Weka TgxV DN250 User manual

Untertitel
Installation, operation
and maintenance
manual
Valves type TgxV DN250/PN6

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Content
1. General information...................................................................................................................................................4
1.1 Applicability.........................................................................................................................................................4
1.2 Contact data........................................................................................................................................................4
1.3 Further applicable documents.............................................................................................................................4
1.4 Storage place of the manual...............................................................................................................................4
2. Safety..........................................................................................................................................................................5
2.1 General safety information..................................................................................................................................5
2.2 Explanations of symbols and notes ....................................................................................................................5
2.3 Intended use .......................................................................................................................................................6
2.4 Incorrect use .......................................................................................................................................................6
2.5 Residual risks......................................................................................................................................................6
2.6 Qualification of personnel ...................................................................................................................................7
2.7 Operator's obligation to exercise due diligence..................................................................................................7
2.8 Personal protection equipment...........................................................................................................................7
3. Transport, storage and packaging...........................................................................................................................8
3.1 Transport.............................................................................................................................................................8
3.2 Storage................................................................................................................................................................8
3.3 Packaging ...........................................................................................................................................................8
4. Cleanliness.................................................................................................................................................................8
5. Designation of the valve components.....................................................................................................................9
6. Installation, assembly and disassembly of valves...............................................................................................10
6.1 Unpack from wooden box / general transportation...........................................................................................10
6.2 General information ..........................................................................................................................................13
6.3 Installation position ...........................................................................................................................................13
6.4 Installation welding of the housing....................................................................................................................14
6.5 Allowed displacement.......................................................................................................................................16
6.6 Assembly and disassembly of the valve...........................................................................................................17
6.6.1 Disassembly of the PM actuator, Samson type, Po......................................................................................17
6.6.2 Disassembly of a TgxV DN250/PN6 valve ...................................................................................................21
6.6.3 Replacing a flow plug or seat seal................................................................................................................24
6.6.4 Assembly of a TgxV DN250/PN6 valve ........................................................................................................27
6.6.5 Assembly of the PM actuator, Samson type, Po ..........................................................................................30
6.6.6 Replacing the seals.......................................................................................................................................33
7. Marking of the valve................................................................................................................................................35
8. Commissioning and operation...............................................................................................................................35
8.1General information ..........................................................................................................................................35
8.2 Pneumatic valves..............................................................................................................................................35
8.3 Electrical and pneumatic additional components..............................................................................................36
8.4 Operation Conditions ........................................................................................................................................36
Ambient and fluid temperature range............................................................................................................................36

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Maximal allowed pressure.............................................................................................................................................36
9. Maintenance.............................................................................................................................................................37
9.1 General information ..........................................................................................................................................37
9.2 Orifice hole and/or guard connection................................................................................................................37
10. Spare parts ..........................................................................................................................................................37
11. EU Declaration of conformity ............................................................................................................................38

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1. General information
The present manual contains instructions for safe and correct installation, operation and maintenance of the
product. It is exclusively intended for specifically trained and authorized experts. In case of problems that
cannot be solved with the help of this manual, please contact the manufacturer.
1.1 Applicability
The present manual applies to valves of type -TgxV with nominal widths from DN250 pressure levels up to
PN6, equipped with a pneumatic diaphragm actuator.
1.2 Contact data
For more information on the product, please contact
WEKA AG
Schürlistrasse 8
CH-8344 Baeretswil
T: [phone]
[e-mail]
www.weka-ag.ch
1.3 Further applicable documents
In addition to the present manual, the technical drawing of the valve and the documentation of additional
components must be considered.
1.4 Storage place of the manual
The operating manual and all other applicable documents are integral parts of the product and must always
be kept in proximity of the product and be accessible to the staff.

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2. Safety
2.1 General safety information
The manual contains detailed descriptions for safe and correct installation, operation and maintenance of
the product.
Read the manual carefully and thoroughly to become familiar with the product.
The manufacturer accepts no liability for damage caused as a result of failure to comply with the safety
information and warnings.
2.2 Explanations of symbols and notes
Safety information and warnings are intended to prevent hazards for the life and health of users or
maintenance staff and to avoid property damage. They are highlighted by the signal words defined below. In
addition, they are marked by warning symbols (pictograms) at the place they appear.
Safety information and warnings indicate important information. The following symbols are used to point out
specific properties or hazards:
Danger
Severe physical injuries and/or major property damage may occur in case that the
appropriate precautionary measures are not taken or not complied with.
Warning
Physical injuries and/or major property damage may occur in case that the appropriate
precautionary measures are not taken or not complied with.
Caution
Minor physical injuries and/or property damage may occur in case that the appropriate
precautionary measures are not taken or not complied with.
Please note
Marks important information on theproduct and/or handling of the product that requires
specific attention.

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2.3 Intended use
At the time of delivery, the product complies with all applicable laws, regulations, and standards.
If the product is used as intended and the warnings in this manual and those at the product are complied
with, the product does not pose any hazards or risks for persons, property, and the environment. This
applies to the entire service life of the product, from delivery and installation to operation, disassembly and
disposal.
The following is considered intended use:
•Only operate the product according to this manual, the specifications from our order confirmation and
the technical drawing.
•Only use original WEKA spare parts for maintenance and repair of the product.
The following must be ensured prior to installation and any maintenance work:
•Depressurise the pipe.
•The pipe must be completely drained and, in case of hazardous media,
purged with suitable cleaning fluids.
•Obtain information about potential hazards that may occur due to residues of
the operating fluid and take appropriate measures (wearing personal
protection equipment, etc.).
•If required, the product must be cooled down or heated up to ambient
temperature.
•Interrupt the auxiliary energy of the actuator.
•Prevent potential re-start of the system by third parties.
2.4 Incorrect use
Any use of the product other than or not within the specifications as described in chapter 0 is considered
incorrect. The following additionally applies:
•Any unauthorised modifications of the product may result in personal injuries, property damage and/or
functional defects. The risk for any such situation is solely borne by the user. Any warranty or liability
claims are excluded.
2.5 Residual risks
Residual risks may still be present even when the product is used as intended.
•Hazard due to crushing by non-secured actuator.
In case of negligent or incorrect use of personal protection equipment:
•Hazard due to noise resulting in loss of hearing
•Thermal hazard (burns, scalding, etc.)
•Hazard due to escape of operating fluid
Despite all precautions taken, there may be residual risks that are not obvious. Residual risks can be
minimized if the safety information and information on commissioning and start-up, as well as the entire
operating manual is observed.

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2.6 Qualification of personnel
The product is exclusively intended for application within systems and facilities where the required work is
performed by trained and qualified experts. Experts are persons who are familiar with installation,
commissioning and operation of this product and who have the appropriate qualifications for their tasks, e.g.
•vocational training or instructions about use and care of appropriate safety equipment based on the
current state of safety engineering
•First-aid training
•For systems with explosion protection equipment: vocational training or instructions and/or authorisation
to perform work at potentially explosive systems
Maintenance and repair work must only be performed by trained and qualified professionals. Work at
electrical systems may only be performed by qualified electricians or by persons who have received
instructions on electro-technical systems.
2.7 Operator's obligation to exercise due diligence
To prevent accidents, faults and damage to the environment, the person respectively responsible for
transport, installation, commissioning, operation, maintenance, and disposal of the product must ensure the
following:
•All warnings and information on hazards must be observed.
•The personnel must be instructed about occupational health and safety, the operating manual and
particularly the contained safety information on a regular basis.
•Regulations and operating instructions for workplace safety and the relevant information about
personnel conduct in case of accidents or fires must be kept in an easily accessible place or hung up
within the premises in an easily visible manner.
•The product must only be operated in perfect and functional condition.
•Only use spare parts as well as lubricants and operating media that are approved by the manufacturer.
•Observe the specified operating conditions and requirements for the place of installation.
•Provide all necessary devices and the personal protection equipment required for the respective work
tasks.
•The specified maintenance intervals and the corresponding regulations must be observed.
•Have installation, commissioning/start-up and maintenance of the product performed only by trained
and qualified personnel according to this operating manual.
•The operator must ensure use of the product as intended.
•Prior to commissioning of the product, the operator shall carry out a risk assessment and define
appropriate inspection and maintenance intervals according to the operating conditions.
2.8 Personal protection equipment
Wearing of personal protection equipment is required during work to minimize potential health hazards.
•The protective equipment required for the respective kinds of work must always be worn.
•The information and instructions on personal protection equipment displayed in the work area must be
observed.

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3. Transport, storage and packaging
3.1 Transport
The valve is transported in wooden box and must be kept in the original WEKA
packaging throughout the transport. Transport below -40 °C and/or above +80 °C is
not permitted.
3.2 Storage
The valves must be stored in a dry and dust-free environment. Storage below -40 °C
and/or above +80 °C is not permitted.
3.3 Packaging
Every valve is separately wrapped in transparent foil, either as one complete unit (housing with insert
completely mounted) or as individual units (housing, insert, additional components). The valve inlet and
outlet are covered by protective caps. To avoid unnecessary pollution, the packaging should only be
removed shortly before the product is needed for installation.
4. Cleanliness
Prior to being packed, the valves are cleaned according to ISO 23208-2005, to be free of oil and grease.
Particularly during installation, cleanliness must be ensured. Even the smallest pollution may impair the
function and/or tightness of the valves.
The following rules must be observed during installation and maintenance.
•The valve inlet and outlet must be covered by protective caps.
•Disassembled components, such as actuator or inserts must be stored in PE
bags in a dry and dust-free place.
•Open valve housings after removing the insert must be protected from ingress of
particles and other kinds of pollution.

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5. Designation of the valve components

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6. Installation, assembly and disassembly of valves
6.1 Unpack from wooden box / general transportation
To detect any transport damage at an early stage, a shock indicator has been
applied to the wooden box. If the wooden box or the shock indicator are damaged,
the WEKA AG company should be contacted
To unpack the valve from the wooden box, please follow the instructions
Fixation of the lifting material
Attach the lifting loops to the yoke of the valve.
Pass the loops through the eyelets at the top of the
pneumatic actuator.
When selecting the lifting material, make sure
that it is designed for the weight of the valve.
Before lifting the valve, make sure that the box
is secured against slipping away.

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Uprightening the valve
Align the valve slowly and evenly until it is vertical.
Loosen the four screws at the bottom of the wooden box.
Now you can lift the valve out of the box.

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Disassembly of the turning and transport device
Now position the valve just above the floor so that the device
cannot fall during disassembly.
Now you can remove the turning transport device from the
valve. (WEKA number 46979).
To remove the device, the 4 screws should be removed with
allen wrench, 8mm.
The other two screws are on the back side of the valve
housing.
Now lift the valve out of the device.
The WEKA AG company recommends to keep the device.

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6.2 General information
To install the valve into the pipeline or into the vacuum box, it is not necessary to completely disassemble
the valve if the following conditions can be met:
Welding of the thread part
The temperature on the welding flange during welding must be kept as low as possible. Between valve
housing and the insert are two static o-ring seals. The welding flange should always be cooled with a damp
cloth.
Welding of the pipe connections
The temperature on the connection pipes during welding must be kept as low as possible. The seat seal can
be destroyed by excessive heat. The connection and the valve body should always be cooled with a damp
cloth.
During the welding the valve should be flushed so that the heat is always conducted out of the valve (heat
does not pass through the seat area)
If this cannot be guaranteed, we recommend disassembling the actuator and valve inserts according to
chapter 6.6.2 Disassembly of a TgxV DN250/PN6 valve. It must be ensured that insert and actuator are
stored packed in a dry and dust-free place.
6.3 Installation position
The valves must be installed in vertical position with the actuator on top. A deviation from the vertical axis is
generally possible up to an angle of 1 degree. Larger deviations are only permitted with the agreement of
WEKA AG. Special fixing devices must be installed for this.
The valve housings must be installed into the pipeline possibly free of tension. Excessive transverse
stresses caused by the pipeline may negatively affect the function of the valve. Any bending or shearing
stresses during or after welding should be avoided.

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6.4 Installation welding of the housing
The valves must be carefully welded in by spot welding and minimum energy input to avoid deformation due
to thermal distortion at the valve housing. The valve housing may be cooled with a damp cloth during
welding. After spot welding, it is recommended to first weld on the fluid pipes and then the vacuum flange.
Ensure cleanliness during work. Pollution at the valve seat or at the guide areas may be the reason for
malfunction or functional failure of the valve.
Step
Picture
Description
1
Fix the thread part in the valve plate with
3 welding spots.
2
Spot-welding of pipes with 3 spots around
the circumference.
3
Weld the pipes with as low heat input as
possible.
If required, cool with a damp cloth.
4
In order to prevent tube
tension, the welding points
should now be removed.
Now weld another 3-6 tack sports at the
thread part and subsequently carefully
finish the weld joint. Check the housing
again for distortion.

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Additional tips for reducing welding heat:
For welding procedure 141, TIG welding:
•Ensure low heat input
•For sockets with 2 mm wall thickness, use approx. 48-52 amps.
•The diameter of the filler wire should be 1-2 mm
These values are only intended as guidelines. Depending on the welder and the welding process, the values
need to / may be adjusted.
Shielding gas:
The flow direction of the shielding gas should always be from the valve into the pipe.
•Welding at the seat socket: The shielding gas input must be from the output socket
•Welding at the output socket: The shielding gas input must be from the seat socket
Welding sequence:
First, weld 2 quarters of the circumference on opposite sides. Leave to cool. Then, weld the rest.

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6.5 Allowed displacement
The following information shows the permissible pipe forces F(max) or moments Mb(max) which may act on
the valve with a cryogenic length of 1400 mm. The maximum deflection (r max) for a valve is calculated
based on the forces or torques.
The permissible forces or torques for different cryogenic lengths can be determined using the intercept
theorem.
•maximum allowed deflection of 1.0 mm
•maximum resulting force: Fmax = 8.500 N or Mmax = 12.000 Nm (not overlapping)
oExample: Fx = 4250 N combined with Mz = 6000 Nm would be a valid combination

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6.6 Assembly and disassembly of the valve
The work must be performed in a clean environment using suitable tools.
All disassembled parts must be taken to a clean place directly after disassembly and protected by means of
a plastic bag to avoid pollution or damage.
In case that additional components, such as switches, sensors or other elements are installed at the
actuators, these do not necessarily need to be disassembled beforehand. However, WEKA AG
recommends disassembling them to avoid damage and minimize the risk of injury.
Tools
The required tools are listed in the respective chapters. Special tools or special
auxiliary agents can be ordered from WEKA AG. They are not included in the scope
of delivery.
Previous knowledge
A certain amount of previous knowledge of mechanical handling is mandatory to
prevent damage to the valve. Tightening of fasteners, such as screws and nuts, must
be performed according to generally applicable mechanical engineering guidelines.
Risk of injury
During certain work steps, parts are put into movement under great use of force. To
avoid injuries, act with special care and caution. Also, some components may be
very heavy. If possible, handling such components should be carried out using a
crane.
Training
WEKA AG offers training courses in addition to this manual; participants receive
valuable advice to make their work and specific work steps easier
6.6.1 Disassembly of the PM actuator, Samson type, Po
Prior to beginning with your work, you must first determine whether the actuator is
Po (normally closed, pressure tend to open) or Ps (normally open, pressure tend to
close), because there is a difference in the work steps for the two types. This
information can be found on the type plate of the actuator.
The disassembled components must be stored in a clean place. Damage to the
sealing surfaces can lead to tightness but not only problems.
Required tools and auxiliary agents
Allen-type wrench, 5mm
Open-end spanner SW24
Open-end spanner SW60
Hook spanner 120 - 130

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Step
Picture
Description
Additional note: Depending on the nominal width of the valve, the components may slightly vary in
appearance. However, the steps remain the same.
1
If position controller is used:
Unscrew the blue marked screw with an Allen-
type wrench, 5mm
The plate can be removed together with the
spacer and bracket.
➔The position controller (Tapper) are not
connected anymore
2
Remove the two screws at the coupling using
an open-end spanner SW24.
The coupling can be disassembled.
ATTENTION
The insert must not be turned
during disassembly, this could
result in irreversible damage to the
seat surface or to the actuator
diaphragm.

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3
Connect the compressed air line to the
actuator.
The maximum and minimum air pressure
values are provided in the customer drawing.
Depending on the additional parts for the
actuator, the air connection can be at a
different location.
Please note:
The maximum air pressure of 6
bar must not be exceeded; higher
pressure will result in damage to
the actuator.
Attention:
The actuator and the coupling are
moving parts. Risk of injury! Keep
your hands off..
4
Loosen the lower nut from the actuator using a
Hook spanner 120 - 130
The nut can be extended and removed
between the spindles from the actuator.
5
Remove the actuator (blue marked) with a
crane.
Use the two eye bolts for this.
ATTENTION:
The insert must not be turned
during disassembly, this could
result in irreversible damage to
the seat surface.

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6
Remove the compressed air line from the
actuator.
Attention:
The actuator and the coupling are
moving parts. Risk of injury! Keep
your hands off.
7
The dimension "X" must be measured from the
upper edge of the coupling to the yoke stop
During assembly of the valve, the dimension
"X" must be set! Otherwise, the valve travel will
be incorrect
We recommend writing down the
dimension "X" and the respective tag no. of
the valve.
8
Using two open-end spanners, hold the
coupling (blue marked) and the nut at the
insert. Remove the coupling and put it aside.
Loosen the counter-nut from the insert.
Open-end spanner SW60 & SW60
Dimension "X"