Spectron MV3 Series User manual

Operating Manual
for
MV3 valve series

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Operating Manual
MV3 valve series

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Operating Manual
MV3 valve series
Contents
Contents.......................................................................................................................................................3
1. Introduction...........................................................................................................................................4
1.1 General information........................................................................................................................4
1.2 Intended use ..................................................................................................................................5
1.3 Personnel requirements .................................................................................................................5
2. For your safety......................................................................................................................................6
2.1 Symbols used.................................................................................................................................6
2.2 Essential safety information............................................................................................................6
3. Description............................................................................................................................................8
3.1 Overview of MV3 valves .................................................................................................................8
3.2 Functional description ....................................................................................................................9
3.3 Technical data ................................................................................................................................9
3.4 Connection options.........................................................................................................................9
4. Operation............................................................................................................................................10
4.1 Labelling.......................................................................................................................................10
4.2 Installation.................................................................................................................................... 11
4.3 Commissioning.............................................................................................................................12
4.4 Taking out of operation .................................................................................................................12
5. Faults..................................................................................................................................................13
6. Maintenance, cleaning and repairs .....................................................................................................14
6.1 Regular maintenance work and visual inspections .......................................................................14
6.2 Regular cleaning ..........................................................................................................................14
6.3 Repair information........................................................................................................................14
6.4 Returns ........................................................................................................................................14

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Operating Manual
MV3 valve series
1. Introduction
1.1 General information
Validity
This Operating Manual is valid for the MV3 valve series.
Manufacturer
Spectron Gas Control Systems GmbH
Fritz-Klatte-Straße 8
65933 Frankfurt
Deutschland / Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.spectron.de
Publication date
March 2017
Retention and completeness
This Operating Manual constitutes part of the MV3 valve series and must be kept accessible to
authorised personnel at all times.
Under no circumstances may chapters be removed from this Operating Manual. If the Operating Manual
is lost or pages are missing – in particular the chapter "For your safety," – it/they must be replaced
immediately.
Copyright
This Operating Manual contains information protected by copyright law.
It must not be photocopied, reproduced, translated or copied onto data carriers, either in full or in part,
without prior authorisation. All rights reserved.
Updates
No update service is provided for this Operating Manual by Spectron Gas Control Systems GmbH.
Changes may be made to this Operating Manual without prior
notification.

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1. Introduction
1.2 Intended use
Intended use
Valves of the MV3 valve series in chrome-plated brass with PVDF valve seat seal are intended for use
with non-corrosive gases up to quality 6.0. In the stainless steel version with PCTFE valve seat seal,
they are also suitable for use with corrosive gases up to quality 6.0.
The permissible pressure range and the flow direction of the individual connections are specified on
the underside of the valve. The gas type is not specified, but results from the seal material used in the
respective model in compliance with standards ISO 11114-1 and -2.
Valves of the MV3 series are used to close off and re-open a gas line. Pressure is introduced via the inlet
connection (see labelling on the underside of the valve). Appropriate measures must be taken to prevent
the introduction of pressure via the outlet connections of the valve.
Valves of the MV3 series – if free of electrical components such as proximity switches, contact pressure
gauges or pressure transducers – may be used in areas with potentially explosive atmospheres, as the
fittings comprise no potential source of ignition in themselves (ignition hazard assessment in accordance
with DIN EN 13463-1). The ignition hazard must be taken into account in the case of valves with electrical
components. The ignition hazard must be evaluated based on the documentation for the respective
electrical components, taking into account their incorporation into the overall system, and Directives
2014/34/EU ("ATEX 114") and 1999/92/EC (ATEX 137) must be observed.
Foreseeable misuse
The following operating conditions are deemed to constitute misuse:
Operation with gases for which, as specified by the above-listed standards, the valve model in question
is not designed.
Use with gases in their liquid state
Operation outside the permissible technical limit values
Non-observance of the legal regulations and other
provisions valid on-site
Failure to comply with this Operating Manual
Failure to carry out inspection and maintenance work
Failure to heed the labelling and the information in the product data sheet
Pressurisation counter to the normal direction of flow
1.3 Personnel requirements
Definition of "authorised person"
Authorised persons are persons with technical training who have received technical instruction on the
gas supply system and the associated hazards and have successfully completed training courses on
"The supply of pressurised gases."
Tasks of the operating personnel
Operating personnel must be able to recognise and – in as far as possible and permissible – remedy faults
and irregularities.
Requirements placed on operating personnel
In order to perform their tasks, operating personnel must meet the following requirements:
The operating personnel must have received instruction in the operation of the MV3 valve series
from an authorised person and must have read and understood this Operating Manual in its entirety.

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2. For your safety
2.1 Symbols used
Note! Caution! Warning! Danger!
Danger!
This symbol warns that there is a "risk of fatal injury" or a health hazard
for personnel.
2.2 Essential safety information
Note!
The following safety information is intended to supplement the applicable national accident
prevention regulations and laws. Existing accident prevention regulations and laws must be
complied with at all times.
Various laws, regulations, rules and directives apply when handling pressurised gases and must be
complied with, depending on the gas type.
The following legislation and publications are applicable (although this is not necessarily a complete list):
EU Directive 2009/104/EC (Work Equipment Directive)
EU Directive 1999/92/EC (ATEX 137)
EU Directive 98/24/EC (Dangerous Substances Directive)
Industrial health and safety ordinance (implementation of Directives 2009/104/EC and 1999/92/EC
in German law)
Ordinance on hazardous substances (implementation of Directive 98/24/EC in German law)
TRBS (technical regulations on industrial safety and health) publications
German technical rules for hazardous substances (TRGS)
TRAS (technical regulations on plant safety) publications
BGV A1 German trade association basic accident prevention regulations
BGR 104 German trade association rules on explosion protection
BGR 132 German trade association rules for the avoidance of ignition hazards resulting from
electrostatic charges
BGR 500 2.26 German trade association rules on welding, cutting and related work procedures
BGR 500 2.31 German trade association rules for working on gas lines
BGR 500 2.32 German trade association rules for the operation of oxygen systems
BGR 500 2.33 German trade association rules for the operation of systems that handle gas
ISO 11114-1 and ISO 11114-2


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2. For your safety
Possible hazard
Prevention measures
Risk of fatal injury!
If oxygen comes into contact with oil or grease, there
is arisk of fire due to a chemical reaction.
Keep all components which come into contact with oxygen
completely free of oil and grease.
Risk of fatal injury!
Gas escaping into the ambient air can ignite; there is a risk
of fire and explosion.
Smoking and naked flames are strictly prohibited in the
vicinity of gas supply equipment
Risk of fatal injury!
The fitting may be damaged as a result of unauthorised
modifications or conversions and may no longer work
as intended. There is a risk of the system malfunctioning,
catching fire or being damaged.
No changes or modifications may be made without the
written approval of the manufacturer's authorised technical
experts.
Risk of fatal injury!
If gases other than those specified on the type plate are
used, there is a risk of the system malfunctioning, catching
fire or being damaged.
Use only for the gases indicated on the device.
If there are no gas types specified on the fitting, consult
the manufacturer to find out which gases it can be used
with.
On no account may the fitting be put into operation
without this information.
Risk of fatal injury!
If components which are not suitable for the pressure range
of the gas supply system are connected, they may rupture
under the pressure load.
All accessories to be connected (screw fittings, pipes,
fittings, etc.) must be suitable for the indicated pressure
range for the gas supply system.
If valves of the MV3 series are used outside the permissible
temperature range, there is a risk of the system
malfunctioning, catching fire or being damaged.
Do not use in ambient temperatures below −30°C or over
+60°C.
Dirt particles penetrating into the valves of the MV3 series,
can cause malfunctions and damage to the fitting.
It must be ensured that no dirt particles of any kind can get
into valves of the MV3 series. For this and other reasons,
valves of the MV3 series are equipped with various filters,
which must not be removed.
Improper handling and impermissible use can lead to
danger for the user and other persons as well as damage
to the device.
Use and handle valves of the MV3 series only as
instructed in this Operating Manual.
If the connecting surfaces or gaskets of the fittings are
damaged or missing, there is a danger of gas escaping in an
uncontrolled manner.
Check the connecting surfaces for damage, and do not
install if the connecting surfaces are damaged or gaskets
are missing.

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3. Description
3.1 Overview of MV3 valves
Manually operated MV3 valve Pneumatically operated MV3 valve
Elements of the MV3 valve series
Item
Designation
Description
1
Valvebody
With the respectively labelled inlet and outlet connections
2
Handwheel
With integrated (red-green) position indicator
3
Pneumatic drive
For controlled valve operation
4
Pneumatic screw fitting
For connection of the compressed-air supply
5
Inductive proximity switch
For detection of the switching position of the pneumatic drive
2
1
1
1
3
1
4
1
5
1

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3. Description
3.2 Functional description
The valves of the MV3 series are shut-off valves which are diaphragm metal-to-metal sealed to the
atmosphere and have a polymer seal in the valve seat. They can be configured either as manually or
as pneumatically operated valves.
In the manually operated version, the shut-off mechanism is opened by turning a handwheel anti-clockwise
and closed again by turning it in the opposite direction (clockwise). A position indicator integrated in the
handwheel displays the current status (open or closed). Depending on the status, a red dot (the valve is
closed) or a green dot (the valve is opened –or partly opened) appears in a window on the handwheel.
Pneumatically operated valves cannot be operated. They are actuated exclusively via a control unit
connected to the pneumatic drive. The control pressure is between a minimum of 6 bar and a maximum
of 8bar and is applied via a pneumatic screw fitting on the upper side of the pneumatic drive.
The switching status and thus the valve status (open/closed) is indicated via a green ring, which is visible
(valve status open) or not visible (valve status closed) beneath the pneumatic screw fitting.
There is no red marking.
Optionally, the pneumatic drive can be equipped with an inductive proximity switch for detection of the
switching status. The scanning signal can then be processed and if necessary, displayed, by the connected
control unit.
The pneumatic drives come in two different basic versions. One version holds the shut-off valve in closed
position without the application of control pressure and open it when the control pressure is applied
introduction. This drive version is referred to as "Normally Closed" or "NC."
A second version holds the shut-off valve in open position without the application of control pressure and
closes it when the control pressure is applied. This drive version is referred to as "Normally Open" or "NO."
Caution!
In both versions, the pneumatic drive initiates a sudden movement of the valve closing unit –
both when opening and closing the valve. This can lead to pressure surges in the upstream
and downstream pipe system and must be allowed for, including consideration of the gases
transported (e.g. oxygen or acetylene), when configuring the overall system.
3.3 Technical data
Note!
The technical data can be taken from the Spectron data sheet for the relevant product. If this
is not available, you can view and download it at www.spectron.de.
The maximum inlet pressure is stamped on the valve or shown on the type plate.
3.4 Connection options
Inlet pressure connection: 1/4"-NPT female thread or with welded-on VCR connectors
Outlet pressure connection: 1/4"-NPT female thread or with welded-on VCR connectors


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4. Operation
4.1 Labelling
Labelling example
On the valve underside:
"PN300" (max. inlet pressure)
Arrows in angled position of the respective connection holes. These indicate whether the connection
is an inlet or outlet connection
In addition, a pneumatically operated valve has a type plate, for example with the following information,
on the pneumatic drive:
- Operating pressure 200 bar - Valve type MV3
- Control pressure 6-8 bar - Seal material PCTFE
- Part No. 71834321 - Headed screw 71834353
Caution!
Valves of the MV3 series are not labelled with the gas type they are designed for use with.
This can be identified, for example, in accordance with ISO 11114-1 and ISO 11114-2,
based on the body material and the seal material normally used with it:
body material brass, chrome-plated: PVDF
body material stainless steel: PCTFE
Note!
Customised versions may deviate from this!
Note!
There is an additional stamp (e.g. K92) embossed on the valve underside of the valvebody
as verification of successful leakage and functional testing.



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4. Operation
4.2 Installation
Caution!
It is essential to check that the connecting threads and connecting surfaces of the MV3 valves
and the parts to be connected to them (screw fittings, gaskets, cables, plugs etc.) are in perfect
condition.
Step
Activity
1
Make sure that
the MV3 valve is suitable for the intended application (type of actuation / gas type used /
operating pressure)
that the connecting parts of the piping system to be connected match the connecting
threads of the MV3 valve
2
Connect the connecting parts of the pipework system to the respective connections of the MV3
valve. Observe the arrows on the underside of the valvebody indicating the prescribed flow
direction for the respective connection.
¼“-NPT screw connections must be wrapped in PTFE tape. The first two thread turns must be
kept free of PTFE tape.
For oxygen or other gases with an oxidation potential greater than air, only use PTFE tape
that has BAM approval.
3
Fix the valve in position on a mounting plate. To do this, use the thread holes of size M6 (or M5
for Spectropur valves) on the underside of the valvebody and corresponding screws.
4
In the case of an MV3 valve with pneumatic drive:
Connect valve and valve control with a suitable pneumatic hose and route the hose
professionally.
If your valve is also equipped with an inductive proximity switch for detection of the valve
switching status, connect the proximity switch to the valve control unit with a suitable
connecting cable. Observe the connection diagram and operating instructions both for
the proximity switch and the control unit.
It is essential to observe the enclosed "Installation instructions for the pneumatic drive"
5
First check the pneumatic drive, and thus the shut-off valve, for correct functioning without using
amedium.
6
Purge the gas supply system after completing installation and check all connections for leakage
using suitable means.

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4. Operation
4.3 Commissioning
Proceed as follows to put a manually operated MV3 valve into operation:
Slowly (!) turn the handwheel anti-clockwise and slightly against the end resistance. If the valve is
equipped with a position indicator (red-green), the colour of the dot on the display will change from
red to green as you open the valve.
Pneumatically operated MV3 valves can only be put into operation via a connected pneumatic control unit.
4.4 Taking out of operation
Proceed as follows to take a manually operated MV3 valve out of operation:
Turn the handwheel clockwise, slightly but firmly against its end resistance. If the valve is equipped
with a position indicator (red-green), the colour of the dot on the display will change from green to
red when the valve is closed.
Pneumatically operated MV3 valves can only be taken out of operation via a connected pneumatic control
unit.

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5. Faults
Faults/cause
Remedy
Unintended or uncontrolled leakage
of gas from the MV3 valve.
Take the gas supply system out of operation and have the
MV3 valve inspected by the manufacturer.
Increasingly high torque is required
to operate the MV3 valve.
The increased torque indicates a defect in the closing
mechanism.
In as far as this is possible without the use of tools, close the
MV3 valve. Take the gas supply system out of operation and
have the MV3 valve inspected by the manufacturer.
Scratching or cracking noises are heard
when opening or closing the MV3 valve.
These noises indicate a defect in the closing mechanism.
In as far as this is possible without the use of tools, close the
MV3 valve. Take the gas supply system out of operation and
have the MV3 valve inspected by the manufacturer.

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6. Maintenance, cleaning and repairs
6.1 Regular maintenance work and visual inspections
Regular maintenance work
To ensure that the equipment remains in perfect working order and that a constantly high level of
operational safety and reliability is maintained,
valves of the MV3 series should be inspected by an expert once a year.
Regular visual inspections
Visual inspection of all
parts for
Interval
Damage
Correct functioning
Leaks
Integrity/stability
Corrosion
Regular inspections at intervals of 12 months and each time the device is put
into operation make an important contribution to the cost-effectiveness and
preservation of the value of the fittings.
Note!
Do not put the valve into operation if you find defects during a visual inspection! Have it inspected
immediately by the manufacturer or an authorised specialist company.
6.2 Regular cleaning
Warning!
Detergents or disinfectants can corrode and ruin gaskets inside the fittings. Do not use detergents
or disinfectants for cleaning!
Heavy soiling can lead to malfunctions. If it becomes necessary to clean the valves, use only
adamp, lint-free cloth.
6.3 Repair information
Caution!
Repairs may only be carried out by specialist personnel in authorised repair workshops.
Following repairs, the entire valve must be checked in accordance with the original Spectron
inspection instructions.
Safe and reliable operation can only be guaranteed if original spare parts are used.
Note!
The manufacturer accepts no liability for damage resulting from unauthorised repairs or
modifications carried out by the user or third parties without the express written approval
of the manufacturer.
6.4 Returns
If valves are returned to the manufacturer for testing, maintenance or repair, and they have been in contact
with corrosive or toxic gases, it is imperative that they are purged with inert gas.



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Spectron Gas Control Systems GmbH
Fritz-Klatte-Straße 8
65933 Frankfurt
Deutschland / Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.spectron.de