CONFLOW UNIWORLD Series Manual

M/UNIWORLD-M/E
05 2020
Installation and Maintenance Manual
Electric Valves “PSL – PSL/AMS”
2 Way –3 Way
WWW.CONFLOW.IT
Servizio Assistenza
E-mail: [e-mail]

UNIWORLD Series M/UNIWORLD-M/E ed. 01 2020
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Summary
1 –GENERAL SAFETY INFORMATION.......................................................................................................3
2 - GENERAL ASSEMBLY INSTRUCTIONS ..................................................................................................3
2.1 –ASSEMBLY ON THE SYSTEM (GENERAL NOTES).................................................................................... 3
3 –ELECTRIC VALVES TYPE 2000 EP –2100 EP –2600 EP –2700 EP –5000 EP -5100 EP –5600 EP –5700 EP
–5800 EP...............................................................................................................................................4
3.1 –COMMISSIONING (GENERAL NOTES) ................................................................................................... 5
3.2 –ELECTRIC VALVES COMMISSIONING..................................................................................................... 5
3.2.1 –ELECTRIC VALVES WITH HANDWHEEL COMMISSIONING –MANUAL FUNCTION......................... 6
3.2.2 –ELECTRIC VALVES WITH LUBRICATOR COMMISSIONING ASSEMBLED ON BONNET..................... 7
3.3 –ACTUATOR ASSEMBLY ON VALVE......................................................................................................... 7
3.3.1 –ACTUATOR REPLACEMENT–ASSEMBLY PSL202-214 AMS and PSL 201–214 BASIC ..................... 7
3.3.2 –ACTUATOR REPLACEMENT –ASSEMBLY PSL320-325 AMS PSL320-325 BASIC models on request
................................................................................................................................................................... 9
3.4 –COVER REMOVAL................................................................................................................................ 10
3.5 –“BASIC VERSION” INTERNAL SWITCHES ............................................................................................. 11
3.5.1 –BASIC VERSION” INTERNAL SWITCHES PSL201-214 .................................................................... 11
3.5.1.1 –BASIC VERSION” INTERNAL SWITCHES FORCE / STROKE ......................................................... 11
3.6 - ELECTRICAL POWER SUPPLY................................................................................................................ 12
3.6.1 –“AMS” VERSION WIRING DIAGRAMS .......................................................................................... 12
3.6.2 –“PSL BASIC” VERSION WIRING DIAGRAMS.................................................................................. 13
3.6.3 –“PSL AMS” AC / DC MONOPHASE MAIN POWER SUPPLY .......................................................... 14
3.6.4 –“PSL AMS” AC THREE-PHASE MAIN POWER SUPPLY (on request).............................................. 14
3.6.5 –“PSL BASIC” AC / DC MONOPHASE MAIN POWER SUPPLY ......................................................... 15
3.6.6 –“PSL BASIC” AC THREE-PHASE MAIN POWER SUPPLY (on request)............................................ 15
3.7 –“AMS VERSION” INTERFACES ............................................................................................................. 16
3.7.1 –COMMUNICATION INTERFACES .................................................................................................. 16
3.7.2 –INPUT TERMINALS ....................................................................................................................... 16
3.7.3 –OUTPUT TERMINALS.................................................................................................................... 17
3.8 –“AMS VERSION” ACCESSORIES ........................................................................................................... 18
3.8.1 –ANTI-CONDENSATE RESISTOR (Optional on request).................................................................. 18
3.8.2 –ADDITIONAL LIMIT SWITCH SETTING (Optional on request)....................................................... 18
3.9 –STATUS DISPLAY / COMMISSIONING ELEMENTS................................................................................ 19
3.10 –COVER CLOSURE ............................................................................................................................... 19
3.11 –“AMS SERIES” PRE-COMMISSIONING CONTROL OPERATIONS........................................................ 20

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3.11.1 –“AMS SERIES” LIMITATION IN FINAL POSITION......................................................................... 20
3.12 –“AMS SERIES” FINAL COMMISSIONING - START-UP......................................................................... 20
3.12.1 –AUTOMATIC COMMISSIONING ................................................................................................. 21
3.12.2 –MANUAL COMMISSIONING....................................................................................................... 21
3.13 –“AMS” SERIES STATUS MESSAGES.................................................................................................... 22
3.13.1 –ANOMALY SIGNALLING RELAY................................................................................................... 22
3.13.2 –ERROR INDICATIONS.................................................................................................................. 22
3.14 –MAINTENANCE ................................................................................................................................. 22
3.14.1 –BODY GASKET REPLACEMENT ................................................................................................... 22
3.14.2 –PACKING REPLACEMENT............................................................................................................ 24
3.14.2.1 –VALVES 2000 EP –5000 EP –2100 EP –5100 EP –5800 EP................................................... 24
3.14.2.2 –VALVES 2600 EP –5600 EP –2700 EP –5700 EP.................................................................... 26
3.14.3 –REPLACEMENT OF THE PLUG PROFILE - SOFT SEAL and COMPARTMENT................................ 26
3.12.5 –ACTUATOR MAINTENANCE........................................................................................................ 27
4 OPERATING ANOMALIES............................................................................................................... 27
4.1 –VALVE OPERATING ANOMALIES IN GENERAL..................................................................................... 27
4.2 –“AMS” TYPE OPERATING ANOMALIES - ACTUATOR LIST OF ERRORS ................................................ 28
5 –RISK ANALYSIS................................................................................................................................ 31
6 –ATEX ON REQUEST WITH SPECIAL ACTUATOR EXECUTION ............................................................... 32
7 –LIST OF RECOMMENDED SPARE PARTS............................................................................................ 32
8 –DECLARATIONS OF CONFORMITY ACCORDING TO DECLARATIONS IN FORCE……………………………... 33-37

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1 –GENERAL SAFETY INFORMATION
ATTENTION THIS PRODUCT WAS DESIGNED FOR USE IN THE MANUFACTURING INDUSTRY
WITHOUT MILITARY PURPOSE. IT IS STRICTLY FORBIDDEN TO USE CONFLOW PRODUCTS FOR THE
PRODUCTION OF WEAPONS OF MASS DESTRUCTION. OTHER USES MUST BE APPROVED IN ADVANCE
BY THE MANUFACTURER.
REQUIREMENTS
OF
CONFORMITY
THE IMPORT-EXPORT OF CONFLOW PRODUCTS FROM ONE COUNTRY TO ANOTHER IS REGULATED
BY SAFETY AND TRADE LEGISLATION IN THESE COUNTRIES. BEFORE SENDING THE PRODUCT TO A
THIRD COUNTRY, CHECK THE PRODUCT DOES NOT CONFLICT WITH THE REGULATIONS OF THAT
COUNTRY.
Before installing the valve, remove the plastic guards covering the flanges and the connection couplings.
ATTENTION During commissioning of the valve or during operation, do not touch the body which could conduct heat
if the fluid used is at high temperature.
ATTENTION During operation, do not touch the stem as it is in movement, it may be hot and could catch your finger
or clothing.
ATTENTION During operation, do not touch the motor, the surface temperature of the motor could rise and therefore
could cause abrasion.
ATTENTION Before starting any maintenance operations, ensure the valve is not pressurised and/or hot.
ATTENTION Do not remove the descriptive label fastened to the yoke since it reports the serial number, data which
is indispensable for tracking the valve over time.
Please refer to this number for supply of spare parts
Do not remove the stroke label which is the main reference for valve calibration
ATTENTION The electrical actuator must be handled solely and exclusively by competent and authorised staff
ATTENTION Before removing the cover of the actuator, ensure the main power supply is disabled, preventing any
possible involuntary removal. The live areas must be isolated before starting to work.
ATTENTION Ensure the actuator always works in optimal conditions, any damage or error and change of operating
characteristics, which may regard safety, must be notified.
Non-compliance with the main safety information, the standards in force and the assembly instructions can:
Cause danger for the safety of those carrying out manoeuvres or for third parties.
Damage the valve or adjacent objects.
Compromise the efficient operation of the valve.
2 - GENERAL ASSEMBLY INSTRUCTIONS
2.1 –ASSEMBLY ON THE SYSTEM (GENERAL NOTES)
Before assembling the valve, accurately clean the tubing with compressed air, water or another blowing fluid to eliminate foreign bodies,
welding waste and various dirt that could damage the sealing surfaces of the valve.
ATTENTION Assemble the valve with the direction arrow imprinted on the body in the same direction as the tubing
fluid.
Assembly is however recommended of a “Y” filter (our “FY” series) on the tubing, upstream of the valve.
Assembly of the valve can be carried out in the vertical or horizontal position, see Figure 1, page 4. You are however advised to
assemble vertically to prevent wear of the trim due to the weight and relevant rubbing.
ATTENTION It is forbidden to weigh the valve down with foreign objects. It is compulsory to protect the valve from
external stress.
ATTENTION The PSL-AMS actuators can work at ambient temperatures between
–20 / + 60 °C. The operating modes correspond to DIN EN 60034:-1:S2 for the short cycle and S4 for the standard
operations. The degree of protection is IP65, IP67 on request, in compliance with standard EN 60529
ATTENTION During installation of the valve, leave sufficient space to allow recover of the cover, see Fig.2

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ATTENTION
EXTERNAL USE
When using the actuators
in environments with
temperature fluctuations
or high humidity, you are
advised to use an anti-
condensate resistor as
well as a higher degree of
protection (optional
accessories).
3 –ELECTRIC VALVES TYPE 2000 EP –2100 EP –2600 EP –2700 EP –5000 EP -5100 EP –5600 EP
–5700 EP –5800 EP
PSL202-204 AMS
PSL210-214 AMS
(Stroke 50)
PSL320-325AMS ON REQUEST
Figure 2: Dimensions mm –AMS Version
90°
90
°
Figure 1: Installation position

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3.1 –COMMISSIONING (GENERAL NOTES)
The valves are supplied calibrated and tested, ready to work in the conditions requested by the client during the order phase. Having
ensured all warnings have been respected, slowly open the shut-off valves upstream and downstream of the valve.
THE PACKING IS MAINTENANCE-FREE.
ATTENTION After the first working hour, check tightening of the nuts on the body unit according to the “Nut tightening
forces” table
ATTENTION Comply with the values in the “Nut tightening forces” table each time maintenance operations are carried
out.
ATTENTION If the valve is equipped with a BELLOWS seal, never rotate the stem for any reason. A possible wrong
manoeuvre could cause torsion and breakage of the bellows.
3.2 –ELECTRIC VALVES COMMISSIONING
The PSL-AMS actuators were designed as valve electrical actuators. The actuator is assembled on the value using small columns.
The mechanical power is generated by a 24 volt DC motor, which is controlled electronically using pulse width modulation (PWM). The
motor torque is transmitted from a series of cylindrical gears to a trapezoidal screw. The screw converts the torque produced into an
axial force with a screw drive. The vertical linear movement of the screw drive is self-locking and is transmitted by a connection joint to
the valve stem.
When no voltage is present or for calibration works, the actuator canbe activated in emergency mode using the handwheel (see 3.2.1),
except when the PSCP fail-safe unit is used.
PSL201-204
PSL210
PSL214
PSL320-330 ON REQUEST
Figure 3: Dimensions mm –Basic Version

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NUT TIGHTENING FORCES table
ATTENTION Always comply with the tightening valves on each maintenance
DN
NUT DESIGNATION
KEY SIZE
Nm
15-20
M8
No. 4
13
15-20
25 –32
M8
No. 6
13
15-20
40 –50
M12
No. 6
19
25-30
65-80
M16
No. 6
24
55-60
100
M16
No. 8
24
70-80
125
M16
No. 10
24
Spiral wound
60-65
PTFE
65-70
150
M20
No. 10
30
Spiral wound
60-70
PTFE
70-75
200
M20
No. 12
30
Spiral wound
60-70
PTFE
70-75
3.2.1 –ELECTRIC VALVES WITH HANDWHEEL COMMISSIONING –MANUAL FUNCTION
The handwheel is used to activate the actuator in the event of no voltage or during installation works such as assembly of the valve or
setting of the limit positions.
ATTENTION The handwheel is permanently engaged and rotates during operation of the motor in the series devices
of the PSL202-214 and BASIC version.
ATTENTION Do not exceed the electrical limit switch setting using the handwheel.
The mechanical limits must be correctly set.
If these instructions are not observed, damage or malfunctions of the actuator can occur.
Do not activate the handwheel using excessive force. If these instructions are not observed, damage or malfunctions of
the actuator can occur.
ATTENTION The actuators on request PSL320-325 AMS and BASIC version have a handwheel that must be
manually engaged, the button on the cover must be pressed to engage the handwheel.
PSL202-204 AMS
PSL201-204 BASIC
PSL210-214
AMS and BASIC
PSL210-214
PSL320-325 AMS and BASIC
ON REQUEST
Figure 3: Manual operation:

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3.2.2 –ELECTRIC VALVES WITH LUBRICATOR COMMISSIONING ASSEMBLED ON BONNET
During automatic operation, the lubricator must remain closed, turn the handwheel clockwise ref. 7
To grease the packing, proceed as follows: Close the main plug with the handwheel ref. 7
Unscrew the handwheel of the loader ref. 5, load with grease, screw back in the handwheel ref. 5 only by a few rotations.
Open the main plug using the handwheel ref. 7, screw in the handwheel ref. 5 after loading the grease inside the packing and close
the main packing again using the handwheel ref. 7. The greasing operation is recommended every 600 working hours or when the
stem moves in a linear manner.
You are advised to use anti-seize, molybdenum disulphide grease for temperatures > 200 °C
3.3 –ACTUATOR ASSEMBLY ON VALVE
The valves are supplied calibrated and tested, ready to work with the actuator assembled in the conditions requested by the client
during the order phase.
3.3.1 –ACTUATOR REPLACEMENT–ASSEMBLY PSL202-214 AMS and PSL 201–214 BASIC
The images below show assembly of a PSL 204 AMS actuator (also valid for version PSL204), the passages are however identical to
those of the types of actuators.
ATTENTION While assembling the actuator on the valve, use the handwheel and do not electrically activate the
actuator, if these instructions are not complied with, damage may be caused to people and the actuator and/or valve.
Small columns
Locking screw for
spring pack
Valve stem
Tightening nut
Joint
Flange

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1
2
3
Ensure the coupling joint can be screwed
in by hand
Manually move the coupling to the upper
end
Place the actuator on the valve
The small columns are screwed in with
hexagon socket head cap screws inserted
under the flange
4
With the stem downwards, move the coupling until the stem touches the valve.
Screw in the joint for 12 mm on stems M10 and 16 mm for stems M14
5
6
Fasten the coupling joint
Tighten the locking screws crossways with 8 Nm force.

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3.3.2 –ACTUATOR REPLACEMENT –ASSEMBLY PSL320-325 AMS PSL320-325 BASIC models on request
ATTENTION While assembling the actuator on the valve, use the handwheel and do not electrically activate the
actuator, if these instructions are not complied with, damage may be caused to people and the actuator and/or valve.
Observe the following passages for actuator assembly:
Unscrew the rotary nut (item 8) from the screw drive (item 1) and move it towards the stem of the valve (item 7).
The coupling joint must adapt to the valve stem.
Move or unscrew the coupling joint (item 3) on the valve stem and fasten to the valve stem. Secure
the coupling joint using a counter a counter-nut (item 2).
Move the valve stem with the coupling joint and the Belleville washers (item 9) in the screw drive,
screwing the rotary nut on the bottom using the cross key supplied.
Move the small columns (item 10) into the holes of the assembly flange and screw in with the locking screws.
ATTENTION Before the locking screws are screwed in, ensure the columns are completely inserted in the holes of
the assembly flange. If necessary, correct the position of the actuator using the handwheel. If these instructions are not
carried out, they may cause personal injuries or damage the valve.
Figure 4: Actuator assembly on the valve
1
=
screw drive
2
=
fastening with counter-nut
3
=
coupling joint
4
=
fastening plate
5
=
locking nut
6
=
valve body
7
=
valve stem
8
=
rotating nut
9
=
Belleville washers
10
=
small assembly columns