Warex DKZ 103 Manual

Documentation WAREX order no.: 140212

Dokumentation / Documentation
Zwischenbau-Absperrklappe / butterfly-valve
type: DKZ 103 <APS>
zum Einklemmen zwischen Flansche nach / for mounting between flanges, drilled in acc. to:DIN2501 – PN10
-für Medium / for medium: Schüttgut / bulk goods
-Eigenschaften / characteristics: rieselfähig, chemisch neutral, nicht zum Anbacken neigend /
dry, chemical not aggressiv, not sticky
-Betr. –Druck / operat. pressure: drucklos / pressureless
-Ausl. –Druck / design pressure: < 0,5 bar
-Betr.-Temp. / operat. temp.: 0° C …+ 60° C
-Umgeb. –Temp. / ambient. temp.: 0° C …+ 50° C
-Kennzeichnung / indification : CE 158
-Kategorien / category: II 1 / 3 D c
-druckstoßfest (nicht zünddurchschlagsicher) bis / shock (not flameproof) up: 10 bar
-Gehäusewerkstoff / body of: Silumin
-Gehäuse mit Anschluss für Erdung/ housing with connection for grounding
-Klappenscheibenwerkstoff / disc of: 1.4301
-Dichtung / sealing element: Buna CB schwarz / black - elektr. leitfähig / conductive
----------------------------------------------Pos. 1----------------------------------------------
Ihre Material-Nr. / your mat.-no.: V062713.B04
-Nennweite / size: DN 300
-Maßblatt / outline draw.: 0305292M... (ähnlich / similar)
-elektro. pneum. Steuerung : 000331b
-mit aufgeb. pneum. Antrieb / pneum. Actuator, type: AT 220. DR
-5/2 Wege Magnetventil, / solenoid valve, type: Herion, 2623077.3046
-Signalgeber im Gehäuse / signal devices in the housing, type: P&F, SC 3,5 NO
-Vakuumpumpe / Vacuumpump: L14
WAREX- Auftragsnummer / order-no : 140212

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 1 of 8
“ATEX 1” Installation and Maintenance
Manual
Installation, operating and maintenance instructions according to 94/9/EG (“ATEX”) for Warex
butterfly valves of the series DKZ(E) 101, 103, 105, 110 and DKF 102
General
This operating manual is intended to enable the proper installation and trouble-free operation
of the butterfly valves (especially in accordance with DIN EN 13463-1). Therefore, you must
read and observe these installation instructions.
Failure to comply with these instructions can result in danger to life and limb and damage to the
system, which can cause the manufacturer’s guarantee to become invalid.
All work on the butterfly valve must be performed by trained and experienced personnel. Only
suitable tools should be used and the personnel should be equipped with any necessary
protective clothing.
If the valve is not used immediately, it should be stored with the valve disk slightly open in the
original package in a clean, dry room.
The valves are custom-designed for a specific purpose (see Warex order or cover sheet) and
therefore may be used only for the intended purpose described therein. In accordance with these
requirements, the valve is also labeled pursuant to 97/23/EG and 94/9/EG. Important structural
elements of the valve and their function must be inspected at regular intervals.
Protective systems / devices in accordance with 94/9/EG
Protective systems consist of 2 butterfly valves of the <GS> series (surge-proof and flame
puncture proof), an intermediate container and a control unit with the EC type inspected
actuator, which ensures that at least one valve is closed. The intermediate container must be
designed in accordance with DIN 14460.
In order to enable proper operation and to ensure explosion-proof uncoupling, one butterfly valve
must always be closed.
There are two types of systems: ignition puncture proof devices (butterfly valves of the <GS>
series) included as part of a protective system (in which the control unit is considered separately)
and complete systems including type inspected controls.
For the operation as a protective system, the respective operating manuals for the controls must
be observed as well.
For protective systems, the pneumatic multiturn actuators must be double-acting and the solenoid
valves must be spring-return, closed and currentlesss. In addition, the category of the devices
used for zone distribution must correspond to the ambient conditions.
Only when they are closed and the seal of the valve disc is intact are the butterfly valves in the
series DKZ 103 GS DN50 – 500 and DKZ 110 GS DN50 – 300 (in accordance with ATEX H023
and H004) resistant to ignition explosion of propane/air mixtures, gas/air mixtures and hybrid
mixtures with similar explosive processes to propane/air mixtures, or resistant to explosion of
organic dusts in dust explosion classes St1 and St2. Furthermore, when closed, the protective
systems using series DK 103 GS butterfly valves are also resistant to ignition explosions of
aluminium dust/air mixtures and to those metallic dust/air mixtures with dust in dust explosion
class St3 (KSt≤500) with similar explosive processes to aluminium dust/air mixtures. Both series
can resist an explosion pressure of 10 bar.
Automated butterfly valves must be connected with an end position indicator so that the closed
condition can be determined with certainty.
They are suitable for ambient temperatures from –20 to +60°C.
For coarse-grained products such as granulates, the tight sealing of the valve may be hindered.
In this case, the valves cannot be used as a protective system, if the productless closing of the
butterfly valve cannot be ensured at all times.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 2 of 8
Caution – aluminum housings must never be in direct contact with zone 0 + 20.
For metal sealing butterfly valves the minimum closing times (see tables) must be maintained –
danger of sparks!
DN
50 65 80 100 125 150 200 250 300 400 500
Min.
allowable
closing time
in sec.
0.04 0.05 0.06 0.08 0.10 0.12 0.16 0.20 0.24 0.31 0.39
DN 600 700 800 900 1000 1200 1400 1600 1800 2000
Min.
allowable
closing time
in sec.
0.47 0.55 0.63 0.71 0.79 0.94 1.10 1.26 1.41 1.57
Flange connection
The dimensions of the Warex butterfly valves are such that they can be clamped between all
standard DIN and ANSI flanges. If the valve is used as an end element instead of an
intermediate element, then it must be possible to let off the medium without danger. The
dimensions of flanges and flange screw connections must comply with the operating instructions.
Please note, however, that butterfly valves designed for a specific flange size will not fit other
flanges. Make sure that the flanges are parallel, of good workmanship, have undamaged surfaces
and are connected in stress-free condition. For the design of the flange, see the sketch at the end
of these instructions.
The use of flange seals is not allowed for valves with rubber flange coatings. Flange gaskets are
used only for metal valve seals.
Installation
Before installation, the valve must be checked for proper functioning. Especially the sealing lips
for the flange seal must be in perfect condition.
Installed manual transmissions, electric and pneumatic actuators should be checked for smooth
running; never use force!!
Furthermore, make sure that the butterfly valve matches the required specification. The sleeve,
valve disk and shafts must be sufficiently stable for the flow medium. The indicated pressure
and temperature limits must be above the operational conditions.
Warex centric butterfly valves are suitable for both directions of flow; the seal and flow
characteristics are not affected by the direction.
For use in explosive areas, the valve and the measurement and control equipment must be
classified according to 94/9/EG for external (environment) and internal (pipe).
The valve housing must always be grounded (for potential equalization, see drawing 1007914
Mb). The bypass resistance must have a value of < 106Ωcompared with the ground.
Before installation, the pipe must be expanded using a suitable tool – never misuse the valve for
this purpose.
For vertical installation, the butterfly valve must be installed with horizontal shafts, especially in
the case of larger nominal diameters. Closing the lower valve disk half in the direction of flow
produces a self-cleaning effect.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 3 of 8
For vertical installation, after correct alignment of the valve in the pipe, the lower half of the flange
connection screws must be inserted first.
If there is no rubber flange coating, both flange gaskets must be coated with graphite and
inserted between the flange. The valve and any flange gaskets must be aligned central to the
pipe cross section and clamped into place by slightly tightening the lower flange connection
screws.
Insert the remaining flange connection screws and tighten crosswise in order to prevent
misalignment or twisting of the housing.
Avoid welding in the flange area after the valve has been installed. The heat caused by welding
will inevitably damage the seal.
For outdoor use, make sure that electric components are not directly exposed to weather – it may
be necessary to install a guard.
After installation, the butterfly valve must be checked for proper functioning.
Actuator
Depending on the model, the valve can be actuated by a hand lever, a manual transmission, a
pneumatic multiturn actuator or an electric actuator.
Valves delivered with an actuator from the factory are precisely adjusted and should not be re-
adjusted as long as the valve functions properly.
After removal and reinstallation of the actuator, the actuator setting must be checked and
corrected, if necessary. Pneumatically controlled butterfly valves should be set “nearly dead
center” or “slightly ahead” (approx. 1°) (with the exception of APS valves – use dead center
setting), to enable easier opening and to ensure proper sealing in case of wear.
The following applies to all valves:
Clockwise = valve closed
Counter-clockwise = valve open
Depending on the medium (especially fluids) the butterfly valves must be opened and closed
slowly, in order to prevent pressure surges (knocks) in the pipe system and any ensuing
damages.
Maintenance
Other than regular inspections, additional maintenance of the butterfly valves, such as lubrication,
is not necessary – for special instructions, see Wearing parts. For valves with a shaft seal using
gland packing, the latter should be inspected regularly (see also Glands).
For maintenance of the actuators, see the maintenance instructions of the respective
manufacturer. For protective systems, the following points must be inspected regularly:
Wear of seal 1x per month* (see explanation)
Check of “End position – CLOSED” of the valve
disk
(see Actuator for more information)
1x per month
*The seal should be checked once each month for signs of wear or washout and replaced, if
necessary. If there are no signs of wear here over an extended period, then the inspection can be
performed at greater intervals, at the discretion of the operating authority. In case of excessive
wear, on the other hand, the inspections should be performed more frequently. In order to prevent
interruptions due to age or fatigue, the seal should be replaced no later than after 2 years of
operation.
Especially in protective systems, wear of the seal can diminish the flame puncture resistance.
Failure to comply with this regulation means danger to life and limb and can also damage the
system. Especially after a malfunction, the protective system and, in particular, the sealing sleeve
must be checked for damage.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 4 of 8
Glands
Valves for hot gases (temperature above 200°C), glands are used for the shaft seals instead of
O-rings.
Leaks in the gland packing can generally be eliminated by resetting the gland screws. If this is not
possible, the gland packing must be replaced. Excessive re-adjustment should be avoided.
Wearing parts
The primary wearing part of a butterfly valve is the sealing sleeve. Depending on the use, regular
inspections for wear are necessary (crucial for use as pipe end valve or in protective systems).
Especially in protective systems, wear of the seal can diminish the flame puncture resistance.
Failure to comply with this regulation means danger to life and limb and can also damage the
system.
The user can easily replace removable seal elements; vulcanized sleeves can be replaced only in
the factory.
Especially in protective systems the sealing sleeve must be inspected after a malfunction and
replaced, if necessary.
Complete seal and wearing part sets are available for pneumatic multiturn actuators.
Use only original replacement parts.
Replacing the seal
Assuming the valve has been removed, proceed as follows:
1. After disassembly of the actuator, the actuator shaft and the bearing journal, the valve disk is
free and can be removed from the housing. Check the disk for damage on the entire
circumference (the permissible dimension can be found in the drawing or ask the
manufacturer)!
2. Now, beginning at the collar, press the sealing sleeve out of the guide grooves and remove it
from the housing. Here also check the housing for damage!
3. When inserting a new sleeve, make sure that the collar of the sleeve clearly locks into the
housing grooves.
4. Check whether the O-ring seal of the actuator shaft is intact and replace, if necessary.
5. After assembly of the valve (in reverse order, see No. 1), check the butterfly valve for proper
functioning, in particular the actuator adjustment (see Drive chapter).
Technical function
The butterfly valves are designed as intermediate flange valves with a centric or eccentric valve
disk with bearings.
The stable housing is cast in one piece; only stainless steel housings are welded.
The housing lining and rubber flange coating have a one-piece design, whether they are
vulcanized or removable. The rubber flange coating is designed so that a complete seal in the
opening area and at the flange connections, in addition to proper functioning of the valve, is
guaranteed only without an additional flange gasket.
Disassembly:
Before disassembly, approval must be obtained from the responsible works management
(depending on local regulations). It is important that the pipes be de-pressurized, or in the case of
hazardous media, that they are emptied and rinsed with suitable means.
Before installation or removal and before performing any work on the butterfly valve, the electric
power and compressed air must be shut down by authorized personnel, for safety reasons.
Removal from the pipes is possible only with the valve disk closed.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 5 of 8
Safety instructions / dangers:
Before working on the butterfly valve, the pipes must be de-pressurized.
Important: Never place your hand or other parts of your body into an open butterfly valve that has
not been released of energy (electric power + compressed air). This is extremely important
especially during cleaning.
The butterfly valves´ maximum surface temperature corresponds to the temperature of the
materials conveyed. The ignition temperatures of the gases surrounding the butterfly valves must
comply with the temperature classes stated in the operation manual. The equipment is to be
classified into temperature class T6 for a temperature of the materials conveyed of up to 68 °C,
into temperature class T5 for up to 80 °C, into temperature class T4 for up to 108 °C and into
temperature class T3 for a temperature of the medium of up to 160 °C. The admissible ignition-
and glowing temperatures of the dusts surrounding the butterfly valves must be adhered to as
stated in the operation manual. The ignition temperature of dispersed dusts must at least amount
to the 1,5 – fold of the temperature of the materials conveyed, and the glowing temperature of
dusts deposited on the valves (the maximum dust layer thickness may be 5mm) must at least
exceed the temperature of the materials conveyed by 75 K.
Especially dust deposits on the surfaces must be removed at regular intervals.
Use of the valve at product temperatures above +50° can cause the valve housing to become
extremely hot. Protective measures must be taken to prevent burns to the skin. Especially for
valves with manual actuators, the operating personnel must be protected, e.g. by wearing
protective gloves.
Coated valve disks must have a surface resistance of = 109O (measured at 23 °C and 50%
rel. humidity). If dusts with a minimum ignition energy (measured with induction) of = 3 mJ or
explosive gases, vapors or fog flow through the valve, then the seals used must have a
surface resistance of = 109O ( measured at 23°C and 50% rel. humidity). For gases of
category IIC, the valve disk must be grounded directly.
The interior of the butterfly valves must never have an insulating surface. In all devices, externally
applied chargeable layers and/or non-conductive layers must not be greater than 2mm for gases
and vapors of group II A and II B, and not greater than 0.2 mm for gases and vapors of group II
C.
In addition, provisions must be made to exclude blockage of the valve (which cancels the ignition
puncture resistance) or spark formation due to foreign bodies. The connection of electric
components must comply with the electric power data and may be performed only by authorized
and trained personnel.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 6 of 8
Dimensions of the connection flange:
Figure Ashows the incorrect shape of the connection flange.
The bolt force is supported by the sealing sleeve of the butterfly valve.
Figure Billustrates the correct form of the connection flange.
The bolt force is supported by the sealing surface of the connection flange on the housing of the
valve.
WAREX VALVE GmbH

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 7 of 8

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden
Tel. [phone] – Fax [phone]
Revised: 05.06.09/RevD/opz (Subject to change) ATEX1-EN-D Page 8 of 8

Stauverbrink 2 • D-48308 Senden • Telefon [phone] • Telefax 02536/9958-29
GmbH
VALVE
®
GmbH
ZwischenflanschklappeTypDKZ103 <APS
®
>*
Absperrklappe mit pneumatisch beaufschlagter Dichtmanschette
hier mit pneumatischem Drehantrieb
Bei dieser Absperrklappe wird die Manschette
nach dem Schließen der Klappe mit Druckluft an
dieKlappenscheibeangedrückt (statische Abdich-
tung).Insofern bietet sichals Antrieb für eineAPS-
Klappeeindoppelt-,odereinfachwirkenderpneu-
matischer Antrieb förmlich an.
DieseAbsperrklappeistmiteinempneumatischen
DrehantriebderFirmaAirTorquedargestellt, wahl-
weise sind auch Antriebe anderer Hersteller, ent-
sprechend den Kundenvorgaben und Werksnor-
menderAnwenderlieferbar,deren Anschluss nach
DIN/ISO5211 erfolgt (siehe auchunsere Preisliste).
With this model the sleeve is pressed on to the
valve disk by means of compressed air after the
valvehasclosed(staticseal).So,asingleordouble-
acting pneumatic drive is ideal as an actuator for
an APS valve. This shut-off valve is shown with a
pneumatic actuator from Air Torque, but on re-
quest we can supply actuators from other manu-
facturers, in accordance with customer speci-
fications and the factory norms of the end user.
Connection as per DIN/ISO 5211 (see also our
price list).
Range of Nominal Widths DN 50 - 1000
Operating Temperature - 40°C to + 200°C
Differential Pressure up to 6 bar
Sleeve detachable or galvanised
Nennweitenbereich DN 50 - 1000
Betriebstemperatur - 40°C bis + 200°C
Differenzdruck bis 6 bar
Manschette austauschbar oder
fest einvulkanisiert
* Air Pressure Sealing®
7/1

Stauverbrink 2 • D-48308 Senden • Telefon 02536 / 9958-0 • Telefax 025 36 / 99 58-29
GmbH
VALVE
®
GmbH
Zwischenflanschklappe Typ DKZ 103
Bei der Absperrklappe Baureihe 103 handelt es
sich um eine dichtschließende Zwischenflansch-
klappe für Flansche nach DIN 2501.
Eswirdabsolute DichtheitnachDIN3230B0 Leck-
rate 1 gewährleistet.
Das Gehäuse ist einteilig, die Dichtmanschette ist
fest in die Armatur einvulkanisiert. Für die Nenn-
weiten DN 50 bis DN 600 ist auch die Verwen-
dung einer auswechselbaren Manschette mög-
lich.
Die Absperrklappe ist sowohl für feste und flüssi-
ge wie auch gasförmige Medien geeignet,
Temperaturbereichevon-40bis+200°C.FürHeiß-
gase mit Temperaturen über 200°C ist diese Bau-
reihe als Drosselklappe in metallisch dichtender
Version erhältlich.
Merkmale der Warex-Klappe
- Wartungsfreie Ausführung
- Gehäuse mit hoher Eigentragfähigkeit
- Zentrisch gelagerte-strömungsgünstig
ausgebildete Klappenscheibe, mit spezi-
eller Wellenverbindung gewährleisten ab-
solute Dichtheit in beide Durchflußrichtun-
gen
- Dichtungen mit seitlichem Überstand und
zusätzlicher Dichtleiste gewährleistet
vollkommene Abdichtung zwischen Flan-
schen ohne zusätzliche Flanschdichtun-
gen
- Robuste Ausführung
- Wellenende und Armaturenkopf ausgebil-
det zum Aufbau der verschiedensten An-
triebsmöglichkeiten, Schnittstellen nach
DIN/ISO 5211
Materialspezifikationen:
Gehäuse Silumin, GG25, GGG 40,
Edelstahlgehäuse
Klappenscheibe Edelstahl, GGG, PVDF,
bechichtet, geschl. + poliert
Manschette Perbunan, NBR, Hypalon,
EPDM, Viton, Silikon, u.a.
Wellen+Zapfen Edelstahl
Buchse MS, PTFE
O-Ringe Perbunan, Viton
Allgemeine Informationen zur
Baureihe DKZ 103 Series 103 is a tight-seal interposed flange valve
for flanges as per DIN 2501.
The valves are absolutely air-tight in line with DIN
3230 BO Leak Rate 1.
The housing is one-piece, and the sealing sleeve
comes in two designs - detachable or fixed
(galvanised).
The shut-off valve is suitable for solid, liquid and
gaseousmediaandthetemperaturerange is from
-40 to +200°C.
Thisseriesisalsoavailableasa throttlevalve (metal
sealclosure)for hot gases with a temperatureover
200°C.
Features of the Warex Valve
- maintenance-free design
- largely self-supporting housing
- centrally-positioned valve disk designed
to promote a good flow, with special shaft
connection, giving an absolute seal in
both directions of flow.
- seals with lateral overlap and an
additional sealing rim give a perfect seal
between the flanges without any extra
flange seals.
- sturdy construction
- The shaft end and the armature head are
designed to fit to a wide range of drives.
Interfaces as per DIN/ISO 5211
Materials Specifications
Housing Silumin (Wilmil), GG25,
GGG40, stainless steel
Valve Disk stainless steel, GGG, PVDF,
laminated, ground and
polished
Sleeve Buna N, NBR, Hypalone,
EPDM, Vitone, Silicone,
amongst others
Shafts and Lugs stainless steel
Stuffing Box MS, PTFE
O Rings Buna N, Vitone
General Information on the
DKZ 103 Series
6/1

WAREX-VALVE GmbH – Stauverbrink 2 – 48308 Senden – Tel. [phone] – Fax [phone]
19.02.02/RevA/Re BetriebshinweiseAPS-de-engl.doc Seite 1 von 1
Betriebshinweise für zentrische APS – Klappen
Funktionsbeschreibung / Ansteuerung: Function / Positioning of the Elements:
Jede APS- Klappe wird bevor sie das Werk verläßt auf Ihre Funktion
und Dichtheit geprüft. Bei dieser Prüfung wird der erforderliche
Spanndruck für die jeweilige Dichtmanschette festgelegt, abgestimmt
auf den vom Kunden vorgegebenen Differenzdruck. Der ermittelte
Spanndruck ist von dem an der Armatur angebrachten Etikett
abzulesen.
Die Manschette darf keinesfalls direkt, ohne Druckminderer,
welcher auf den werkseitig vorgegebenen Spanndruck eingestellt ist,
an die Luft- bzw. Stickstoffversorgung angeschlossen werden.
Die konstruktive Gestaltung der Dichtmanschette gestattet es, daß
der Spanndruck der APS-Dichtmanschetten, bei hohem
Differenzdruck deutlich unter diesem liegen kann. So kann
beispielsweise ein Spanndruck von 3 bar bei einem Differenzdruck
von 6 bar schon ausreichend sein. Eine allgemeine Aussage ist
hierbei leider nicht möglich.
Eine weitere unabdingbare Voraussetzung für einen störungsfreien
Betrieb ist, daß die Dichtmanschette erst mit einer zeitlichen
Verzögerung von ca. 0,5 bis 2 sec nach dem Schließen (nach Erhalt
des Signal des Endschalters für Stellung ZU) der Klappe mit Druckluft
beaufschlagt wird, und damit sichergestellt ist, daß die
Klappenscheibe die Stellung "ZU" erreicht hat bevor die
Dichtmanschette an diese angepreßt wird - und eine statische
Abdichtung erfolgt. Gleiches gilt für den Öffnungsvorgang - hier sollte
die Dichtmanschette über einen Zeitraum von ca. 2 -3 sec vor dem
Öffnen der Klappe entlüftet werden.
Achtung, bei Einsatz im Vakuumbereich reicht eine normale
Entlüftung der Dichtmanschette keinesfalls aus, hier muß der
Dichtmanschette die Luft mit Hilfe einer Vakuumpumpe entzogen
werden bzw. die Entlüftung der Klappe sollte an das zentrale
Vakuumnetz angeschlossen werden.
Wir empfehlen strikte Einhaltung dieser Betriebshinweise, da bei
Nichtbeachtung sämtliche Gewährleistungsansprüche erlöschen.
Eine Möglichkeit diese wichtigen Parameter für einen störungsfreien
Betrieb der APS-Klappen zu gewährleisten ist beispielsweise die
pneum. Ansteuerung gemäß Zeichnungs-Nr. 000331a. Hier hat die
elektrische Ansteuerung der Ventile nach o. a. Beschreibung zu
erfolgen. Alternativ ist eine elektropneum. Steuerung gemäß
Zeichnungsnummer 0003564, 0003475d bzw. 0003784b (bei
Belüftung mit Stickstoff) lieferbar – hier sind die erforderlichen
Verzögerungszeiten in der Steuerung integriert, so daß die
Ansteuerung der <APS>-Klappe identisch mit einer „normalen“
Absperrklappe ist.
Druckluftversorgung:
Die Luftversorgung sollte mit trockener gefilterter Druckluft oder falls
erforderlich (bitte prüfen) mit Stickstoff erfolgen, da bei Ausfall der
Dichtung die Luft in den Innenraum entweichen kann.
Sicherheitshinweise:
Der Ein- bzw. Ausbau bzw. sämtliche Arbeiten an der Absperrklappe
sind aus Sicherheitsgründen nur durch autorisiertes / geschultes
Personal durchzuführen. Der Rohrstrang ist drucklos zu schalten, die
Strom- und Druckluftversorgung von autorisiertem Personal
stillzulegen.
Diese Betriebshinweise dienen als Ergänzung der bestehenden
Einbau und Wartungsanleitung für Warex Absperrklappen.
Standzeiten:
Um eine maximale Standzeit bei schwierigen Produkten und hohen
Differenzdrücken (Einlaufklappe für Drucksendegefäß) zu erreichen
ist es empfehlenswert das Absperr- und das Dichtsystem mittels einer
„einfachen“ Vorabsperrklappe zu trennen und zusätzlich einen
Produktabweiser oberhalb der geöffneten Klappenscheibe zu
installieren.
All APS valves are tested for function and tightness of seal before
they leave the factory. The gripping pressure required for the
sealing sleeve is calculated and set in accordance with the
differential pressure given by the customer. This gripping pressure
is recorded on the label on the armature. Therefore, when
ordering an APS valve, please make sure you give the differential
pressure.
In general we can say: ”the gripping pressure should be as little as
possible but as much as necessary”.
The sleeve should never be attached directly to an air supply for
a pneumatic drive without a pressure reducer (at the factory-set
gripping pressure).
Even with a high differential pressure, the design of the sealing
sleeve allows you to have a relatively low gripping pressure. For
example, a gripping pressure of 3 bar may be sufficient for a
differential pressure of 6 bar. We cannot give you any hard and fast
rules for this, because the values depend on the nominal widths of
the valves, the composition of the elastomers and the media, and
so each individual system has to be calculated separately.
Another pre-requisite for a perfect functioning is a delay switch, i.e.
the sleeve must be pressurised with compressed air 0,5 - 2 seconds
after the valve has closed (after the signal of the limit switch). In
this way, you can be sure that the valve disk is closed (”ZU”) before
the sleeve is pressed down on to it. This ensures a static seal. The
same thing is true in reverse, i.e. when opening the valve.
The sealing element relaxes again approximately 2 seconds before
the valve disk is opened and is ideally supported by a vacuum
dispenser. The sealing elastomer therefore retains its elasticity over
a lengthy period. A vacuum dispenser is also required if the shut-off
valve is used with a vacuum. Particularly in the high vacuum range
the ventilation of the seal collar should be done via a vacuum
system present at the customer.
We would urge you to keep very strictly to this procedure, because
failure to do so will result in all guarantees becoming null and void.
One way of making sure that these important parameters are kept
to, so as to ensure perfect functioning of your APS valve, is to use
one of our operating systems for example see drawing 000331a.
Here you have to switch the both solenoid valves by a PLC-Control
as above described.
Alternatively, control systems as per drawing 0003534, 0003475d or
0003784b (by nitrogen) can be supplied. Here, the required delay
times are integrated into the control system so that the positioning
of the <APS> valve is identical with that of a “normal” shut-off valve.
Air Supply:
The compressed air supply should be via dry filtered compressed
air or if necessary (please check) via nitrogen – because by a
failure of the sealing element the air could get inside.
Safety Instructions:
Installation and removal and carrying out all work on the shut-off
valves should be done only by fully authorised / trained personnel.
For safety reasons, before removing or installing, or performing any
work on the shut- off valve, the electricity and pneumatic air supply
are to be shut down.
It is vital that the pipes are depressurised.
These operating instructions are in addition to the existing
installation and maintenance manual for Warex shut-off valves.
Lifetime of wear parts:
To reach a maximum lifetime by handling difficult products with high
differential pressure (e.g. inlet valve of a vessel for pneumatic
conveying) it could be helpful to open and close the valve without
product and to install a deflector above the open disk.
WAREX-VALVE GmbH