GRUNDFOS ALLDOS 525 User manual

15.750045-V3.0
Pressure Loading Valve 525
Operation Manual
Read this manual completely and keep it!
No warranty in case of damages caused by incorrect operation.
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Imprint
Pressure Loading Valve 525
Operation Manual
Version 3.0
Publisher
ALLDOS Eichler GmbH
Reetzstraße 85 • 76327 Pfinztal (Söllingen)
Postfach 1160 • 76317 Pfinztal
Germany
Tel. [phone] / Fax. [phone]
Mail: [e-mail]
Internet: www.alldos.com
© 2007 by ALLDOS Eichler GmbH
Subject to change.
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Content
Imprint............................................................................................. 2
1 General ........................................................................................... 4
1.1 Introduction ......................................................................................4
1.2 Using this Paper ..............................................................................4
1.3 Warranty ..........................................................................................4
2 Safety Instructions .......................................................................... 4
2.1 Application of the Product ................................................................4
2.2 Obligations of the Operating Authority .............................................4
2.3 Averting Dangers .............................................................................5
3 General description ........................................................................ 5
3.1 Function ...........................................................................................5
3.2 Ambient and Operating Conditions ..................................................5
3.3 Admissible Media ............................................................................5
4 Technical Data ................................................................................ 6
4.1 Pressure Loading Valves DN 4 and DN 8 .......................................6
4.2 Pressure Loading Valves DN 20 .....................................................8
4.3 Pressure Loading Valves DN 32 ...................................................10
4.4 Pressure Loading Valves DN 50 and DN 65 .................................12
5 Installation .................................................................................... 13
5.1 Picture of optimal installation: ........................................................14
5.2 Connections ...................................................................................14
6 Setting of Opening Pressure ........................................................ 15
6.1 General ..........................................................................................15
6.2 Setting Instructions for Opening Pressure .....................................16
7 Possible Faults ............................................................................. 16
8 Maintenance ................................................................................. 17
8.1 Intervals for Cleaning and Maintenance ........................................17
8.2 Replacing the Diaphragm ..............................................................17
9 Spare Parts and Accessories ....................................................... 17
9.1 Adapter for installation directly on the pump .................................17
9.2 Set of counter flanges for Pressure Loading Valves DN 32
and DN 65 .....................................................................................18
9.3 Spare Parts for Pressure Loading Valves .....................................18
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1 General
1.1 Introduction
This operation manual contains all the information required for starting up and handling
the described pressure loading valves.
If you require further information or if any problems arise, which are not discussed in
detail in this operation manual, contact ALLDOS directly for the information needed.
1.2 Using this Paper
The headings WARNING,CAUTION and NOTE have the following meaning:
!
Warning
Danger of injuries and accidents!
Caution
Danger of incorrect operation or damage to the product!
Note
There is an exceptional feature.
1.3 Warranty
Warranty in accordance with our general terms of sale and delivery shall only be valid, if:
• the product is used according to the information within this paper,
• the product is not being opened or used improperly,
• maintenance and repair is implemented exclusively by authorized and qualified per-
sonnel,
• original spare parts are used for repairs.
The safety instructions specified in this document must be observed at all times!
2 Safety Instructions
The component has left the factory in a safe error-free state. In order to maintain this state
and ensure safe operation, the user most observe the instructions and warning notes
provided in this technical information.
If safe operation is no longer possible, the component must be shut down and secured
against unintentional operation. This is the case:
• If the component is visibly damaged
• If the component no longer seems operational
• Following long periods of storage under unfavourable conditions
2.1 Application of the Product
The pressure loading valve described here is used to maintain the required
counterpressure for the pump, if insufficient counterpressure is available in the system or
open outflow is specified.
!
Warning
Other applications are not intended and are not permitted. ALLDOS Eichler GmbH
accept no responsibility for damages caused by unintended use.
2.2 Obligations of the Operating Authority
The operating authority of the plant is responsible for
• instructing the operation personnel
• arranging regular maintenance
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2.3 Averting Dangers
!
Warning
When dosing dangerous media, observe the corresponding safety precautions!
!
Warning
Please observe the chemical resistance of dosing media with regard to materials.
!
Warning
Wear protective gloves and glasses when executing work at the connections or
lines!
!
Warning
Only use the prescribed line types!
Repair only by authorized personnel!
3 General description
3.1 Function
The pressure loading valve keeps the pump's backpressure constant. The valve opens
and the liquid is dosed, if the pressure exceeds the opening pressure adjusted at the
valve.
3.2 Ambient and Operating Conditions
3.3 Admissible Media
Admissible Mediatemperaturer
!
Warning
Pressure loading valves must not be used for abrasive or crystallizing media.
!
Warning
Pressure loading valves are not absolutely tight. When dosing dangerous sub-
stances take appropriate protective measures!
Additional information with regard to the medium, medium temperature and operating
pressure is available on request.
Admissible storage
temperature
20 °C to +50 °C
Admissible ambient
temperature
0 °C to +40 °C
(at an installation height of up to 1000 m above sea level)
Admissible humidity rel. humidity: 70% at 40 °C, 90% at 35 °C
Pressure range
Material until 10 bar
1.4571 -10 °C to 40 °C
PVC 0 °C to 40 °C
PP 0 °C to 40 °C
PVDF -10 °C to 40 °C *
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4 Technical Data
4.1 Pressure Loading Valves DN 4 and DN 8
Order No. Nominal
width
Pressure
release
Valve
body Gasket Hose type Pipe Connection Image
525-0565 4 3 PP Viton PE-SL4/6 G 5/8" 1
525-0565.1 4 3 PP EPDM PE-SL4/6 G 5/8" 1
525-0566.1 4 3 PVDF PTFE RO4/6" G 5/8" 2
525-0567 4
83 PVC Viton PE-SL4/6
PVC-SL6/12 RO10/12" G 5/8" 1
525-0567.1 4
83 PVC EPDM PE-SL4/6
PVC-SL6/12 RO10/12" G 5/8" 1
525-0567.2 4
83 PVC PTFE PE-SL4/6
PVC-SL6/12 RO10/12" G 5/8" 1
525-0570 4 3 1.4571 RO4/6" G 1/4" 5
525-0573 4 3 PP EPDM PE-SL5/8 G 5/8" 1
525-0600 4 3 1.4571 RO4/6" G 1/4" 4
525-0608 4 3 PTFE Viton GL 18" -
525-3173
4
8 3 PP Viton
PE-SL4/6
PE-SL6/9
PE-SL9/12
G 5/8" 1
525-3173.1
4
8 3 PP EPDM
PE-SL4/6
PE-SL6/9
PE-SL9/12
G 5/8" 1
525-3174
4
83 PVC Viton
PE-SL4/6
PE-SL6/9
PE-SL9/12
PVC-SL6/12
RO10/12" G 5/8" 1
525-3174.1
4
8 3 PVC EPDM
PE-SL4/6
PE-SL6/9
PE-SL9/12
RO10/12" G 5/8" 1
525-0563 8 3 PP EPDM PE-SL9/12 G 5/8" 1
525-0568 8 3 PP Viton RO12/16" G 5/8" 3
525-0568.1 8 3 PP EPDM RO12/16" G 5/8" 3
525-0569.1 8 3 PVDF PTFE RO12/16" G 5/8" 3
525-0571 8 3 1.4571 RO1/4" G 1/4" 6
525-1565.1 8 3 PP EPDM PVC-SL6/12 G 5/8" 1
525-3177 8 3 PVDF PTFE PE-SL6/9 G 5/8" 1
Drilling scheme for Images 1-4
Image 1
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Image 2
Image 3
Image 4
Drilling scheme for Images 5 and 6
Image 5
Image 6
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4.2 Pressure Loading Valves DN 20
Order No. Nominal
width
Pressure
release
Valve
body Gasket L Hose type Pipe Connection Image
525-1113 20 3 PVC Viton 149 PVC-SL13/20 RO20/25 G 11/4" 7
525-1113.01 20 3 PVC Viton 149 PVC-SL19/27 G 11/4" 8
525-1113.1 20 3 PVC EPDM 149 PVC-SL13/20 RO20/25 G 11/4" 7
525-1113.11 20 3 PVC EPDM 149 PVC-SL19/27 G 11/4" 8
525-1113.21 20 3 PVC PTFE 149 PVC-SL19/27 G 11/4" 8
525-1163 20 3 PP Viton 152,5 RO20/25 G 11/4" 7
525-1163.01 20 3 PP Viton 152,5 PVC-SL19/27 G 11/4" 8
525-1163.1 20 3 PP EPDM 152,5 RO20/25 G 11/4" 7
525-1163.11 20 3 PP EPDM 152,5 PVC-SL19/27 G 11/4" 8
525-1183.1 20 3 PVDF PTFE 145,5 RO20/25 G 11/4" 7
525-2133 20 3 1.4571 - G3/4 10
525-4113 20 3 PVC Viton 149 3/4" NPT 9
Drilling scheme
Image 7
B A
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Image 8
Image 9
Image 10
B A
A
B
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4.3 Pressure Loading Valves DN 32
* With insertion section for pipe 32/40 in PP and also in PVDF
Order No. Nominal
width
Pressure
release
Valve
body Gasket L Pipe Connection Image
525-1173 32 3 PP Viton 229 RO32/40" flange DN32 12
525-1173.01 32 3 PP Viton 205 RO32/40" G 2" 13
525-1173.1 32 3 PP EPDM 229 flange DN32 12
525-1173.11 32 3 PP EPDM 205 RO32/40" G 2" 13
525-1223 32 3 PVC Viton 205 RO32/40" G 2" 11
525-1223.1 32 3 PVC EPDM 205 RO32/40" G 2" 11
525-1243 32 3 PVC Viton 229 flange DN32 12
525-1243.1 32 3 PVC EPDM 229 flange DN32 12
525-2233 32 3 1.4571 - G 11/4" 14
525-2243 32 3 1.4571 PVC ? flange DN32/G 11/4" 15
525-2403 32 3 PVDF PTFE 229 RO32/40" flange DN32 12
Drilling scheme
Image 11
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Image 12
Image 13
Image 14
A
B
A
B
BA
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4.4 Pressure Loading Valves DN 50 and DN 65
Image 15
A
B
Order No. Nominal
width
Pressure
release Valve body Gasket L Connection Image
525-2363 50 2,2 PP Viton 264 flange DN50 17
525-0610 65 1,5 PVC Viton 266 flange DN65 17
525-0611 65 1,5 PVC EPDM 266 flange DN65 17
525-0612 65 1,5 PP Viton 326 flange DN65 17
525-0613 65 1,5 1.4571 PVC-
WEICH - flange DN65 16
Drilling scheme for Image 16
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5 Installation
!
Warning
The installation must only be carried out by authorized specialists!
!
Warning
When dosing dangerous media, always refer to the corresponding safety data
sheets!
!
Warning
Wear protective gloves and glasses when executing work at the connections or
lines!
Image 16
Image 17
L
A
B
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5.1 Picture of optimal installation:
5.2 Connections
The pressure loading valves have an input (A) and an output on the pressure side (B).
They are installed in the pressure line.
Pressure loading valves DN4 and DN8 can also be mounted directly on the pressure
valve for the dosing pump with an optional adapter (D) (for the adapter for pump
installation, see section ’spare parts and accessories’).
!
Warning
During installation, observe the flow direction of the dosing line. (Direction arrow
on valve housing)
Caution
When using a pressure loading valve in conjunction with a pulsation damper, the
pressure loading valve must be installed after the pulsation damper.
Note
It is recommended that the pressure loading valve is installed directly in front of
the addition point in the dosing line.
For direct pump installation, the line connected to the injection unit should be as
short as possible.
1Dosing tank
2Electric agitator
3Extraction device
4Suction pulsation damper
5Dosing pump
6Overflow valve
7Pressure loading valve
8Pulsation damper
9Measuring glass
10 Injection unit
1
2
3
45
6
7
9
10
8
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.
For line installation
1. Connect the pressure line from the dosing head to the input (A).
2. Connect the outgoing pressure line to the output on the pressure side (B).
For installation directly on the pump
1. Remove connection from the input (A).
2. Screw the adapter (D) for pump installation onto the input (A) and onto the pressure
valve for the pump.
3. Connect the outgoing pressure line to the output on the pressure side (B).
!
Warning
Danger of injuries! Never operate the pump if the line is not correctly connected to
the pressure loading valve.
4. After 48 operating hours, tighten the screws on the upper part of the valve.
Max. torque: :
6 Setting of Opening Pressure
6.1 General
The opening pressure can only be set if a manometer is installed in the system between
the pump and the pressure loading valve.
!
Warning
Settings on the pressure loading valve must only be carried out by authorized spe-
cialists!
The opening pressure of the pressure loading valve is set in the factory to the value spec-
ified in the technical data. The opening pressure during operation depends on various fac-
tors, e.g. the flow, the stroke frequency of the pump, or the back-pressure. If an exact
setting is required, the pressure loading valve must be adapted to the local conditions.
The opening pressure must only be set to values below the maximum permissible opera-
ting pressure.
A
B
D
DN4 2Nm
DN8
DN20 5Nm
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!
Warning
Danger of injury! Never set the opening pressure higher than the maximum permis-
sible operating pressure of the dosing system and dosing pump.
!
Warning
When dosing dangerous media, always refer to the corresponding safety data
sheets! Wear protective clothing (goggles, gloves) when working on the connec-
tions and lines!
Caution
The pressure loading valve does not function as a shut-off valve. Therefore, the
adjusting screw must not be tightened too far.
6.2 Setting Instructions for Opening Pressure
7 Possible Faults
Proceed as follows if the factory-set pressure is to be changed:
With the pump running:
1. Remove the cap from the top part of the pressure loading valve.
2. Read the current opening pressure on the manometer.
3. For DN4 and DN8 use a hexagon wrench,
for DN20 - DN65 use a pair of needle-nose pliers:
• in the clockwise direction to increase the pressure
• in the counterclockwise direction to reduce the pressure
until the desired opening pressure is set.
4. Attach the cap again.
Fault Cause Elimination
pressure loading
valve set incorrectly
(too low)
Set pressure loading
valve to a higher
opening pressure
Diaphragm faulty Replace diaphragm
Contamination Clean pressure
loading valve
pressure loading
valve produces
no backpressure
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8 Maintenance
!
Warning
When dosing dangerous media, always refer to the corresponding safety data
sheets!
Wear protective clothing (goggles, gloves) when working on the connections and
lines!
Maintenance must only be carried out by authorized specialists!
8.1 Intervals for Cleaning and Maintenance
• at least every 12 months or after 8000 operating hours or
• should faults occur.
Clean the pressure loading valve, and replace the diaphragm and O-rings if necessary.
Spare parts-> see section ’spare parts and accessories’
8.2 Replacing the Diaphragm
1. Shut down the dosing system.
2. Make it impossible for a return flow or overpressure to occur.
3. Loosen the 4 screws on the top part of the pressure loading valve.
4. Remove top part of pressure loading valve.
5. Remove the diaphragm.
6. Insert new diaphragm.
7. Return top part of pressure loading valve and tighten screws diagonally.
Max. torque: :
8. Start up the dosing system again.
9. Tighten the screws on the top part of the pressure loading valve again after 48 hours
of operation.
Max. torque: :
9 Spare Parts and Accessories
9.1 Adapter for installation directly on the pump
* not suitable for pumps with Plus3 System
DN4 2Nm
DN8
DN20 5Nm
DN4 2Nm
DN8
DN20 5Nm
Order No.
Nominal
width Material
Connection
(pump-valve)
529-057 DN 4 PVC 3/8“ an 5/8“
529-058 DN 4 1.4571 3/8“ an 1/4“
529-062 DN 4 PP 3/8“ an 5/8“
529-064 DN 4 PVDF 3/8“ an 5/8“
529-059 DN 8 1.4571 5/8“ an 1/4“
529-061 DN 8 PVC 5/8“ an 5/8“
529-063 DN 8 PP 5/8“ an 5/8“
529-065 DN 8 PVDF 5/8“ an 5/8“
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9.2 Set of counter flanges for Pressure Loading Valves DN 32 and DN 65
9.3 Spare Parts for Pressure Loading Valves
Spare parts - Order No.
Order No.
Nominal
width Material Description
529-412 DN 32 V4A
Consisting of lapped flange, headed bush, screws,
collars and nuts
529-417 DN 32 PVC
529-420 DN 32 PVDF
529-443 DN 65 PVC
529-444 DN 65 PP
529-421 DN 32 PP Consisting of welding neck flange, flat gasket,
screws, collars and nuts
529-445 DN 65 V4A Consisting of welding neck flange, screws, collars
and nuts
Pressure
loading valve
Nominal
width Diaphragm O-rings Amount
Pressure
springr Adjusting screw
525-0565 4 10.6243-401 52.105-2 2 10.6247 10.6490-400
525-0565.1 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-0566.1 4 10.6243-401 52.344 2 10.6247 10.6490-400
525-0567 4 10.6243-401 52.105-2 2 10.6247 10.6490-400
525-0567.1 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-0567.2 4 10.6243-401 52.344 2 10.6247 10.6490-400
525-0570 4 10.6243-401 - - 10.6251 10.6490-400
525-0573 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-0600 4 10.6243-401 - 2 10.6247 10.6490-401
525-0608 4 10.6243-401 52.183 2 10.6247 10.6490-401
525-3173 4 10.6243-401 52.105-2 2 10.6247 10.6490-400
525-3173.1 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-3174 4 10.6243-401 52.150-2 2 10.6247 10.6490-400
525-3174.1 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-0563 4 10.6243-401 52.105-1 2 10.6247 10.6490-400
525-0568 8 10.6243-401 52.105-2 2 10.6247 10.6490-400
525-0569.1 8 10.6243-401 52.344 2 10.6247 10.6490-400
525-0571 8 10.6243-401 - - 10.6251 10.6490-400
525-1565.1 8 10.6243-401 52.105-1 2 10.6251 10.6490-400
525-3177 8 10.6243-401 52.344 2 10.6251 10.6490-400
525-0568.1 10 10.6243-401 52.105-1 2 10.2663 10.6490-400
525-1113 20 10.6243-402 52.141 2 10.6251 10.2617-41
525-1113.01 20 10.6243-402 52.141 2 10.6251 10.2617-41
525-1113.1 20 10.6243-402 52.141-1 2 10.6251 10.2617-41
525-1113.11 20 10.6243-402 52.141-1 2 10.6251 10.2617-41
525-1113.21 20 10.6243-402 52.141-2 2 10.6251 10.2617-41
525-1163 20 10.6243-402 52.141 2 10.6251 10.2617-41
525-1163.01 20 10.6243-402 52.141 2 10.6251 10.2617-41
525-1163.1 20 10.6243-402 52.141-1 2 10.6251 10.2617-41
525-1163.11 20 10.6243-402 52.141-1 2 10.6251 10.2617-41
525-1183.1 20 10.6243-402 52.141-2 2 10.6251 10.2617-41
525-2133 20 10.6243-402 - - 10.6251 10.2617-41
525-4113 20 10.6243-402 52.141 2 10.6251 10.2617-41
525-1173 32 10.6243-403 52.202 2 10.2663 10.2664-41
525-1173.01 32 10.6243-402 52.202 2 10.2663 10.2664-41
525-1173.1 32 10.6243-402 52.261 2 10.2663 10.2664-41
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525-1173.11 32 10.6243-402 52.261 2 10.2663 10.2664-41
525-1223 32 10.6243-402 52.154-2 2 10.2663 10.2664-41
525-1223.1 32 10.6243-402 52.393 2 10.2663 10.2664-41
525-1243 32 10.6243-402 52.202 2 10.2663 10.2664-41
525-1243.1 32 10.6243-402 52.261 2 10.2663 10.2664-41
525-2233 32 10.6243-402 - 1 10.2663 10.2664-41
525-2243 32 10.6243-402 - 1 10.2663 10.2664-41
525-2403 32 10.6243-402 52.422 2 10.2663 10.2664-41
525-0610 65 - 52.260 2 - -
525-0611 65 - 52.259 2 - -
525-0612 65 - 52.260 2 - -
525-0613 65 10.1572-41 54.020-4 1 10.3361 10.3349-402
Pressure
loading valve
Nominal
width Diaphragm O-rings Amount
Pressure
springr Adjusting screw
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