Capacity Kit

4.Flow of water continues after mixer is turned off due to worn hot water seat. (34) 5.Variable discharge temperature continues after replacement of motor. (27) 6.Flow of water continues after mixer is turned off and shutoff disc and/or hot water seat has been replaced. 7.T increase capacity of mixer to 9.0 G .M. o .P @45 P differential (0.06 l/s @310 kPa) .S.I. 8.T decrease capacity of mixer to 1.0 G .M. o .P @45 P differential (0.06 l/s @310 kPa) .S.I.

Low Capacity Kit

THERMOSTATIC MOTOR TESTING 1. Remove thermostatic motor and valve assembly as shown in Figure 15. Pull valve and overload spring assembly from motor. Motor bellows should offer a firm, not spongy, resistance to an object inserted inside the bellows. If motor bellows does not offer firm resistance, it is not fully charged and should be replaced. 2. Reinsert valve assembly into thermostatic motor. The motor should cause a W64 (1.2mm) outward travel of the overload spring assembly with an increase of 45F (25C). This can be measured by marking the valve assembly while the motor is immersed for a few minutes in 65F (18C) water, and then marking the assembly with the motor immersed in 110F (43C) water (Figure 12). The distance between the two marks should be 3/64 (1.2mm). If the travel is less, the motor has lost part of its charge and should be replaced.
Figure 15.

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CONSTRUCTION OF WATER MIXER

Item Part No.

Part Name

No. Reqd. 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1

Material Brass Brass R ubber Monel Sirvene Brass Brass Acrylic Acrylic Brass Buna-N Zamac Brass Brass Brass Brass Phos. Brz. Hycar Brass C.P Steel . Buna-N

EXPOSED FOTOGUARD DIAL #225-282A

Troubleshooting Gasket and Disc 1. W leak at stem and/or bonnet. ater Replacement 2. Flow of water continues after mixer is turned off. Valve and Cylinder Replacement Motor Replacement 3. V ariableor untempered dischargetemperature(limedeposits can beremoved with the useof various commercially availableproducts designed for this purpose. 4. If items 2 and 5 arefreeof limeand freemoving and dischargetemperatureis variableand untempered.

Material 225-357 Includes items: 3, 6, 15, 19, 20 225-394 Includes items: 2 through 6 225-395 Includes items: 3, 7, 20

* Thevalveassembly (5) and cylinder (2) must both bereplaced at thesametime when using kit. Do not usethenew valveassembly with an old cylinder, or viceversa.

1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23

200-046 225-238G 225-253 227-354A 440-169 440-168 436-036 225-294A 225-137 225-051G 030-126 225-258 440-173 227-430 047-013

1/2" Plug Piston Cylinder Bonnet G asket Valve Spring Valve Assembly Valve Disc Thermostatic Motor Assembly T emperature Adj. Stem Limit and Lock Screw Handle (Fotoguard) Handle (Fotopanel) R etaining Screw W asher Lock R ing Packing Stop R ing Packing R ing Packing G Nut land 1/4-20 x 5/8 Lg. Fil. Hd. Br. Screw Mixer Bonnet R etaining R ing Shutoff Disc Knob Insert Plug Button (Fotoguard) Q R uad ing

MAINTENANCE OF PRESSURE EQUALIZING SECTION Model 440-2000 Fotopanel (Items Refer to Figure 17) 1. Shut off water supplies upstream from inlets to pressure equalizing section, 2. Remove four bonnet screws (4) and lift bonnet assembly (5) from body of pressure equalizer. The bonnet assembly is connected to the mixer inlets by means of sliding couplings each with 2 O-ring seals (7 and 8). 3. Lift cartridge assembly (9) and its couplings from body of pressure equalizing assembly and replace new cartridge. (Figure 17) Use cartridge replacement kit No. 410-248. Note: The cartridge assembly must be replaced completely and must not be disassembled. 4. Replace bonnet assembly and fasten to body of prep sure equalizing section. Make certain that couplings (3 and 7) are properly positioned.

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MAINTENANCE OF SHUT-OFF SWITCH Models 440-1000, -2000 and -3000 Fotopanels (Refer to Figure 18) Leakage through the switch can occur if the shutoff disc (5) becomes twisted. If this occurs: 1. Shut off water supplies at the checkstops. 2. Remove the four screws (l), support ring (10) and bonnet (8). 3. Lift bonnet and stem assembly (See Figure 18). 4. Examine sliding plate at bottom of stem assembly. Its surface must be smooth and clean. If the hole in it is a complete circle, replace the stem assembly with a new one whose hole is partially triangular. 5. Replace disc (5), O-ring (3) and gasket (4) with parts contained in repair kit No. 440.145. Pull stem assembly from bonnet to replace O-ring (2), also found in kit No. 440.145. 6. Assemble bonnet, stem assembly and support ring. Position bonnet properly with molded cam portion at the top so knob rotation is oriented correctly. Two of the Orings (3) provide internal seals at the inlet adapter and outlet manifold from the shutoff body. If they leak, replace them by removing the screws holding the shutoff body and the manifold to the mounting plate.

CALIFORNIA PROPOSITION 65 WARNING

WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
(Installer: California law requires that this warning be given to the consumer.)

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Reprinted March 2002 Powers, a Watts Industries Co.

3400 Oakton Street, Skokie, IL 60076 Phone: 800.669.5430 847.673.6700 Fax: 847.673.9044 www.powerscontrols.com

5435 North Service Road, Burlington, Ontario, L7L 5H7 Canada Phone: 888.208.8927 Fax: 888.882.1979