the santech control valve test system - omega-usa.com santech control... · • the santech control...

Santech Industries, Inc.2450 Handley Ederville Road - Ft. Worth, TX 76118 USAPhone: (817) 589-1212 Fax: (817) 589-5900E-Mail: [email protected] - Web: http://www.santech.com

Leading Through Technology ™

LIT-0220 © 2010 12/17/10 CK Santech Industries,

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The Santech Control Valve Test System

Mechanical Control Valves

Electronic Control Valves

A12-5100 Ford ScrollA13-5227 GM - V5 A13-5228 Delphi - CVC165 / CVC185 / CVC7p A20-5020 Denso - 5SA / 5SL / 7SBU A20-5021 Denso - 5SA / 5SL / 7SBUA20-5022 Denso - 6CA17 / 6CA17C / 7SB16C A25-5002 Sanden - SD7V16 / PXE16A25-5003 Sanden - SD6V12 / SD7V12A25-5004 Sanden - SD7V16A75-5100 Delphi - CWV618 A70-5100 Diesel Kiki - DCW17

E20-7003 Denso - 6SEU12 / 6SEU16 / 7SEU16 E20-7007 Denso - 6SEU12 / 6SEU16 / 7SEU16 E20-7010 Denso - 5SE09C / 5SE12C E20-7011 Denso - 5SE09C / 5SE12C E20-7012 Denso - 5SE09C / 5SE12C E20-7013 Denso - 5SE09C / 5SE12C E20-7014 Denso - 6SEU12 / 6SEU16 / 7SEU16 E20-7017 Denso - 5SE09C / 5SE12C E20-7019 Denso - 6SEU12 / 6SEU16 / 7SEU16 E20-7020 Denso - 6SEU12 / 6SEU16 / 7SEU16 E20-7025 Denso - VW PassatE25-7001 Sanden - PXE w/o Tab / PXE16E25-7002 Sanden - PXE w/Tab / PXE16 E25-7003 Sanden - PXE w/Tab / PXE16 E25-7004 Sanden - PXE w/o Tab / PXE16E70-7000 Zexel - DCS17EE75-7000 Calsonic - CWE618K20-2174 Denso - 6SEU12 / 6SEU16 / 7SEU16 w/PigtailK20-2175 Denso - 5SE09C / 5SE12C w/ Pigtail

The Santech Control Valve Test System can test the Mechanical and Electronic Control Valves shown in the lists below using the proper testing fixtures. The follow-ing pages illustrate the operation of the system for each of the types of control valves.

• The Santech Control Valve System is a relative test unit, not an absolute one. A known good control valve is tested to set the operating parameters that the unknown control valve is tested against.

• The Santech Control Valve Test System can be used to validate your control valves before your compressor func-tion test and eliminate costly disassem-bly or returns,

• Simple to operate, uses only plant air.• Fixtures have quick connect hoses.• The base unit is a V5 Control Valve

TestFixturew/flowmeterandairfilter• Accessories(fixturesandElectronic

Valve Controller CLT1) convert the Base Unit into a full test system.

Features




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The T95-8008 V5 Control Valve Test Fixture is the base unit for testing all control valves,usingfixturesthatareaddedtothebaseunitforeachdifferentcontrolvalve.The Electronic Control Valve Test Unit includes an additional component, the Elec-tronic Valve Controller CLT1. The general instructions below list all the common set-up and operational insrtructions. Each control valve will have the set-up and test instructionsforthefixtureituses.

Caution:Donotforceacontrolvalveintothefixturebytappingonit.Thiswillchange the calibration of the valve due to the way the control valve is constructed.

T95-8008 Test FixtureMechanical Control Valves and Fixtures

T95-8008 Test Fixture Installation Instructions for Mechanical Control ValvesSet-Up Procedures• Turn both Pressure Regulators counterclockwise to zero pressure.• Set the “Air Cylinder” Switch to “UP” and Set the “TEST” Switch to “OFF”.• Attach Plant Air ((90-120 PSI / 6 - 8 BAR) to the Quick Connection on the back of the test unit.Fixture Installation Procedures• The V5 Control Valve Fixture is the T95-8008 as received, continue to the Test Instructions on the V5 page.• For all other Mechanical Control Valves, before adding the Fixtures;

• Remove the V5 Control Rod from the bottom of the Air Cylinder.• Install the V5 Dummy Control Valve.• Place the Lower Control Valve Fixture over the V5 Test Port and lightly tighten the Allen Screws.• Place the Upper Control Valve Fixture on the end of the Air Cylinder plate by aligning the two pins and letting the magnets hold it

in place, or• Screw the Control Valve Holder onto the Air Cylinder Shaft.

Hose Connections• There are possibly three different color hoses on each Fixture.

• The Red Hoses will be connected to one of the High Side Connections on the back of the Base Unit.• The Blue Hoses will be connected to one of the Low Side Connections on the back of the Base Unit.• The Black Hose will be connected to the Air Filter mounted on the back of the post.

• For the individual Control Valve Test Fixture Hose Connections refer to the Hose Connections listed in the individual Control Valve Section.

Common Operating Procedures• Confirmthe“AirCylinder”switchisinthe”UP”positionandconfirmthe“Test”Switchisinthe“OFF”position.• ConfirmbothofthePressureRegulatorsareturnedcounterclockwisetothe0PSIposition.• Place the Control Valve to be tested into the bottom cavity, or in the upper unit if it is designed to hold the Control Valve and remove it

from the Fixture.Control Valve Test Procedures• The Test Instructions for each Control Valve is listed in the individual Control Valve Section.Testing Shut Down Procedures• When the Control Valve Operations Test is complete;

• Turn the “Test” Switch to the “OFF” position.• Turn the “Air Cylinder” Switch to the “Open” Position.• Turn the Pressure Regulators counterclockwise to the 0 PSI position.• Remove the Control Valve being tested.• If another Control Valve is to be tested, repeat from the Common Operating Procedures.

Note• The Santech Control Valve Test System is a Relative test system and it depends on having a known good Control Valve to test for

setting the test acceptance values for the Control Valves being tested.




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A13-5227 GM Control Valve

T95-8008 Test Fixture Test Procedure

A13-5228 Delphi Control Valve

Mechanical Control Valves and FixturesV5 V5-15R12 Control Valve - Red Top

O-Ring Kit - K13-2122Screen - A13-5132

V5 / V5-15 V7R134a Control Valve - Orange Top


V5 R134a Control Valve - Yellow Top


CVC165-185 CVC7 R134a Control Valve - Purple Top


A13-5121 GM Control Valve A13-5126 GM Control Valve

Operation Instructions for base unit V5 Control Valve Fixture1. Lightlycoat(useMineralOil)theo-ringsonthecontrolvalveandinsertthecontrolvalveintothefixtureattachedtotheaircylinder.2. Turnontheaircylinderswitchtoinsertthecontrolvalveintothetestfixture.Thiswillalsoholdthecontrolvalveinplacetotest.3. Lift the knob and turn the left side pressure regulator to 90 - 100 PSI (6-7 bar). Push the knob down to lock the setting. Do not

change the setting during the test.4. Lift the knob and turn the right side pressure regulator until the pressure approaches 25 PSI. Continue to increase the pressure at a

slow pace and observe both gauges. 5. The right side gauge will start to equalize with the left side gauge. Continue until the gauges are equalized, and watch for a jump in

the right side gauge which will signal the activation point for the control valve.6. At this point, the control valve is trying to regulate the pressure and as you increase the pressure, there will be little change in the

right side gauge until you pass the point where the control valve can no longer regulate the pressure. At this point, the gauges will both increase together.

7. The activation point should be between 29 and 32 PSI. If the control valve activates below 29 PSI, or above 32 PSI, the valve is questionable. The closer to the activation point the better the control valve.

8. Should the control valve equalize immediately, or show erratic behavior, the control valve is either not functioning correctly, or bad.9. When the pressure is increased, if the right and left side gauges track up tp 50 PSI, the control valve is bad.

A12-5100 Ford Control Valve Test Procedure

Ford Scroll There is not a Test Fixture or Test Procedure for this valve at this time.




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A20-5022 Denso Control Valve

A20-5021 Denso Control Valve

T95-8025 Test Fixture

A20-5020 Denso Control ValveMechanical Control Valves and Fixtures

5SA / 5SL 7SBUGreen epoxy on adjustment screw

O-Ring Kit - K20-2178Screen - 20-5121

6CA17C 7SB16CBlue paint on adjustment screw(Early Version)O-Ring Kit - K13-2122Screen - A13-5132

T95-8011 Test Fixture

5SA / 5SL 7SBUClear epoxy on adjustment screw


CAUTION: Remove the Screen from Control Valve before Testing!Hose Connections• Red Hoses connect to either of the High Side Connections on back of unit.• Blue Hoses connect on either of the Low Side Connections on back of unit.• Black Hose connects to Air Filter mounted on the back of the post.Test Procedure• OpentheFlowmetervalvetoallowmaxiumflow.• Set the High Side Pressure Regulator to a value between 40 PSI and 60 PSI• Adjust the Flowmeter for a maximum of 3 scfm. (May not reach 3 scfm)• Adjust the Low Side Pressure Regulator until the ball in the Flow meter starts to drop. This

is the activation point of the Control Valve.• ContinuetoincreasetheLowPressureRegulatoruntiltheballisatthebottomandnoflow

occurs. This is the maximum control point of the valve.

Hose Connections• Red Hoses connect to either of the High Side Connec-

tions on back of unit.• Blue Hoses connect on either of the Low Side Connec-

tions on back of unit.

Test Procedure• Set the High Pressure Regulator to 30 PSI.• Adjust the Low Pressure Regulator until the High Pres-

sure Gauge stops rising and both needles fail to move as the Low Pressure Regulator is increased.

Test Procedure continued• The Low Pressure Regulator should turn a half to full turn with no

movement of the gauges. This is the control area for the valve.• If the Low Side Pressure is increased more, the gauges will rise together.

Then decreasing the Low Side Pressure will bring the Control Valve back into the operating range at the upper control point.

• The Low Side Pressure where the needles stop moving as the Low Side Pressure in increased is the Operating point of the Control Valve.

• The Critical Pressure should be near 30 PSI, or 2 BAR.

T95-8011 Test FixtureTest Procedure





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A25-5002 Sanden Control ValveMechanical Control Valves and Fixtures

SD7V16 PXV16O-Ring - M96-2153

A25-5003 Sanden Control Valve

A25-5004 Sanden Control Valve T95-8015 Test Fixture



Hose Connections• Attach the Red Hose from the Upper Fixture Unit to the “A” High Side Connection on the back of the Test Unit.• Attach the Red Hose from the Lower Fixture Unit to to the “B” High Side Connection on the back of the Test Unit.• Connect the Blue Hoses to either of the “A” and “B Low Side Connections on the back of the Test Unit.

Test Procedure• Adjust the Low Side Pressure to 36 PSI.• Adjust the High Side Pressure until the pressure stop rising but no more than 40 PSI.• Turn the Test Switch to “OFF”, the Air Cylinder to “UP” and remove the Control Valve. Unit is set up to test a Control Valve.• To test a Control Valve, insert an Control Valve in the Base Unit and switch the Air Cylinder to “DOWN”.• The system is set-up to test the Control Valve as soon as the Test Switch is moved to “ON”. When the Test Switch is moved to “ON”,

the Low Side Pressure will rise to 36 PSI and teh High Side Pressure will rise to about 40 PSI.• The rate of rise will vary, but if the pressure does not rise, the Control Valve is bad.• Observe the High Pressure Gauge as it is risingand note the prssure where both gauges “Jump”. This is the Activation PSI for the

Control Valve.• If the gauges do not “Jump” at the correct value, or at all, the Control Valve is bad.




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T95-8036 Test FixtureA75-5100 Delphi Control Valve

CWV618


Mechanical Control Valves and Fixtures

A70-5100 Diesel Kiki Control Valve T95-8028 Test FixtureDCW17

T95-8036 Test Fixture Test ProcedureHose Connections• Red Hoses connect to either of the High Side Connections on back of unit.• Blue Hoses connect on either of the Low Side Connections on back of unit.• Black Hose connects to Air Filter mounted on the back of the post.

Test Procedure• Set High Side Pressure to 40 PSI.• Adjust the Flowmeter for a maximum of 3 SCFM. (Lower than 3 SCFM is ok)• IncreasetheLowSidePressureuntiltheHighSidePressureGaugestartstoincreaseinPSI,andflowstartstodecreaseintheFlowme-

ter.. This is the Low Activation Point for the Control Valve.• ContinuetoincreasetheLowSidePressureuntiltheHighSideGaugestopsincreasingandflowstopsintheFlowmeter.Thisisthe

High Control Pressure.

T95-8028 Test Fixture Test ProcedureHose Connections• Red Hoses connect to either of the High Side Connections on

back of unit.• Blue Hoses connect on either of the Low Side Connections on

back of unit.• Black Hose connects to Air Filter mounted on the back of the

post.

Test ProcedureCheck the Low Side Bellows• Set High Side Pressure to 0 PSI. • Adjust Low Side Pressure up to 60 PSI.• If Flow occurs and increases, the Low Side Bellows is working• AttheLowSidePressurewheremaximumflowoccurs,adjust

theFlowmeterforamaximumflowofnomorethan3SCFM

Check the High Side Bellows• Set the Low Side Pressure to 55 PSI.• Adjust the High Side Pressure from 0 to 60 PSI.• If Flow decreases the High Side Bellows is working.Operational Test• Adjust the Low Side Pressure to 60 PSI and back off to 55 PSI• Adjust the Flow in the Flowmeter to 1.4 SCFM• IncreasetheHighSidePressureuntiltheflowstartsotdecrease• Continue to increase the High Side Pressure up to 60 PSI.• The Low Side Pressure should slowly increase to about 58 PSI• TheflowintheFlowmetershouldslowlydecreasetoabout0.8

SCFM• Ifthefloworthepressuredonotchange,theControlValveis

bad.

charles

Sticky Note




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T95-1400 - Electrical Control Valves - Testing UnitTesting Unit includes:Hand Held Unit for Operation Control

Simulation Electronic Box (to bypass system while control valve is disconnected)

Power Lead for 12v Battery Supply

Direct Connector for Chrysler/Jeep Compressors

Direct Connector for Mercedes Compressors

Direct Connector for Volkswagen/Audi Compressors

Plastic Storage/Carrying Case

Instruction Manual Included

COMPRESSOR LEADS SIMULATOR

CONTROL UNIT

Electronic Control Valves and Fixtures

POWER SUPPLY




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Setting up the test unit1. Turn both pressure regulators counterclockwise to zero pressure.*2. Set the “Air Cylinder” switch to “UP”.3. Set the “Test” switch to “OFF”.4. Insert a dummy V5 plug in the test stand.5. Install the Control Valve Test Fixture base onto the test stand with the bolts provided. a. Connect the two (2) Red hoses to the high side ports (bottom ports) on the rear of the test stand.6. Install the Control Valve Upper Fixture Unit onto the top movable section by screwing the upper unit onto the screw mounted in the center of the upper test stand . a. Connect the two (2) Blue hoses to the low side ports (top ports) on the rear of the test stand. b. Connect the Black hose to the airfilterattachedtotheflowmeter.7. Insert the control valve to be tested into the upper unit.8. Close the test unit by operation of the “Air Cylinder” Switch on the left side of the test stand to the “Down” position.9. Flip the “Test” switch on the right side of the panel to the “ON” position.

(* Note: As the pressure is being adjusted down with the air pressure regulators, a hissing sound will occur. This is the regulator releasing the pressure and is a normal occurrence.)

Test if the coil is good1. Adjust the low side PSI = 30 PSI.2. Adjust the high side PSI = 30PSI.3. Flowshouldoccur,soadjusttheflowto3SCFM(StandardCubitFeetperMinute)maximumusingthe dialonthebottomoftheflowmeter.Ifnoflow,thecontrolvalvehasarestrictiontoflowandshouldbe scrapped.4. Connect the Electronic Control Valve Coil wires to 12 VDC, observing polarity.5. Flow should stop and go to 0 SCFM to indicate a good coil.6. Ifflowdoesnotstop,checkthepolarityoftheconnectionstothecontrolvalve.7.Ifflowdoesnotstop,thecoilisbadandshouldbescrapped.

Test the operation of the Electronic Control ValveThe operation of the Electronic Control Valve will follow a family of curves based on the high side and low side pressure settings. Use a known good electronic control valve to establish the base curve for the units to be tested.Chart 1 shows a typical curve for the high side = 20 PSI and the low side = 30 PSI through the 0 to 8 control posi-tions of the CLT1 Electronic Control Valve Controller. The eight positions on the CLT1 represent voltages varying from 0 to 12 VDC that determine the position of the control valve when regulating.

Electronic Control Valves and FixturesElectronic Control Valve Operational Tests




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Check operation against an ideal control valve

1. With a known good control valve inserted into the top unit and the top unit lowered, set the low side pressure to 30 PSI, and set the high side pressure to 20 PSI to determine a curve for a known good electronic control valve. 2. Usingtheknobontheflowmeter,adjusttheflowfor3.0SCFM.3. Connect the CLT1 to the electronic control valve with the control level set to zero (0). 4. Push the button for level 1 on the CLT1. A. The low pressure should stay at about 30 PSI. Record the PSI. B.Theflowshouldstayatabout3.0SCFM.RecordtheSCFM5. Push the button for level 2 on the CLT1. A. Record the low pressure PSI Value. B. RecordtheflowSCFMValue.6. ContinuetopushthenextcontrollevelontheCLT1andrecordthelowpressurePSIandtheflow SCFM values.7. After all eight (8) levels have been recorded, check the measurements against the values in Chart 1 and Chart 2. The curves should be similar and close to these values.

To test an unknown Electronic Control ValveRepeat the procedure above and compare the unknown control valve with your data for a known good electronic control valve.Notes: Each electronic control valve will operate a little differently, but should follow this trend. To better determine the operating characteristics and develop a more accurate “Ideal” set of curves for your application, use a larger sample of 5 or more known good control valves from your stock to test and plot like the data in Charts 1 and 2. Average

Control Valve Flow with High Side at 20PSI

0.000.501.001.502.002.503.003.50

0 1 2 3 4 5 6 7 8

CLR1 Control Level

Flow

SC

FM

Flow atHS=0 PSI

Flow atHS=20 PSI

Flow atHS=40 PSI

Low Side PSI with High Side at 20 PSI

30.031.032.033.034.035.036.037.038.0

0 1 2 3 4 5 6 7 8

CLR1 Control Level

Low

Sid

e PS

I Low SidePSI atHS=0 PSI

Low SidePSI atHS=20PSILow SidePSI atHS=40PSI

Chart 1. Low Pressure Reaction to CLT1 Levels at High Side = 0 PSI to 40 PSI

Chart 2. Flow Reaction to CLT1 Levels at High Side = 0 PSI to 40 PSI

Electronic Control Valves and FixturesElectronic Control Valve Operational Tests




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E20-7014 Denso Control Valve


6SEU12 6SEU16 7SEU16

O-Ring Kit - K20-2166

These control valves are tested on the base unit, T95-8008, as described in the instructions on the Electronic Control Valve Set-Up Page.

Attach the bottom base using the allen bolts. Attach the top base to the cylinder shaft. Connect the Red hoses to either of the Red connections on the back and the Blue hoses to the Blue connections. Connect the Black hose to the Air Filter on the Fowmeter.













PXE13 PXE16(VW Passat)





K20-2174 Denso Control Valve Kit T95-8029 Test Fixture




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5SE09C 5SE12C


5SE09C 5SE12C



5SE09C 5SE12C


Hose Connections• Red Hoses connect to either of the High Side Connections on back of unit.• Blue Hoses connect on either of the Low Side Connections on back of unit.• Black Hose connects to Air Filter mounted on the back of the post. Test Procedure• These control valves are tested on the base unit, T95-8008, as described in the instructions on

the Electronic Control Valve Set-Up Page.• Attach the bottom base using the allen bolts. • Attach the top base to the cylinder shaft.

5SE09C 5SE12C


5SE09C 5SE12C


E20-7010 Denso Control Valve E20-7011 Denso Control Valve

E20-7017 Denso Control Valve K20-2175 Denso Control Valve Kit


5SE09C 5SE12C


E20-7012 Denso Control Valve E20-7013 Denso Control Valve

E25-7006 Sanden Control Valve E25-7006 Test Procedure

SD6C12 PXE13 / PXE16(Peugeot 307)O-Ring Kit - K20-2166

There is not a Test Fixture of Test Procedure for this Valve at this time.



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PXE13 PXE16(Extended Connector)


Hose Connections• Red Hoses connect to either of the High Side Connections on back of unit.• Blue Hoses connect on either of the Low Side Connections on back of unit.• Black Hose connects to Air Filter mounted on the back of the post.

Test Procedure• These control valves are tested on the base unit, T95-8008, as described in the instructions on the

Electronic Control Valve Set-Up Page.• Attach the bottom base using the allen bolts. Attach the top base to the cylinder shaft.

PXE13 PXE16


Test Procedure for T95-8031 and T95-8032 Test Fixtures

E70-7000 Zexel Control Valve T95-8033 Test Fixture / Procedure

DSC17E


Test Procedure• This control valve is tested on the base

unit, T95-8008, as described in the instructions on the Electronic Control Valve Set-Up Page.

• Attach the bottom base using the allen bolts. Attach the top base to the cylin-der shaft.

CWE618


E75-7000 Calsonic Control Valve T95-8035 Test Fixture / ProcedureTest Procedure• This control valve is tested on the base

unit, T95-8008, as described in the instructions on the Electronic Control Valve Set-Up Page.

• Attach the bottom base using the allen bolts. Attach the top base to the cylin-der shaft.

E25-7001 Sanden Control Valve T95-8032 Test FixtureE25-7004 Sanden Control Valve

E25-7002 Sanden Control Valve T95-8031 Test FixtureE25-7003 Sanden Control Valve

PXE13 PXE16(Extended Connector)


PXE13 PXE16


(With Tab) (With Tab)

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