Nor-Cal Products Intellisys TBV-D User manual

Throttling Butterfly Valves
Nor-Cal Products, Inc.
1967 South Oregon St.
Yreka, CA 96097, USA
Tel: [phone]
Fax: [phone]
www.n-c.com
In Europe
2 Charlton Business Park
Crudwell Road, Malmesbury
Wiltshire SN16 9RU, UK
Tel: [phone]
Fax: [phone]
TBV-OP-LIT 01/04
TBV-D, TBV-G,
for Throttling Butterfly Valves
TBV-IQA and TBV-IQD
for Throttling Butterfly IQ Valves
UVD90-G
for Universal Valve Drives
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INTELLISYS THROTTLING BUTTERFLY VALVES
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Contact Nor-Cal Products
Intellisys Customer Support
at 800-824-4166 ext. 186
or visit our website
at www.n-c.com
List of Figures
2.1.1 ..............Dimension call-outs for standard TBV-series products ........................................................................... 6
2.2.1 ..............Dimension call-outs for standard TBV-IQX-series products.................................................................... 7
4.1 .................Typical installation and configuration of a TBV-series control valve ........................................................ 9
A-I.I ...............Installation of a NW-type TBV valve .................................................................................................... 11
A-I.II ..............Installation of an ISO-type TBV valve with OF-style adjoining flanges................................................... 11
A-I.III ..............Installation of an ISO-type TBV valve with N-style adjoining flanges..................................................... 11
List of Tables
2.0.1 ..............General equipment specifications ........................................................................................................ 5
2.0.2 ..............TBV reliability........................................................................................................................................ 5
2.1.1 ..............TBV-series dimensions, torque and weight specifications...................................................................... 6
2.2.1 ..............TBV-IQ-series dimensions, torque and weight specifications ................................................................. 7
5.1 .................Recommended TBV-series preventive maintenance actions and intervals............................................ 10
5.2 .................Possible failure modes and recommended actions.............................................................................. 10
A-I.I ...............Installation hardware, NW flanges...................................................................................................... 11
A-I.II ..............Installation hardware, ISO “OF” style flanges...................................................................................... 11
A-I.III ..............Installation hardware, ISO “N” style flanges........................................................................................ 11
A-II.I ..............TBV spare parts .................................................................................................................................. 12
A-II.II ..............TBV and APC cable assemblies and accessories................................................................................... 12
A-II.III .............NW Installation Hardware .................................................................................................................. 13
A-II.IV ............ISO Installation Hardware ................................................................................................................... 13
Table of Contents
1.0 .................Introduction......................................................................................................................................... 4
2.0 .................Device specification - General............................................................................................................... 5
2.1 ............Device specification - TBV series valves.................................................................................................. 6
2.2 ............Device specification - TBV-IQ series valves ............................................................................................. 7
3.0 .................Unpacking and installation................................................................................................................... 8
4.0 .................Theory of operation.............................................................................................................................. 9
5.0 .................Product support ................................................................................................................................. 10
Appendix I .....Installation hardware.......................................................................................................................... 11
Appendix II ....Valve, spare parts and cable assembly ordering information................................................................ 12
Appendix II.I ..TBV heater jackets and accessory ordering information ...................................................................... 13
Appendix III ...Limited warranty and intellectual property coverage........................................................................... 14
Information in this manual is subject to change without notice.
Global Sales and Service
Nor-Cal Products maintains sales and
service centers in over 30 countries worldwide.
Please visit our website at www.n-c.com to
find the center nearest you.
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1.0 - Introduction
NOTE: Calls attention to helpful tips about proper
installation, maintenance or use of the controller.
CAUTION: Highlights areas of concern that, if overlooked, could
result in damage to the controller or surrounding equipment.
WARNING: Alerts the installation, operating or maintenance
personnel of hazardous aspects of the controller, which, if
ignored could result in serious personal injury or death.
Important Personnel Safety and Product Protection Information
Throughout this manual, information that is of particular importance to the installation, the safety of
operating personnel and the protection of equipment are highlighted by the following three symbols.
The WARNING symbol is also used on the equipment wherever necessary.
Thank you for purchasing a new Intellisys™ TBV- and TBV-IQ- series throttling butterfly valve or UVD-series universal valve driver from Nor-Cal Products.
Before installing and operating the product, please read this manual thoroughly as it contains critical hook-up and operating tips. If you encounter any
problems, or if you have any questions, please contact our Intellisys Customer Service Support at [phone] x186 or visit our web site at www.n-c.com.
Nor-Cal Products’ TBV-series butterfly valves and UVDs are designed for downstream pressure control over a wide range of vacuum control applications
in conjunction with an APC-series buried box or IQ-series on-valve controller module. The TBV or UVD cannot be operated by other manufacturers’
valve controllers. All interface and communications connections are made directly to the controller module that, in turn, provides power and position
signals to the valve motor. Used with a controller module and the inputs from one or two pressure gauges the TBV-series butterfly valve forms an
integral part of a complete downstream pressure control system.
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2.0 - Device Specification - General
The following figures and tables summarize specifications of the TBV-series product. UVD-series products share the specifications except those that are marked
by an asterisk (*).
TABLE 2.0.1 –GENERAL EQUIPMENT SPECIFICATIONS
FEATURE SPECIFICATION
* Dimensions Refer to Figures 2.1 and 2.2, as well as Tables 2.3 and 2.4
* Weight, in lbs (kg) Refer to Tables 2.3 and 2.4
Rated Input 2A, 2.25Ω (only to be operated by Nor-Cal Products APC controller models)
Rated Output Torque Refer to Tables 2.3 and 2.4
Actuation Speed 125 msec open to closed for direct drive valves (-D)
250 msec open to closed for gear driven valves (-G)
Position Resolution 1:204,800 steps (equivalent to 1.6 arc seconds) for direct drive valves. Finer resolution for gear driven valves,
depending on the exact gear ratio.
* Leak Rate 1 × 10-9 atm·scc/sec He
* Allowable Plate Differential Pressure 15 psi (103.4 kPa)
* Heating Capabilities
Body can be heated up to 392ºF (200ºC) with optional heater kits. Note that certain other components such as the
Viton seals and motor-to-valve coupling may need to be replaced with alternate materials when the temperature
exceeds 248ºF (120ºC).
Protection Class I
Degree of Protection (IP) X0
Laser Class 1 (LED’s)
Certifications CE Standard for Process Equipment including EMC Directive 89/336/EC and Machinery Directive 89/392/EEC
Maximum Altitude 6562 ft (2000 m)
Allowable Ambient Operating Temperature 32ºF – 122ºF (0ºC - 50ºC)
Allowable Ambient Humidity 0 – 95% non-condensing
Installation Clearance For IQ-series TBVs and UVDs 3” (75 mm) is required on all perforated sides. Otherwise, a minimum
of 3 1/2” (90 mm) is needed on top to allow for connector(s).
*Not applicable to UVD-series products
TABLE 2.0.2 – TBV RELIABILITY
SPECIFICATION COMMENTS
* MTBF > 2 million cycles or > 11,500 hours Processes with large amounts of effluent contamination or highly aggressive chemistries may reduce the MTBF due to
condensation on moving parts and/or O-ring degradation.
* Warranty 1 year
*Not applicable to UVD-series products
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TBV-OP-LIT 01/04
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B
2.42
2.58
3.23
1.91 1.28
6.20
C
A
.18
D
2.42
2.58
3.23
4.56
C
A
B
.18
D
1.91 1.28
TABLE 2.1.1 – TBV SERIES DIMENSION, TORQUE AND WEIGHT SPECIFICATIONS (REFER TO FIGURE 2.1.1)
FLANGE
TYPE
NOM.
ID
ACTUAL ID
D A
DIAMETER
B
DIRECT DRIVE
C
GEAR DRIVE
C
MAX. TORQUE
IN-OZ (N-M)
WEIGHT
LBS (KG)
NW-25 1 0.87 (22.1) 2.25 (57.2) 2.75 (69.9) 6.58 (167) - 280 (1.98) 5.5 (2.5)
NW-40 11/21.39 (35.3) 2.25 (57.2) 2.75 (69.9) 6.58 (167) - 280 (1.98) 5.3 (2.4)
NW-50 2 1.98 (50.3) 2.00 (50.8) 3.36 (85.3) 6.89 (175) - 280 (1.98) 5.5 (2.5)
ISO-63 21/22.44 (62.0) 1.00 (25.4) 5.12 (130) 7.34 (186) - 280 (1.98) 7.5 (3.4)
ISO-80 3 2.94 (74.7) 1.00 (25.4) 5.71 (145) 7.66 (196) - 280 (1.98) 8.8 (4.0)
ISO-100 4 3.85 (97.8) 1.00 (25.4) 6.50 (165) 8.09 (205) - 280 (1.98) 9.5 (4.3)
ISO-160 6 5.87 (149) 1.62 (41.3) 8.90 (226) - 10.50 (267) 2100 (14.8) 21.8 (9.9)
ISO-200 8 7.88 (200) 1.62 (41.3) 11.20 (284) - 12.46 (316) 2100 (14.8) 28.5 (12.9)
ISO-250 10 9.88 (251) 1.62 (41.3) 13.19 (335) - 13.46 (342) 2100 (14.8) 38.0 (17.3)
FIGURE 2.1.1 – DIMENSION CALL-OUTS FOR STANDARD TBV-SERIES PRODUCTS (CROSS-REFERENCE TO TABLE 2.1.1)
2.1 - Device Specification - TBV Series Valves
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FIGURE 2.2.1 – DIMENSION CALL-OUTS FOR TBV-IQ SERIES PRODUCTS (CROSS-REFERENCE TO TABLE 2.2.1)
TABLE 2.2.1 – TBV-IQ SERIES DIMENSION, TORQUE AND WEIGHT SPECIFICATIONS (REFER TO FIGURE 2.2.1)
FLANGE
TYPE
NOM.
ID
ACTUAL ID
D A B C
MAX. TORQUE
IN-OZ (N-M)
WEIGHT
LBS (KG)
NW-25 1 0.87 (22.1) 2.25 (57.2) 2.75 (69.9) 8.34 (212) 280 (1.98) 6.8 (3.1)
NW-40 11/21.39 (35.3) 2.25 (57.2) 2.75 (69.9) 8.34 (212) 280 (1.98) 6.5 (3.0)
NW-50 2 1.98 (50.3) 2.00 (50.8) 3.36 (85.3) 8.65 (220) 280 (1.98) 6.8 (3.1)
ISO-63 21/22.44 (62.0) 1.00 (25.4) 5.12 (130) 9.10 (231) 280 (1.98) 8.8 (4.0)
ISO-80 3 2.94 (74.7) 1.00 (25.4) 5.71 (145) 9.42 (239) 280 (1.98) 10.0 (4.5)
ISO-100 4 3.85 (97.8) 1.00 (25.4) 6.50 (165) 9.85 (250) 280 (1.98) 10.8 (4.9)
ISO-160 6 Call Call Call Call Call Call
ISO-200 8 Call Call Call Call Call Call
ISO-250 10 Call Call Call Call Call Call
2.73
2.89
4.47
1.90
A
.62
6.23
C
B
D
2.73
2.89
4.47
1.90
A
.62
6.23
C
B
D
2.2 - Device Specification - TBV-IQ Series Valves
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Unpacking: Inspect the shipping box before unpacking. Any damage should
be reported to Nor-Cal Products or directly to the transportation carrier.
Carefully remove the product from the box and visually inspect it for damage.
NOTE: Do not discard the packing materials until the
product has been inspected to your satisfaction.
If return of the product to Nor-Cal Products should become necessary, please
contact Intellisys Customer Service to obtain a Return Materials Authorization
(RMA) Number.
Pre-Installation Functionality Check: Nor-Cal Products carefully ensures
that every product shipped is in perfect working condition. However, it is still
a good idea to quickly check the functionality of the unit prior to installation
into the vacuum system. To do so, connect the TBV-series valve to a Nor-Cal
Products APC-series controller (or directly to an appropriate DC power source
in case of a IQA or IQD-series valve). The valve will complete a 30-second
initialization sequence during which the valve plate will cycle back-and-forth
a few times. The valve will eventually stop in the open position.
WARNING: The valve plate movement presents a pinching
hazard. Please keep fingers, hands or other objects away from
the valve opening and associated moving parts.
Further verification of the system can be done by toggling the “OPEN /
CLOSE” switch on the controller front/top panel. If the valve does not
operate as described please contact Nor-Cal technical support.
Valve Installation: Install the TBV-series valve in your vacuum system
using the appropriate hardware and cables. To allow for proper ventilation
and access, make sure that at least 3 inches of unobstructed space is available
adjacent to all perforated sides when installing a IQA or IQD-series valve, and
that at least 3.5 inches of space is reserved above the top of the valve to allow
for cable connector hoods. A complete list of installation hardware and
cables assemblies available from Nor-Cal Products can be found in
Appendices I and II.
NOTE: Specific installation instructions should be provided with
each custom UVD-drive. Required UVD fasteners and procedures
are not covered in this Manual.
NOTE: Refer to the appropriate section of the Adaptive
Pressure Controller Operating Manual for more details
about cable connections and pin-outs.
Once the valve is installed in the system, the approximate valve plate position
can be determined in one of two ways:
• Some models of TBV products have a circular cut-out in the motor
housing top. The rear shaft of the motor is slotted in a direction parallel
with the throttle plate (± 2º), and is visible through the cut-out.
• Other models of TBV product and all UVD products include a
rotary arm visible between the motor housing and the actual valve.
The arm is always parallel with the throttle plate (± 2º).
NOTE: The rotary arm in the TBV and UVD models that contain
it serves another important function. It is used to determine
the OPEN and CLOSED valve positions during valve initialization.
DO NOT remove this arm and BE CAREFUL about making
adjustments to the setscrew that is part of the motor
mount base. Moving the position of this screw will
result in a valve position offset.
WARNING: The rotary arm found in some TBV and all UVD
models presents a pinching hazard. Please keep fingers,
hands or other objects away from it.
3.0 - Unpacking and Installation
Heating the Valves: Sometimes it is necessary to heat the TBV-series
valve to prevent process contamination from condensing on the internal
valve surfaces. Nor-Cal manufactured heater jackets are available in both
PID and Thermostatically controlled versions, custom fit for each size valve.
Please refer to Appendix III for heater jacket and related accessories
ordering information.
NOTE: Several important considerations exist pertaining
to heating of the TBV-series valves. These include:
A) The coupling used to join the motor drive to the valve is a
three-piece Oldham style assembly. The center disk of this
coupling is made from the polymeric material Acetal.
When valve operating temperatures exceed 300ºF (150ºC)
this disk needs to be replaced with one made from PEEK.
[The Acetal disk, according to the Manufacturer, has a
maximum operational temperature rating of 150ºF (65ºC).
The disk temperature approaches this limit when the
internal valve temperature is about 300ºF (150ºC).]
B) Four O-rings are used in the valve body to seal the valve
shaft penetrations. On all TBV-series valves, the default
material is Viton®. According to the manufacturer, Viton®
should not be used in applications where the continuous
temperature exceeds 390ºF (200ºC). If the valve temperature
is expected to remain at a higher level, either as a result of
external or internal heat sources, then perfluoroelastomer
O-rings should be used. Nor-Cal Products can provide valves
containing a number of available brand and compound
O-rings. Please refer to Appendix II or contact Nor-Cal
Products Intellisys Customer Support for more details.
C) Under certain circumstances it is possible to preferentially heat
the internal plate and shaft of the valve as compared to the
valve body. This is especially true when the valve is attached to
unheated and uninsulated foreline piping, and when process
effluents are hot. Uneven heating causes the valve plate and
shaft to expand at a faster rate than the valve body, sometimes
to the point of causing the valve plate to seize in the valve bore.
If the possibility for this phenomenon exists with your system,
please consult Nor-Cal Products Intellisys Customer Support
for options and recommendations.
Heating the Valves
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4.0 - Theory of Operation
The TBV-series valve is designed for downstream pressure control. As such, it
is one of four important components in a pressure control system. The other
three essential components include a host system computer, a controller mod-
ule (APC, IQA or IQD) and one or two vacuum gauges, such as a Capacitance
Diaphragm Gauge (CDG). Most manufacturers’ vacuum gauges can be used
to provide the vacuum measurement signal, provided they have a voltage
output proportional to pressure.
FIGURE 4.1 – TYPICAL INSTALLATION AND CONFIGURATION OF A TBV SERIES
CONTROL VALVE (DASHED LINES REPRESENT TBV-IQ SERIES INSTALLATION)
Initialization Sequence: When first powered up, the TBV-series valve
will enter an initialization sequence that lasts for approximately 30 seconds.
The primary purpose for this operation is for the controller to determine
the fully open and closed points, as well as for certain motor and position
calibration steps to occur. While the initialization sequence is active, the
amber FAULT light will be illuminated and the OPEN/CLOSE LEDs may blink in
an alternating fashion. Once the initialization sequence is complete, the valve
will move to the fully open position and the green OPEN LED will illuminate.
Vacuum Chamber
Pump
Host system with
RS232/485 or DeviceNet
communications
APC Controller Throttle
Valve
Vacuum
gauge(s)
Normal Operation: After the initialization sequence is complete normal
operation of the TBV control valve is possible. There are two primary modes
of operation, a) position control mode and b) pressure control mode.
In Position control mode the valve will move to any position in its range
based on a position set-point command from the host. The valve will
remain in that position until instructed to do otherwise. Position control
mode can be useful in certain cases where a pre-determined amount of
baffling or throttling is necessary.
Pressure control mode, on the other hand, is used whenever control to a
specific system pressure level is desired. The host provides the set-point value
and the throttle valve strives to achieve that set point as quickly as possible.
During pressure control mode, external perturbations such as flow changes
and plasma events will automatically be compensated for by the APC, IQA
or IQD controller module so that the pressure set-point is maintained.
Tuning: All Nor-Cal controller modules contain an Adaptive Pressure
Control Algorithm that has been designed to work over a wide range of
flow- and pressure-combinations. There are therefore no “learn modes” to
execute, nor does the user have to set PID parameters. In some instances,
however, vacuum system design may affect the closed loop pressure control
time constants. As a result, pressure control performance may at times
be affected. If satisfactory pressure control cannot be achieved with the
Adaptive Pressure Control Algorithm, please contact Nor-Cal Products
Intellisys Customer Support.
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5.0 - Product Support
Troubleshooting: The Nor-Cal Products’ TBV control valve is designed for years of maintenance free operation. MTBF has been determined to be in excess
of 2,000,000 operating cycles or 65,000 hours of typical continuous operation. However, some regular inspections and Preventive Maintenance will ensure
that unexpected failures do not occur. Please refer to Table 5.1 for recommendations on TBV-series preventive maintenance and service.
TABLE 5.1 – RECOMMENDED TBV-SERIES PREVENTIVE MAINTENANCE ACTIONS AND INTERVALS
RECOMMENDED ACTION PURPOSE / WHAT TO LOOK FOR RECOMMENDED INTERVAL
With controller power OFF, but valve still installed in
system, manually turn TBV shaft via rear shaft slot or
rotary arm (depending on model).
Feel for areas of high friction or binding, as they may
indicate a build-up of process by-product or valve plate
misalignment due to uneven heating.
Weekly, initially, until a process specific service interval has
been determined for the valve.
Remove TBV control valve from system for visual
inspection.
Look for process build-up. Also, inspect for areas
showing scratches in plate edge or valve inner bore.
The latter can be a sign of plate misalignment, possibly
due to uneven heating.
Monthly, initially, until a process specific service interval has
been determined for the valve.
With controller power OFF, remove TBV drive unit and
inspect Oldham coupling disk (valve body can remain
installed in vacuum system)
Inspect for Oldham coupling disk wear and fit.
The presence of a whitish powder indicates disk wear.
Also, the disk should fit snugly on each of the two
hubs, and remain on even when upside down.
After 3 months of use, and then every 3 months, until a
process specific service interval has been determined.
Remove TBV control valve from system and
perform leak check.
Determine loss of shaft seal integrity. All new valves
are tested to 1 × 10-9 atm·scc/sec He
Every 6 months, unless extremely high temperatures or highly
aggressive chemicals are used.
Disassemble valve body to access bearings and O-rings
High vacuum grease used can gradually disappear due
to evaporation or chemical attack. The O-ring seals
can wear or crack due to contamination, chemical
attack or excessive heat.
In heated applications: after 12 months of continuous use.
In low temperature applications: after 24 months
of continuous use. Or, whenever a leak is found
via leak detection.
Aside from the Oldham coupling disk and shaft O-rings, there are no user serviceable parts or components in the TBV-series valve. If a problem does occur with
the TBV control valve, please refer to the basic troubleshooting instructions below or contact Nor-Cal Products Intellisys Customer Support at 800-824-4166 to
obtain additional instructions or a Return Materials Authorization number.
NOTE: A pressure control system issue may not be related to the throttle valve itself. Please also refer
to the Adaptive Pressure Controller Operating Manual for related troubleshooting tips and actions.
Some basic troubleshooting can be done by the user referring to the instructions and suggestions below.
Table 5.2 describes common symptoms and recommended actions.
TABLE 5.2 – POSSIBLE FAILURE MODES AND RECOMMENDED ACTIONS
SYMPTOM POSSIBLE CAUSES RECOMMENDED ACTION
The TBV does not appear to turn on or operate.
The TBV is not connected to the controller module
(standard TBV models only)
Check to make sure the controller-to-valve cable is connected
at both ends, using the correct connectors.
The controller-to-valve cable is faulty (standard TBV
models only) Try another TBV-CRD-XX cable.
The controller module is not on, or is faulty. Check controller module and refer to appropriate controller
Operating Manual
The TBV appears to operate but pressure- or position
control is inconsistent and poor
The valve plate is jammed or partially
jammed in the valve bore.
Turn off controller power and attempt to move the valve shaft
by hand. If binding is observed, remove valve from system
to determine the root cause. Clean off process residue as
necessary using a non-abrasive method. If plate or valve bore
are damaged, contact Nor-Cal Intellisys Customer Support
The Oldham coupling disk is worn or cracked Turn off controller power. Remove drive unit from valve.
Replace the Oldham coupling disk as necessary.
A whining or buzzing sound is heard from
the TBV motor drive
The Oldham coupling disk, or possibly hubs, is loose
or worn and a harmonic resonance point has been
excited
Turn off controller power. Remove drive unit from valve.
Replace the Oldham coupling disk as necessary. If problem
persists, contact Nor-Cal Intellisys Customer Support.
The controller motor control coefficients have been
corrupted.
Turn off controller power. Turn back on and allow
initialization sequence to complete
The wrong controller is being used. Note model and serial number of valve and controller and
contact Nor-Cal Intellisys Customer Support
The motor and valve shaft rotate continuously in one
direction without stopping
The rotor arm used for determination of OPEN and
CLOSED during valve initialization is broken or missing
Contact Nor-Cal Intellisys Customer Support to obtain and
RMA#
The valve has developed a leak to atmosphere along the
valve shaft
O-ring damage and/or loss of vacuum grease can
cause this
The valve plate and shaft need to be removed from the
body so that the O-rings can be replaced and/or re-greased.
Please contact Nor-Cal Intellisys Customer Support to obtain
instructions, or to get an RMA# for valve return.
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INTELLISYS THROTTLING BUTTERFLY VALVES
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TBV-OP-LIT 01/04
INTELLISYS THROTTLING BUTTERFLY VALVES
APPENDIX I – Installation Hardware
For detailed descriptions of clamp and centering rings, see page 13
TABLE A-I.II - INSTALLATION HARDWARE, ISO “OF” STYLE FLANGES
FLANGE
TYPE
FASTENERS
A
REQ’D
QTY
CENTERING RING
B
REQ’D
QTY
ISO-63 TBV-ISO-63-DCP 4ISO-63-CR-SV, or
ISO-63-CR-AV 2
ISO-80 TBV-ISO-80-DCP 8ISO-80-CR-SV, or
ISO-80-CR-AV 2
ISO-100 TBV-ISO-100-DCP 8ISO-100-CR-SV, or
ISO-100-CR-AV 2
ISO-160 TBV-ISO-160-DCP 8ISO-160-CR-SV, or
ISO-160-CR-AV 2
ISO-200 TBV-ISO-200-DCP 8ISO-200-CR-SV, or
ISO-200-CR-AV 2
ISO-250 TBV-ISO-250-DCP 12 ISO-250-CR-SV, or
ISO-250-CR-AV 2
Note: Centering rings listed include Viton O-rings.
Please call for other O-ring materials.
TABLE A-I.III - INSTALLATION HARDWARE, ISO “N” STYLE FLANGES
FLANGE
TYPE
FASTENERS
A
REQ’D
QTY
CENTERING
RING B
REQ’D
QTY
ISO-63 TBV-ISO-63-BOLT 4ISO-63-CR-SV, or
ISO-63-CR-AV 2
ISO-80 TBV-ISO-80-BOLT 8ISO-80-CR-SV, or
ISO-80-CR-AV 2
ISO-100 TBV-ISO-100-BOLT 8ISO-100-CR-SV, or
ISO-100-CR-AV 2
ISO-160 TBV-ISO-160-BOLT 8ISO-160-CR-SV, or
ISO-160-CR-AV 2
ISO-200 TBV-ISO-200-BOLT 8ISO-200-CR-SV, or
ISO-200-CR-AV 2
ISO-250 TBV-ISO-250-BOLT 12 ISO-250-CR-SV, or
ISO-250-CR-AV 2
Note: Centering rings listed include Viton O-rings.
Please call for other O-ring materials.
FIGURE A-I.II: INSTALLATION, ISO “OF” STYLE FLANGES
FIGURE A-I.III: INSTALLATION, ISO “N” STYLE FLANGES
TABLE A-I.I - INSTALLATION HARDWARE, NW FLANGES
FLANGE
TYPE
CLAMP
A
REQ’D
QTY
CENTERING RING
B
REQ’D
QTY
NW-25 NW-25-SSC or
NW-25-CP 2NW-25-CR-SV, or NW-25-CR-AV 2
NW-40 NW-40-SSC or
NW-40-CP 2NW-40-CR-SV, or NW-40-CR-AV 2
NW-50 NW-50-SSC or
NW-50-CP 2NW-50-CR-SV, or NW-50-CR-AV 2
Note: Centering rings listed include Viton O-rings.
Please call for other O-ring materials.
FIGURE A-I.I: INSTALLATION, NW FLANGES
ATBV B
A TBV B
TBV BA
For NW Flanged Valves
For ISO Flanged Valves with “OF” Style Adjoining Flanges
For ISO Flanged Valves with “N” Style Adjoining Flanges
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TBV-OP-LIT 01/04
INTELLISYS THROTTLING BUTTERFLY VALVES
13 Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]
TBV-OP-LIT 01/04
INTELLISYS THROTTLING BUTTERFLY VALVES
APPENDIX II – Valve, Spare Parts, Hardware and Cable Assembly Ordering Information
TBV Part Number and Ordering Information
Use the model number tree and matrix below to define a valid Nor-Cal Products throttling butterfly valve model number.
TBV
Drive Type Nominal Port ID Flange Type Seal MaterialFlange Size
Spare Parts
TABLE A-II.1 – TBV SPARE PARTS
MODEL
NUMBER DESCRIPTION
54-310-004 Oldham Coupling Disk – Acetal. For all valves up to and including 4” (ISO-100)
54-330-006 Oldham Coupling Disk – Acetal. For 6” (ISO-160) valve and some UVD assemblies.
54-330-016 Oldham Coupling Disk – Acetal. For 8” (SIO-200) valve and some UVD assemblies
54-330-017 Oldham Coupling Disk – PEEK. For all valves up to and including 4” (ISO-100)
Call for details Oldham Coupling Disk – PEEK. For 6” (ISO-160) valve and some UVD assemblies.
Call for details Oldham Coupling Disk – PEEK. For 8” (SIO-200) valve and some UVD assemblies
TBV-400-90 Viton O-ring kit. Set of four. For all TBV sizes up to and including 4” (ISO-100)
TBV-600-90 Viton O-ring kit. Set of four. For 6” (ISO-160) TBV
TBV-800-90 Viton O-ring kit. Set of four. For 8” (ISO-200) TBV
TBV-1000-90 Viton O-ring kit. Set of four. For 10” (ISO-250) TBV
Cable Assemblies and Accessories
TABLE A-II.2 – TBV AND APC CABLE ASSEMBLIES AND ACCESSORIES
MODEL
NUMBER DESCRIPTION
TBV-CRD-10 10’ (3 meter) APC controller-to-TBV valve cable
CDG-CRD-DB15-10 10’ (3 meter) APC controller-to-15-pin CDG cable
CDG-CRD-DB9-10 10’ (3 meter) APC controller-to-9-pin CDG cable
CDG-CRD-10 10’ (3 meter) APC controller-to-flying lead CDG cable
APC-CRD-RS232-10 10’ (3 meter) APC controller-to-host RS-232 interface cable. DB-9 connector on host end
APC-PSM-DB15 24 VDC, 3A power supply (100-240 VAC input) for IQ-series TBV. Includes AC power cord and 6’ (2 meter) DC cable with 15-pin D-sub connector
IQ-CRD-RS232-10 10’ (3 meter) long IQD-to-host RS-232 interface cable. DB-9 connector on host end
CDG-IQ-CRD-DB15-10 10’ (3 meter) long IQD-to-CDG interface cable. DB-15 connector on CDG end
CDG-IQ-CRD-Y 1’ (30 cm) long Y-cable used to interface two CDGs to IQD.
Call for details RS-232 Service Software for Windows PC
DRIVE
TYPE
NOMINAL
PORT ID
FLANGE
TYPE
FLANGE
SIZE
SEAL
MATERIAL
D = Direct drive 100 = 1 NW = “KF” quick clamp style 25 = 1.00 NW Blank = Viton
G = Geared drive 150 = 11/2ISO = ISO through bore 40 = 1.50 NW Kxx* = Kalrez
IQA = IQ-Series with Analog/TTL and serial communications* 200 = 2 CF = Conat metal seal 50 = 2.00 NW Cxx* = Chemraz
IQD = IQ-Series with DeviceNet and serial communications* 250 = 21/2ASA = ASA 63 = 2.50 ISO Pxx* = Perlast
* Direct drive only 300 = 3 JIS = JIS 80 = 3.00 ISO xx* = Other
400 = 4 100 = 4.00 ISO *xx Designates compound,
call for details
600 = 6 160 = 6.00 ISO
800 = 8 200 = 8.00 ISO
1000 = 10 250 = 10.00 ISO
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TBV-OP-LIT 01/04
INTELLISYS THROTTLING BUTTERFLY VALVES
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TBV-OP-LIT 01/04
INTELLISYS THROTTLING BUTTERFLY VALVES
APPENDIX II.I – TBV Heater Jackets and Accessory Ordering Information
TBV
Control Type Control Temp. Operating VoltageValve Size
PID Controller
MODEL
NUMBER ZONES
OPERATING
VOLTAGE
HC-935A-1-1 1 120 VAC
HC-935A-1-2 1 240 VAC
CONTROL
TYPE
VALVE SIZE
CODE SIZE FLANGE
CONTROL
TEMPERATURE
OPERATING
VOLTAGE
HC = PID control* 100 1.00 * NW-25 200 = All PID controlled jackets 1 = 120 VAC
HT = Thermostatic control 150 1.50 * NW-40 090 = 90ºC Thermostat 2 = 208-240 VAC
* Requires separate PID controller 200 2.00
* NW-50 120 = 120ºC Thermostat
250 2.50 ISO-63 150 = 150ºC Thermostat
300 3.00 ISO-80
400 4.00 ISO-100
600 6.00 ISO-160
800 8.00 ISO-200
* Includes two special NW clamps
Heater Jacket Part Number and Ordering Information
Use the model number tree at right with the matrix below to define
a valid Nor-Cal Products TBV heater model number.
APPENDIX II – Valve, Spare Parts, Hardware and Cable Assembly Ordering Information
Installation Hardware
TABLE A-II.IV – ISO INSTALLATION HARDWARE
MODEL
NUMBER DESCRIPTION
TBV-ISO-63-DCP ISO-63 aluminum double claw clamp with bolt
TBV-ISO-100-DCP ISO-100 aluminum double claw clamp with bolt
TBV-ISO-160-DCP ISO-160 aluminum double claw clamp with bolt
TBV-ISO-200-DCP ISO-200 aluminum double claw clamp with bolt
TBV-ISO-250-DCP ISO-250 aluminum double claw clamp with bolt
TBV-ISO-63-BOLT M8×70 SS bolt with nut and 2 washers
TBV-ISO-80-BOLT M8×70 SS bolt with nut and 2 washers
TBV-ISO-100-BOLT M8×70 SS bolt with nut and 2 washers
TBV-ISO-160-BOLT M10×100 SS bolt with nut and 2 washers
TBV-ISO-200-BOLT M10×100 SS bolt with nut and 2 washers
TBV-ISO-250-BOLT M10×100 SS bolt with nut and 2 washers
ISO-63-CR-SV ISO-63 stainless steel centering ring with Viton O-Ring
ISO-63-CR-AV ISO-63 aluminum centering ring with Viton O-Ring
ISO-80-CR-SV ISO-80 stainless steel centering ring with Viton O-Ring
ISO-80-CR-AV ISO-80 aluminum centering ring with Viton O-Ring
ISO-100-CR-SV ISO-100 stainless steel centering ring with Viton O-Ring
ISO-100-CR-AV ISO-100 aluminum centering ring with Viton O-Ring
ISO-160-CR-SV ISO-160 stainless steel centering ring with Viton O-Ring
ISO-160-CR-AV ISO-160 aluminum centering ring with Viton O-Ring
ISO-200-CR-SV ISO-200 stainless steel centering ring with Viton O-Ring
ISO-200-CR-AV ISO-200 aluminum centering ring with Viton O-Ring
ISO-250-CR-SV ISO-250 stainless steel centering ring with Viton O-Ring
ISO-250-CR-AV ISO-250 aluminum centering ring with Viton O-Ring
TABLE A-II.III – NW INSTALLATION HARDWARE
MODEL
NUMBER DESCRIPTION
NW-25-SSC NW-25 SureSeal clamp
NW-25-CP NW-25 wingnut clamp
NW-40-SSC NW-40 SureSeal clamp
NW-40-CP NW-40 wingnut clamp
NW-50-SSC NW-50 SureSeal clamp
NW-50-CP NW-50 wingnut clamp
NW-25-CR-SV NW-25 stainless steel centering ring with Viton O-Ring
NW-25-CR-AV NW-25 aluminum centering ring with Viton O-Ring
NW-40-CR-SV NW-40 stainless steel centering ring with Viton O-Ring
NW-40-CR-AV NW-40 aluminum centering ring with Viton O-Ring
NW-50-CR-SV NW-50 stainless steel centering ring with Viton O-Ring
NW-50-CR-AV NW-50 aluminum centering ring with Viton O-Ring
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INTELLISYS THROTTLING BUTTERFLY VALVES
APPENDIX III – Limited Warranty and Intellectual Property Coverage
Limited Warranty
Products manufactured by Nor-Cal Products, Inc. (hereinafter referred to as “Nor-Cal”) are warranted against defects in material and workmanship for a
period of twelve (12) months from the date of shipment from Nor-Cal to the buyer. Any modification to the product by the buyer or their agent voids this war-
ranty. Liability under this warranty is expressly, limited to replacement or repair (at Nor-Cal ’s option) of defective parts. Nor-Cal may at any time discharge its
warranty as to any of it products by refunding the purchase price and taking back the products. This warranty applies only to parts manufactured, and labor
provided, by Nor-Cal under valid warranty claims received by Nor-Cal within the applicable warranty period and shall be subject to the terms and conditions
hereof. Expendable items such as tubes, heaters, sources, bellows, etc., by their nature may not function for one year; if such items fail to give reasonable service
for a reasonable period of time, as determined solely by Nor-Cal, they will be repaired or replaced by Nor-Cal at its election. All warranty replacement or repair
of parts shall be limited to equipment malfunctions which, in the sole opinion of Nor-Cal,are due or traceable to defects in original materials or workmanship.
Malfunctions caused by abuse or neglect of the equipment are expressly not covered by this warranty. Nor-Cal expressly disclaims responsibility for any loss or
damage caused by the use of its products other than in accordance with proper operating and safety procedures. Reasonable care must be taken by the user to
avoid hazards. In-warranty repaired or replacement parts are warranted only for the remaining unexpired portion of the original warranty period applicable to
the parts that have been repaired or replaced. After expiration of the applicable warranty period, the buyer shall be charged at Nor-Cal’s then current prices for
parts and labor plus transportation. Except as stated herein, Nor-Cal makes no warranty, expressed or implied (either in fact or by operation of law), statutory or
otherwise: and, except as stated herein, Nor-Cal shall have no liability for special or consequential damages of any kind or from any cause arising out of the sale,
installation, or use of any of its products. Statements made by any person, including representatives of Nor-Cal, which are inconsistent or in conflict with the
terms of this warranty shall not be binding upon Nor-Cal unless reduced to writing and approved by an officer of Nor-Cal. Merchandise may be returned at the
sole discretion of Nor-Cal Products, but not more than 60 days after shipment. A fee may be charged for restocking the item. An RMA number must be obtained
from Nor-Cal before returning any merchandise.
Intellectual Property Coverage
The product described in this manual is covered under U.S. Patent numbers 5,134,349; 5,202,613; 5,321,342 and 6,612,331. Additional patents are pending.
Viton is a registered trademark of DuPont Dow Elastomers
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