DESCRIPTION

Color film manufacturers have long recognized the impor-tance of maintaining proper water temperatures during filmprocessing. Because valuable negat ives have beendestroyed by erratic water temperatures, film manufacturersoften specify that temperatures be maintained to ±1/2°F(±1/4°C) during film processing. Only a thermostatic mixingdevice can protect against varying water temperatures andwater pressures—and assure stable water temperatures forall types of film processing.The 440 Fotopanel mixes hot and cold water thermostaticallyto deliver tempered water at precisely the temperatureselected. The adjustments permit accurate selection of tem-perature and volume. Once the temperature and flow ratehave been preset, you need only to turn an on-off switch tostart or stop your process.The 440 Fotopanel assures better quality negatives and atthe same time avoids expensive waste of time and materials.

SPECIFICATION

Maximum Hot Water Supply Temperature . . .190°F (88°F)Maximum Static Pressure . . . . . . . . . . . .125 psi (862 kPa)Temperature Range (Std) . . . . . . . . . . .65–125°F (18–52°C)

(Hi-Temp) 120–175°F (49–79°C)

NOTE: To obtain maximum temperature, hot water inlet tem-perature must be 15°F (8°C) or more above setpoint temper-ature for the standard temperature models and 30°F (17°C)or more for the high temperature models.

OPERATION

After first passing through the strainer checkstops, hot andcold water enter the Fotoguard mixer through their respec-tive inlet ports. The right hand strainer checkstop is fittedwith a stem extension to facilitate volume control (see Figure10). Rotating the volume valve counter-clockwise willincrease capacity. Both supplies mix in the chamber contain-ing the valve assembly, and the mixture flows over the ther-mostatic motor. The thermostatic motor positions the valveassembly to maintain the desired temperature.

If the temperature of the mixer is higher than the controlpoint, the thermostatic motor expands and decreases theflow of hot water by moving the valve assembly toward thehot water seat. An increase in cold water flow and decreasein hot water flow will adjust the delivery temperature to thedesired level. The process is reversed if the mixture tempera-ture is lower than the desired control point. Upon cold waterfailure, the hot water will shut off because of expansion of thethermostatic motor and seating of the hot water disc.

By rotating the handle, any desired temperature within therange of the Fotoguard can be obtained. The temperaturesetting requires one complete rotation over the full range ofthe instrument. Clockwise rotation will lower delivery temper-ature, and counterclockwise will raise delivery temperature.Rotating the handle fully clockwise seats the shutoff disc andstops the flow.

At the same time, the hot water disc seats, preventing inter-change of water supplies.

In addition to the mixer and volume control, the Fotopanelis supplied with a shutoff valve which requires only 67°rotat ion to shut off the supply of mixed water to theprocess. In this case, interchange of water supplies is pre-vented by the inlet check valves. The vacuum breaker, alsosupplied with the Fotopanel, prevents siphoning of solu-tions in the event of a pressure failure. A dial thermometerindicates discharge temperature.

TECHNICAL INSTRUCTIONSSeries 440 Fotopanel & Fotoguard

Model 6

Form MV440-2

Figure 1. Top view of Fotopanel & Fotoguard Mixer from Strainer Checkstop

MV440-2 Page 2

OPERATION (cont’d.)

The Model 440-2000 Fotopanel is equipped with a pressure-equalizing section. Hot and cold water is fed into separatesides of a pressure-equalizing valve and act on a force bal-ance diaphragm assembly, The highest supply pressure willcause the diaphragm to close off on that inlet port. This isdone by means of a poppet valve assembly, thus allowingmore supply water to enter from the other port. This processcontinues until fluctuations diminish and a balanced condi-tion is obtained. The hot and cold water supplies are now fedinto the water mixer at equal pressures.

GENERAL SERVICING PROCEDURE

1. Remove on-off knob, temperature adjustment knob, andvolume control knob as shown in Figure 2.

2. Remove six bracket screws and remove stainless steelbox assembly, exposing mounting bracket and pipingassembly 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 trou-

bleshooting the Fotopanel. Be sure to shut off water sup-plies to mixer at strainer checkstops before disassemblingmixer. 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 Fotopanelalso apply to the Fotoguard.

6. See page 3 for procedures involved in servicing and disas-sembly 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. (Counter-clockwise rotation opens checkstop and volumecontrol).

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 waterpipes.

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 coldwater supply failure.

3. Flow is untempered hot or cold water.a. Accumulation of lime deposits in hot water pipes

which restricts the hot water flowb. 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 handstrainer checkstop inlet, and cold to the right hand

volume control inlet. These instructions are also foundin 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 PRES-

SURE EQUALIZER (440-20 Fotopanel). Replace withnew 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 15°F (8°C) or more

above setpoint temperature. 30°F (17°C) for the highcapacity models.

Figure 2. Repair items: Refer to the following pages for the desired item letter.

Item Name 400-1000 440-2000 440-3000A Cabinet 440-175 440-182 440-176B Cover plate 440-174 440-181 440-174C Back plate 440-155 440-186 440-146

REPAIR ITEMSthrough (Refers to Figure 2)CA

HIGH CAPACITY VALVES: MAINTENANCE & TROUBLESHOOTING

(Refer to Figures 3, 4 and 5)Troubleshooting of the mixer involves the same steps foundabove, except for the following variations:1. Discharge temperature is erratic or variable.

A. In the high capacity mixer, lime deposits can build uparound the PISTON causing it to bind in the PISTONCYLINDER. To replace or remove PISTON CYLINDER,use Cylinder Removal Kit No. 225-350. This kit con-tains the following items:a. 1/4-20 x 1ʺ″ lg. (M6.35 x 1.27–2.54 cm) Fil. Hd.

Brass Screw (2).b. Guide Plate.c. Special Seat Removal Wrench.

Also enclosed is Instruction M-1287 on the use ofthe above items.

2. Maximum temperature specified cannot be obtained.A. Hot water inlet temperature is not 30°F (17°C) or more

above the set point temperature.B. The mixer has a concealed maximum temperature

adjustment in the temperature adjustment stem. SeeFigure 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

the temperature adjustment stem with 3/16ʺ″(4.8mm) hex wrench.

c. Using the same hex wrench, turn the maximum tem-perature limit screw clockwise for a lower tempera-ture, and counterclockwise for a higher temperature.

d. Setting the maximum temperature limit screw for atemperature greater than 15°F (8°C) above the stan-dard limit of 125°F (52°C) may render the mixerinoperative.

MV440-2 Page 3

Figure 3.

Figure 6.

Figure 4.

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

Figure 5.

Thermostatic motor and valve assembly can be easily pulledout for servicing parts. Valve assembly can be separated fromthermostatic motor. This exposes piston cylinder.

Note: Figures 3, 4 and 5 refer to high capacity valves only.

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

Item1 Knob 440-169 *227-354 227-354A *227-3542 Knob insert 420-213 (2) 440-173 *420-125 440-173 *420-1253 Washer — 440-224(8) *227-197 440-224(8) *227-1974 Retaining screw 440-167 440-168 *034-510G 440-168 *034-510G5 Plug button — — *227-4306 Sleeve — — *227-198 — *227-196— Dial — — 440-041 225-282A 420-145

Part Name

Fotopanel440-1000and -2000 440-3000 440-1500 440-1510 440-1550

Fotoguard

NAMEPLATE FORMODEL IDENTIFICATION

MODEL YEAR MONTH

6 X 4

MV440-2 Page 4

MAINTENANCE OF THERMOMETER SECTION(Items refer to Figure 7)

If leakage occurs where the manifold (4) enters the shutoffswitch body, disconnect outlet piping from the vacuum break-er. Do not exert excessive torque on the pipe since the vacu-um breaker is supported by the plastic manifold. Remove twomounting screws (1). Pull manifold out of switch body.Replace O-ring (2). If manifold should break, replace it by fol-lowing the above procedure. When reassembling, do not usepipe dope on any plastic threads. Use teflon pipe tape.

F

MAINTENANCE OF STRAINER CHECKSTOPS AND VOLUME CONTROL

1. Before disassembling the checkstop or volume control,turn each clockwise to its closed position. On the leftcheckstop, use a screwdriver. On the right hand check-stop, loosen screw inside of volume stem. Stop can nowbe turned off.

2. The strainers (screens) can now be removed and cleanedas shown in Figure 9. Screen Replacement Kit No. 230-133 can be used if needed. This kit contains the following:

a. 3⁄8ʺ″ x 1⁄2ʺ″ x 1⁄16ʺ″ (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 Re-placement Kit No. 230-131. Gasket kit contains the fol-lowing:

a. 3⁄8ʺ″ x 1⁄2ʺ″ x 1⁄16ʺ″ (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 controlcan be checked if necessary. The water supplies must beshut off. The stem must be then screwed out and the pop-pet removed.

4. The right hand volume stem extension can be removed asshown in Figure 8.

5. See Figure 10 for the internal construction of the righthand volume control.

6. Use Check Valve Replacement Kit No. 23C-132. This kitcontains the following:

a. 3⁄8ʺ″ x 1⁄2ʺ″ x 1⁄16ʺ″ (10 x 13 x 1.6mm) O-ring (2)b. Bonnet Gasket (2)c. Stem Gasket (2)d. Poppet Assembly (2)e. Spring (2)

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

Unscrew bonnet and pull out screen for cleaning.

See figures 10 and 18 for part numbers of volumecontrol and on-off valve knobs and screws.

VACUUM BREAKERS(Items refer to Figure 6)D

Fotopanel Product No.

440-1000, -2000and -3000

(single outlet)043-834 Watts

No. 288AWatts Reg. Co.

Lawrence, Mass.

131-1575131-1813 043-834A Watts

No. 288A-CWatts Reg. Co.

Lawrence, Mass.

Product # Manufacturer

1⁄2 Vacuum Breakers Contact for replacement parts

Figure 7.

Figure 8.

Figure 9.

MV440-2 Page 5

Figure 10

Figure 11.Remove four cap screws and pull out cap assembly. The motor andshutoff disc assembly and stem sleeve should come out with thecap assembly. If not, they can be easily pulled out. When reassem-bling, the portion of the stem sleeve with the hole should be project-ing out of the motor.

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

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

THERMOSTATIC MOTOR TESTING

1. Remove motor assembly as shown in Figure 11. Motor bel-lows should offer a firm, not spongy, resistance to a rigidobject inserted inside the bellows. If motor bellows doesnot offer firm resistance, it is not fully charged and shouldbe replaced.

2. Insert stem sleeve in the motor and immerse into water at75°F (24°C) and 100°F (38°C) as shown in Figure 14. Themotor should cause a 1/32ʺ″ (0.8mm) outward travel of thestem sleeve for a 25°F (14°C) temperature rise. If stemsleeve travel is considerably less, the motor has lost itscharge and should be replaced.

Figure 11.

MV440-2 Page 6

PARTS LIST

3 227-430 Plug button C.P. Steel4 — See figure 3, page 35 — See figure 3, page 36 — See figure 3, page 37 227-166 Retainer C.P. Steel8 440-059 Dial insert Aluminum9 420-217 (20) Screw (8-32 x 11⁄2ʺ″)10 440-207 Dial plate (concealed oval) Stainless steel

440-041 Dial (exposed round) C.P. brass11 410-284 Gasket Neophrene12 * Handle adapter C.P. Zinc13 227-189 Temp. stop models 4, 5, 6 Stainless steel

420-124 Temp. stop model 7 Stainless steel14 227-190 Spacer sleeve Brass15 — Identification tag —16 420-214 (12) Screws (10-24 x 9⁄16ʺ″) Stainless steel17 420-200 Bonnet Brass18 * Bonnet gasket** Rubber18A * Bonnet O-ring Buna-N

19 227-188 Packing gland Brass20 * Packing rings Teflon-asbestos21 420-221 (5) Packing stop ring Brass22 227-234 Adjustable stem models 4, 5, 6 Brass

420-122 Adjustable stem model 7 Brass23 * Motor quad ring Buna-N24 * Shut-off disc nut Brass25 * Shut-off disc retainer Brass26 * Shut-off disc Buna-N27 * Thermal motor —28 227-233 Spacer ring Delrin29 * Combination seat O-ring Buna-N30 * Motor sleeve Brass31 * Combination seat32 * Valve assembly —33 * Valve return spring Inconel34 * Hot water seat Bronze35 227-258 Body 3-port (concealed) Bronze

227-375 Body 3-port (exposed) Bronze

Item Part No. Description Material Item Part No. Description Material

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

Thermostatic Valve (Standard) H

MV440-2 Page 7

Thermostatic Valve (Standard) - Repair and Modification KitsH

Troubleshooting Recommended Repair KitGasket and 1.Water leak at stem and/or bonnet 227-338Disc Replacement 2.Flow of water continues after mixer is turned off. Includes items:

18, 18A, 20, 23, 26, 29Motor Replacement 3.Variable or untempered discharge temperature. (65–115°F) 227-339

(120–175°F) 227-342Includes items:

18, 18A, 23–27, 30Valve and Hot Water 4.Flow of water continues after mixer is turned off due to worn 227-340Seat Replacement hot water seat. (34) (Models 5, 6 and 7)

5.Variable discharge temperature continues after replacement Includes items:of motor. (27) 18, 18A, 29, 30, 32–34

Combination Seat 6.Flow of water continues after mixer is turned off and shutoff 227-351Replacement disc and/or hot water seat has been replaced. Includes items:Standard Capacity 18, 18A, 29, 31–34High Capacity Kit 7.To increase capacity of mixer to 9.0 G.P.M. 227-445 (Models 5, 6, and 7)

@ 45 P.S.I. differential (0.06 l/s @ 310 kPa) Includes items18, 18A, 29, 31–34

Low Capacity Kit 8.To decrease capacity of mixer to 1.0 G.P.M. 227-445 (Models 5, 6, and 7)@ 45 P.S.I. differential (0.06 l/s @ 310 kPa) Includes items

18, 18A, 29, 31–34

THERMOSTATIC MOTOR TESTING

1. Remove thermostatic motor and valve assembly as shownin Figure 15. Pull valve and overload spring assembly frommotor. Motor bellows should offer a firm, not spongy, resis-tance to an object inserted inside the bellows. If motor bel-lows does not offer firm resistance, it is not fully chargedand should be replaced.

2. Reinsert valve assembly into thermostatic motor. The motorshould cause a W64ʺ″ (1.2mm) outward travel of the over-load spring assembly with an increase of 45°F (25°C). Thiscan be measured by marking the valve assembly while themotor is immersed for a few minutes in 65°F (18°C) water,and then marking the assembly with the motor immersed in110°F (43°C) water (Figure 12). The distance between thetwo marks should be 3/64ʺ″ (1.2mm). If the travel is less, themotor has lost part of its charge and should be replaced.

Figure 15.

MV440-2 Page 8

CONSTRUCTION OF WATER MIXER

Item1 200-046 1/2" Plug 1 Brass2 — Piston Cylinder 1 Brass3 — Bonnet Gasket 1 Rubber4 — Valve Spring 1 Monel5 — Valve Assembly 1 —6 — Valve Disc 1 Sirvene7 — Thermostatic Motor Assembly 1 —8 225-238G Temperature Adj. Stem 1 Brass9 225-253 Limit and Lock Screw 2 Brass

10 227-354A Handle (Fotoguard) 1 Acrylic10 440-169 Handle (Fotopanel) 1 Acrylic11 440-168 Retaining Screw 1 Brass12 436-036 Washer 1 Buna-N13 225-294A Lock Ring 1 Zamac14 225-137 Packing Stop Ring 1 Brass15 — Packing Ring 1 —16 225-051G Packing Gland Nut 1 Brass17 030-126 1/4-20 x 5/8 Lg. Fil. Hd. Br. Screw 4 Brass18 225-258 Mixer Bonnet 1 Brass19 — Retaining Ring 1 Phos. Brz.20 — Shutoff Disc 1 Hycar21 440-173 Knob Insert 1 Brass22 227-430 Plug Button (Fotoguard) 1 C.P. Steel23 047-013 Quad Ring 1 Buna-N

Part No. Part NameNo.

Req’d. Material

Troubleshooting

Gasket and DiscReplacement

* The valve assembly (5) and cylinder (2) must both be replaced at the same time when using kit. Do not use the new valve assembly with an old cylinder, or vice versa.

Material

1. Water leak at stem and/or bonnet.2. Flow of water continues after mixer is

turned off.

225-357Includes items:3, 6, 15, 19, 20

Valve andCylinderReplacement

3. Variable or untempered discharge tempera-ture (lime deposits can be removed with the use of various commercially available pro-ducts designed for this purpose.

225-394Includes items:

2 through 6

MotorReplacement

4. If items 2 and 5 are free of lime and free-moving and discharge temperature is vari-able and untempered.

225-395Includes items:

3, 7, 20

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 assemblyis connected to the mixer inlets by means of sliding cou-plings each with 2 O-ring seals (7 and 8).

3. Lift cartridge assembly (9) and its couplings from body ofpressure equalizing assembly and replace new cartridge.(Figure 17) Use cartridge replacement kit No. 410-248.Note: The cartridge assembly must be replaced complete-ly and must not be disassembled.

4. Replace bonnet assembly and fasten to body of prep sureequalizing section. Make certain that couplings (3 and 7)are properly positioned.

MAINTENANCE OF PRESSURE EQUALIZING SECTION

EXPOSED FOTOGUARDDIAL #225-282A

MV440-2 Page 9

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 sur-

face must be smooth and clean. If the hole in it is a com-plete circle, replace the stem assembly with a new onewhose hole is partially triangular.

5. Replace disc (5), O-ring (3) and gasket (4) with parts con-tained in repair kit No. 440.145. Pull stem assembly frombonnet 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 thetop so knob rotation is oriented correctly. Two of the O-rings (3) provide internal seals at the inlet adapter and out-let manifold from the shutoff body. If they leak, replacethem by removing the screws holding the shutoff body andthe manifold to the mounting plate.

MAINTENANCE OF SHUT-OFF SWITCH

CALIFORNIA PROPOSITION 65 WARNING

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

MV440-2 Page 10

© 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.com5435 North Service Road, Burlington, Ontario, L7L 5H7 Canada • Phone: 888.208.8927 • Fax: 888.882.1979