Bell & Gossett V01348H Comfort Trol Zone Control Valve - Manual (Page 3)

3
SERVICE INSTRUCTIONS
Comfort-Trol Zone Control Valves are designed for fast and easy main-
tenance with a standard screwdriver and pliers. It is recommended
that the Comfort-Trol be inspected periodically for signs of leakage,
corrosion or other damage.
The exploded view of the Comfort-Trol in Figure 3 will aid in perform-
ing service or maintenance.
To inspect and service the Comfort-Trol follow the steps listed below:
1. Identify the power leads (#1, #2 and #3 as shown in Fig. 2), and
disconnect them by pulling them off the blade type connectors.
2. Remove the Comfort-Trol operator by squeezing the formed wire
release tabs (Fig. 3) together and lifting up.
3. Remove the operator cover by spreading the cover at the bottom
to disengage the locking tabs and lifting up.
4. The following components can now be inspected and replaced if
required.
A. Seal Kit
In examining the valve seat at the top of the bonnet (Fig. 3, Item
B), look for evidence of leakage around the stem and on the
underside of the knurled head. If there is an indication of leak-
age, replace the seal. Failure to replace the seal may cause
erratic valve operation resulting in failure of the valve to open.
Comfort-Trol is a backseating valve which permits replacing the
seal without draining the system. Using a pliers, loosen and
remove the seal. Carefully insert the replacement seal kit with-
out disturbing the spring loaded valve disc (Fig. 3, Item D) or
system fluid may be discharged from the valve.
Tighten the seal kit, without excessive force, until it is reasonably
secure.
B. Heat motor (power pill with heater)
The large end of the heat motor is wrapped with a black material
which secures the heater element to the power pill. The normal
color of the power pill under the heater is copper. If it turns gray
or black and there appears to be leakage around the piston,
replace the heat motor. See the instructions for replacing the
heat motor.
C. Operator
If the heat motor or switches have failed the entire operator
may be replaced rather than replacing the components. This is
accomplished by simply placing a new operator on the valve
body and pressing down until the wire retainers inside the oper-
ator frame (Fig. 3, Item E) snaps into the retaining groove on the
brass bonnet (Fig. 3, Item C).
5. After servicing the Comfort-Trol, follow the steps below to return it
to operation.
a. Replace the cover on the Comfort-Trol operator so that the
wide section of the operator frame at the switch end of the
operator (Fig. 3, Item F) slips between the end cover and the
raised guides located inside and on both sides of the cover.
Push down on the cover until the two 3/16" long raised tabs at
the bottom of the cover lock over the underside of the operator.
b. Assemble the Comfort-Trol operator onto the valve body (the
operator can be rotated 360° after it is installed) by pushing
down on the operator until the wire retainers inside the operator
frame (Fig. 3, Item E) snap into the retaining groove on the
brass bonnet (Fig. 3, Item C).
c. Reconnect terminal leads #1, #2, and #3 as required by push-
ing the connectors onto the blade terminals until the locking
catch snaps into place.
d. Restore power.
INSTRUCTIONS FOR REPLACING THE HEAT MOTOR
Two versions of the operator frame can be encountered. The design is
identical except for a heat motor access hole at the switch end of the
frame.
UNITS WITH HEAT MOTOR ACCESS HOLE
1. Turn off power to the Comfort-Trol operator.
2. Disconnect power leads from the blade switch terminals.
3. If the valve cover has cooled sufficiently, remove it by spreading
the cover at the bottom to disengage the locking tabs and lifting
up.
4. Disconnect the heater leads at the solderless terminals on the
switch inside the operator (Fig. 4, Item 1).
5. Remove retaining clip (Fig. 4, Item 9).
6. Pull heat motor thru access hole.
7. Replace the heat motor with a V01370 replacement heat motor
and secure in place with the retaining clip.
8. Reattach the heater leads to the solderless terminals on the
switch assembly (Fig. 4, Item 1), making sure the leads do not
contact the operator frame.
9. Replace cover.
10. Restore power.
WARNING: Corrosion or leakage are indications that the
Comfort-Trol may be about to cause serious damage from
leakage or rupture. It should be periodically inspected and if noted
the Comfort-Trol must be serviced or replaced. Failure to follow
these instructions could result in serious personal injury or death
and property damage.
CAUTION: Burn Hazard. Turn off the power to the Comfort-
Trol and allow Comfort-Trol operator to cool to 100°F or
less. This could take 10 to 30 minutes or longer depending on the
ambient temperature. The heat motor is surrounded by an electri-
cal heater which can become very hot so care needs to be exer-
cised to avoid being burned. Failure to follow these instructions
could result in property damage and/or moderate personal injury.
WARNING: Burn Hazard. Do not touch the heat motor until
it has cooled to 100°F or less. This could take 10 to 30
minutes or longer depending on the ambient temperature. It is
heated by an electrical heater which can become very hot. Failure
to follow these instructions could result in serious personal injury
or death and property damage.
WARNING: Do not insert screwdrivers or other objects into
the operator body to pry the cover off. Movement in the leaf
springs will cause the operator to lose calibration and will cause a
failure in the Comfort-Trol.
WARNING: Accidental discharge of hot water fluid. Do not
jar or move the valve disc during replacement of the Seal
Kit. Backseating of valve disc is by spring load only. Failure to fol-
low these instructions could result in serious personal injury or
death and property damage.
05263:V01348 11/11/02 6/17/09 1:33 PM Page 3