alli @ AALBORG w INDUSTRIES Safety valves 1 Installation In the following the measures required to achieve a safe and reliable installation of the safety valves will be described, Ifthe installation is subject to approbation from special authorities, their requirements must be observed, 4.4 Mounting of safety valves Figure 1 shows an installation example of the safety valves, Note: Safety valves should be handled carefully. Any rough treatment can cause damage to the seating surfaces. Waste stoam pipe ‘Suppor Expansion joint vith seating ring Cin Mounting of safety valves, example Figure 1 safe_O1b.edr Language UK Page 13@ AALBORG INDUSTRIES It is recommended to provide each safety valve with a separate waste steam pipe, ‘which must have a sufficient inside diameter determined by the full exhaust quantity of the valve as well as the resistance of the pipe (pressure loss) and must be at least cone dimension larger than the outlet flange. The pressure loss in the escape pipe including the exhaust loss should not be higher than 10% of the set pressure for the valve. The vertical pipe must run as straight as possible and be thoroughly anchored and supported to the structure of the vessel to withstand the reaction during blow out. A. long escape pipe with more bends may necessitate that a pipe with a larger inside diameter is chosen in order to secure that the back pressure will not be too high. It is necessary to install a horizontal expansion device between the valve outlet and the escape pipe or in other ways. This is to secure that forces from the latter are not transferred to the safety valve body with subsequent tensions and dislocation of the body resulting in leakage or, at the worst, destruction of the valve. Aalborg Industries recommends an expansion device as shown in Figure 1. The escape pipe will normally expand about 2.5 mm per metre of pipe from the valve to the fixed point ‘The distance between the centre lines of the safety valve and expansion joint must be as short as possible. A large horizontal length increases the risk of tensions in the valve body during blow out, and in such cases a support is required to avoid forces/tensions are transferred to the safety valve and boiler. Note: It is very important that the gaskets used have the correct dimensions compared to the inlet and outlet flanges, and that the hole is big enough to allow free passage. The bolts must be tightened equally all the way round the flange to avoid unequal tensions. 1.2 Drain ‘The drain from the drip tray must be led separately to an open outlet to prevent penetration of steam from other sources involving a risk of blocking the valve. ‘The outlet may be covered by a ‘splash-cover’ to avoid splashing to the surroundings when a safety valve is blowing, 1.3 Lifting device The safety valve can be equipped with a lifting device. Any extensions from the lifting lever of a safety valve to the operating stand must be arranged in such a way as not to transmit any force to the lever when at rest, see Figure 2, By securing a steel wire to the lifting device, it is possible to operate the safety valve in a safe distance. The safety valve can be operated by means of the lifting lever at 85% of the set pressure. Warning: It is very important to make sure that no rest operation of the lifting device and steel wire. Language UK Page 23@ ® ‘Figure 2 safe_02.edr Language UK Page 303Industries @ AALBORG Safety valves General In the following the measures required to achieve a safe and reliable operation as ‘well as maintenance of the safety valves will be described, together with adjustment and dismantling instructions. An installation example of the safety valve is shown in Figure 1 ‘Mounting of safety valves, example Waste steam pipe support Expansion joint with sealing ving So Figure 1 safe Ole.cdr Maintenance and start-up of boiler A regular inspection of the safety valve is recommended at least once a year. Some media and appliances requite a more frequent inspections, this is according to the ‘experience of the supplier. Language UK Page 1/4ili, AALBORG Warning: Prior to any handling and dismantling of the safety valve ensure that the system is depressurised. Before lighting-up the boiler, pipe connections must be thoroughly cleaned for dirt and foreign bodies. If the valve is not completely tight, which often is the case after start up of the plant, this is usually caused by impurities between the seat and the cone. In order to remove these impurities the valve must be heavily blown out by means of the lifting device. Ifthe valve is not tight after several blows, it may be due to the fact that a hard foreign body has got stuck between the cone and the seat, and itwill then be necessary to dismount the valve for overhaul. Warning: In case of a leaking safety valve the valve must be inspected and over-hauled as soon as possible. It must be ensured that the boiler is totally depressurised before dismounting the valve. ‘Note: Before dismantling the safety valve in the workshop the position of the adjusting screw must be measured and noted which will facilitate the adjustment later when the valve is to be adjusted when in service. In case the facings between the cone and the seat have been damaged, they must be grinded. Step A: The cone can be grinded against a cast iron plate, using a fine grained carborundom stirred in kerosene. Step B: The seat in the valve body can be grinded in the same way by using a cast iron punch of suitable size. Note: Never use the cone itself when grinding the seat, Warning: The spindle and the valve cone must always be secured against turning as the seat and the cone may thus be damaged. Step C: Before assembly the valve must be thoroughly cleaned, and all traces of grinding material and impurities must be removed. Step D: When the valve has been mounted and the boiler is commissioned, the valve must be checked for leakage and adjusted to the set pressure. Step E: The adjustment screw is secured by means of its lock nut, and the valve is, sealed. Language UK®@ alll, AALBORG INoUSTRIES The following should be regarded as recommendations of routine checks on the safety valves, in order to secure a correct function: Monthly Step A: Examine the safety valves for any leaking, such as: — [Is water seeping from the drain plug at the valve body? — Is the escape pipe hot due to seeping steam from the valve seat? Step B: Examine the drain and expansion device atthe escape pipe. Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts Yearly Step A: The safety valve should be tested in operation by raising the boiler pressure, ‘Step B: Expansion and exhaust pipe should be examined at the same time. Adjustment and dismantling Safety valves are delivered with the required spring setting and sealed against unauthorised adjustment. Adjustments are only allowed in the spring margins. Outside the margin a new spring is required. The pressure in a system should not exceed 90% of the set pressure. Al item numbers mentioned in the following sections refer to Figure 2. 3.1 Dismantling of lifting device Safety valve with open cap: Step A: Remove bolt (39) and remove lift lever (41) 3.2 Set pressure change without spring change Note: Pay attention to spring range. Step A: Spindle (14) must be held fast by all alterations. ‘Step B: Loosen lock nut (21). Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for low set pressures. Step D: Secure the new setting with the lock nut (21) and reassemble lifting device. “Language UK Page 34® alli AALBORG 3.3 Spring change Step A: Spindle (14) must be held fast by all alterations. Step B: Loosen lock mut (21) and tur adjusting serew (17) anticlockwise, then the spring (37) is not under tension. Step C: Loosen the nuts (8) and remove the bonnet (42). Step D: Remove the upper spring plate (26), spring (37), spindle (14) with disc (12), guide plate (4), and lower spring plate (26). Step E+ Clean the seat (2) and dise (12) Step F: Remount the spindle unit with the new spring and upper spring plate, Assemble bonnet (42) and adjust to the spring range, Step G: Secure the spring setting through the lock mut (21) and remount lifting device. Assembling drawing of safety valve = orem = Figure 2 Language UK, Page 44od SAFE Safety valves ARI-SAFE - Full lift- / Standard - safety valve ARLSAFE Full lift safety valve DIG Standard safety valve F “Types apprved ae oTRD and AD-A2 Diet ace wth pg *TOV-SV-..-663-019 Figure sott2 +TOV-SV-..-720-F Figure saints + Furber appa: ee ini ARI-SAFE Standard safety valve for the heating technology *Tipetes apr ace. to TRD 721 Diet ated wth ping + TOV. SV... 688. DIGH Figure 903 sTOV-SV-...€89-D Figure $04 Diet ade wih weight SV-.-757-D Figure $90 ARL-SAFE-P Standard safety valve DIGIF *Typorest approved ac. to TAD and ADA2 Diet loaded with srg: TOV-SV-..-811-0/G Figure s2tz2s Figure 921823, ARE-SAFE-TC Full lift safety valve DIG ‘Standard safety valve F + Types pproned ace. to TAD and ADA2 Diet oaed wih srg *TOV-SV,.-995-018 Figue 4143 +TOV-SV...-1005-F Figure e143 [FOR HORIZONTAL APPLICATION Page 20 ‘ARLSAFE-TC tL Standard safety valve fig for the heating technology Fig 200 Fig. 950/960 * potas appre ac. 0 TROT21 Dette wh ping *TOV-8V-..-997-DIGM Figure 945 Features: STOV-8V-..-97-D gue 948 «Dretloadd wit sping nd + Dretinade wit weit (ny Fg, 90) ARESAFE-TCP Weare soattise Standard safety valve DIGIF + Prcon algrent eeuide * Typet approved ace to AD-A2 + Possible wth sf soal cise Direct loaded with spring: “TOV. SV... -1041 . DVGIF Figure 961-63 ig. 961 Penta ih EPOM below Page 18 «Posie wih ness te! below ARISAFETOS + Atoomnon feu ypos SAFE TOMTCPTCS) Standard safety valve D/GIF 1 “Types proved ceo AD 2 ie ated wh ping . TOY SV. 1041 «DIG Figure 951-59, fom oo oe YP Gry 7 ‘on 0062 -Daasitjecto ateraionSAFE (@ ARISAFE- Fulllft safety valve Dic Standard safety valve F 28 35 7 4 Fig. 901 osed iting device dosed bonnet Hgot 902/911 /912 JPN 16/16 po ane aT Tana eNO sa0i [maT ath9 —PNAOIT6 sana le », | eeiatevren Te atone SR an oD oe a SRS. a i 225, 666-05 {0615 | sear ee pss ap and is aa seam, agressive pies vans and igus [Satay va sin Wades crest iaged 2 fs Eee : fea, fading xy be, cdo oN Sc pat, 2 AA, ss on Ta ac Se OO, 2 casio eeu ars ei i Mass ow (i, erst (ign, vcs, operate), St gauge pressure fay, bac gauge pressure (a [Order data” [ARESAFE safely valve Fire 20 Wei Ck) fe Ree ASOD a back pressure (ia back pressure z TEiion 040- Data Siac aaonale} 8} 8/8] 8) 8| 8] £) B) B18] ‘max. set pressure stainless steel execution ‘N80. (aan azo TRD 421 and AD elt RZ (iis Do tigher pases on eqest 02-05, 052-1 15-15 155-2 205-27 275-96 37-8 81-9 31-14 141-19 191-25, lion 2 - Data subjectoateraon29 4 42 rN ™ TT Fig. ..812 ‘pen iting device ‘dosed bonnet closed bonnet Fig... 811 gastghtcop Fig, $02 pening device ‘open bonnet iin O90 Data sjetio aerationSafety valve-approvals 2 ‘Elion 0000 - ala ajacioaeraon | | |© ARL-VASI® - VAlve Sizing-Program Contents of ,ARF-VASI®™ (Program part ,Safety valves") Sting (Caletiaton of vasiza wi given copaciy. + Capactyreacion oes (Capac and reacon forces calelton wth given va + Bac pressirein the out pipe Complete tack pressure calcitonin the cut pipe Pressure dtp inthe ine pipe ‘Alona resistance caticent and ma. il pipe length caliaion. Media: Inet cia databark (over 180 Medi) with coeons: Vapour gases Steam fatuated and supeheated) Lins Hot waar Thermal expansion Special features: Project administration othe chosen sit vale tear wh contol vate, rosur educing ves, stop vahes and butery vas. Stand ANSHunits wih drect conversion o another databank, ~ ALARI safely ves aro ntogried in a databank. Resistance coficients of elbows and tings Intgrates. Direct sth over of languages (German / Engst) soporte tothe seeen and pin. ‘Systom Requirements: \WaNDOWS 95/98 ME7¥T or 200 ‘Eton GO -Datasbjoc SanParts easy 95,0005 | ca603,07048 [tosten(@scony)— 14ale ast as ces Seed sa SEC —— ee pea Sse ae POM itba — |0bar [Se aaa S 20 bar bar asber [ba joebar fatter |atbar | 18ber Intermediate values for max. permissible operational pressures can be determined by inearierpolaion of te given temperature / pressure char only from 120°C upwards. I | | | | | | SEE a ee | OO ce ARTS ROE SOO os we 40 Boar _|eOdar —|sebe 20bar —[osbar [otter — |z2bar ot tar 100 | sober |b ~ [sar [tba [bar] rebar |oonar —[erbar ~ [tar Intel value fr frist operational ressies can be delemined by Hear etalon ike gon js {temperate pressure car ony rom 20° pads, | * Sis ard Henson rat ot of A-70 | £7) Information Restitions of technical ules to be observed! 1 The engine deleting a ytem ora plans esonable forthe slction of the cect al i len RE -Uaa aw eon i | IDimensions SAFE Figure 901 - 912, 903, 904, 990 oz |pRTeoR 260] 140 | ts | ts | tes, at 16 D254 Sa Drainage hole wth plug” ‘Gar ianges ace to IN raed fae, fag asc W DIN 506 oan] * Fig, 903, 804, 980 and starts steals spec design SAFE-P Figure 921-924 ‘wear SAFE-TCP Figure 961-963 SAFE-TCS Figure 951-953 ea aif "Tres connedlons on requ ‘ion 040 -DatasbjoctoateratonEPOM 95°C upto +180°0 Abbreviation E Bellow saelss soe Viton PM) 25°C upto 180°C Abbreviation V Neoprene (CR) 20°C upto +125°C Abbreviation N | @ /EPOM below (max. +120°) | Mota soa! Sottsaing i (Other variations: +Sianles ste! below sea), +Rutberbelon metal ea Rute below/ Sot sealing dae Want beon Sot sealing dsc + Ausing bot + Support orguos led Lock bs Test 93g + untae + Proximity sch + Hosting jacket + uptura se + Romovate ng a esting jacket ~~ Technology forthe future. y ARL-Aratuten Albert ichter GmbH & Co. KO, D-39759 Schl Hate Sukenbrock, “To. +49 5207 1904-0, Telefax +49 52 07 /994-158 of 189 _nfernot hip-kaww.ar-amatren som mal info.verieb @arranmaturen.com z ‘Eton O80- Dal sitjento aaronOa & Operating and installation instructions Safety valves SAFE & SAFE SAFE-P (Series 900) (Series 920) SAFE-TC SAFE-TCPITCS (Series 940) Contents (Series 960/950) 41.0 General information on operating 7.0 Care and maintenance.. Instructions ... 27.4 Setting instructions.. 2.0 Notes on possible danger 27.44 Removing the cap 2.1 Significance of symbols 2. 7.4.2 Changing the set pressure “without” 2.2 Explanatory notes on safety information een 2 spring change .. Panta ellie) 7.1.3 Changing the set pressure “wit” 5 spring change ... 7.2 Representation ... 4.0 Descriptio 44 Scope of applications.. 3 i a 8.0 Troubleshooting. 15 ae ~~ 9.0 Troubleshooting table 8 aa) pen 5 10.0 Dismantling the valve or the top part ..... 17 41.0 Warranty / Guarantee . "7 12.0 EC declaration of conformi Manufacturers declaration. 4.4 Technical data ~ remarks. 4.5 Marking 5.0 Installation. 5.1 Genera notes on instalation... O 6.0 Putting the valve into operation.. en Rev. 0040401000 2704Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 1.0 General information on operating instructions ‘These operating instructions provide information on mounting and maintaining the fittings. Please contact the supplier or the manufacturer in case of problems which cannot bo solved by reference to the operating instructions. They are binding on the transport, storage, installation, start-up, operation, maintenance and repair, The notes end warnings must be observed and adhered to, ~ Handling and all work must be carried out by expert personnel or all activities must be supervised and checked. {tis the owner's responsibility to define areas of responsibility and competence and to monitor the personnel. - In addition, current regional safety requirements must be applied and observed when taking the fittings out of service as well as when maintaining and repairing them. ‘The manufacturer reserves the right to introduce technical modifications at any time. These Operating Instructions comply with the requirements of EU Directives. 2.0 Notes on possible dangers 24 Sig icance of symbols ATTENTION! | AN te Warning of general danger. Non-compliance with operating instructions is dangerous! Read the operating instructions before installation, operation, maintenance or disassembly and adhere to them strictly. 2.2 Explanatory notes on safety information In these Operating and Installation Instructions dangers, risks and items of safety information are highlighted to attract special attention. Information marked with the above symbol and “ATTENTION ! " describe practices, a failure to comply with which can result in serious injury or danger of death for users or third parties or in material damage to the system or the environment. tis vital to comply with these practices and to monitor compliance. All other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itseff) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. Page 2 Rev. 0040401000 2704Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS Rove 3.0 Storage and transport ‘ATTENTION ! LN - Protect against external force (like impact, vibration, efc.). - Valve mountings such as actuators, handwheels, hoods must not be used to take external forces, e.g. they are not designed for use as climbing aids, or as connecting points for Iifting gear. ~ Suitable materials handling and lifting equipment should be used. See catalog sheet for weights. ~ At-20°C to +65°C. ~The paintis a base coat to protect against corrosion during transportation and storage. Do not damage paint protection. 4.0 Description ) 4.1 Scope of applications © 7 Safety valves are used to protect pressurised systems. ‘ATTENTION T ZN - Refer to the data sheet for applications, limits on use and possibilities. - Certain media require or prectude the use of special materials. - The valves are designed for standard operating conaltions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering - Valves made from grey cast iron are not authorised for use in systems subject | to TRD 110. | - When media in Fluid Group 1 are used, sea! exteriors must be designed so that they pose no danger to humans or the environment. - Open safety valves (open bonnet / open cap) are not permissible for fluids, dusty atmospheres, open air use or for any Group 1 fluids in accordance with Pressure Equipment Directive 97/23/EC. “ O The information complies to the Pressure Equipment Directive 97/23/EC. It is the responsibility of the machine planner to ensure compliance. The special markings on the valve must be taken into account. Refer to the catalogue sheet to see which materials are used in standard versions. Please contact the supplier or the manufacturer if you have any questions. 4.2. Operating principles Safety valves are safety devices designed to prevent the pressure in any pressurised system from exceeding the maximum permissible pressure by more than the permissible tolerance of, usually +10% Rev. 0040401000 2704 Page 8Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 43 Diagram Fig. 901 Fig. 961 32 31 3% 35 23 26 — 9. 7, aS = & -£ E = S fig. 1 Fig. 902 /912 / 903 / 904 / 922/924 1945 / 946, WEDI Bellow Fig. e155, 961/962 Disc series 950 Bellow series 940 - ~ 36 Page 4 Rev. 0040401000 2704@) Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS. 4.3.1 Parts list Pos. | Description Pos. |Description | 1 “Body 32 Hex. nut a 2 ‘Seat (not changeable) [33 | Liftbolt 2 Screwed seat (SAFE-TC) 34 Screw 3 Stud 35 Lift fork 4 ‘Spindle guide [36 Lifing lever 7 Gasket (37 Spring is Hex. nut Eg Screw g Lift imitation ring 35 Bolt 10 Spindle ring ~ 40 ‘Split pin i Bonnet, closed at Lever open _ 72 Disc unit ao Bonnet, open 3 Lifting aid a3 Bellow 14 Spindie aa Ring 15 Gasket 45 Ring 16 Spring type straight pin 47 Ball 17 Adjusting screw Retaining ring 18 Ball s5 | Bellowunit 9 Spindle cap 59 Protective rim 20 Parallel pin [60 | Spacer 2 Look nut 64 Coupling 22 Hex. head screw _ 62 Weight 23 Lead seal (63 Guide bush a 25 | Snapring | [65 ‘Coupling [26 | Spring plate 66 ‘O-Ring 27 Gasket ‘67 il Lift button 28 Cap, closed 68 ‘Spring type straight pin 25 ‘Cap open 70 | Balanced piston Ei Ring Refer to the data sheet for information about materials. Rev. 0040401000 2704 Page 5@ Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS Rena 4.4 Technical data - remarks for - Principal dimensions - Pressure-temperature-ratings, etc. refer to datasheet. Series 900: DN 20/32 - DN 150/250, 1°x2" - 6"x10" EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, SA 216 WCB PN 16/16, PN 40/16, ANSI 150/150, ANSI 300/150 Approval acc. to: Figure 901, 902, 911, - DIN EN ISO 4126-1, VdTOV leaflet 100, AD2000-A2 and 912 TRD 421 Application letter D/G and F - ASME Code Section VIll-Division 1 (UV-Stamp) Figure 903, 904, 990 -VdTOV leaflet 100, -100/4, TRD 721, DIN EN 12828. Application letter D/G/H and D (for Figure 904, 990) Series 920: DN 20 - DN 100 EN-JL1040, 1.0619+N, 1.4408 PN 16, PN 40 Approval ace. Figure 921-924 - DIN EN ISO 4126-1, VdTOV leaflet 100, AD2000-A2 and TRD 421, Application letter D/G and F Series 940: DN 15 - DN 25 (6 1/2"-G 1") EN-JS1049, 1.4408 PN 40 ‘Approval ace, to: Figure 941-943 - DIN EN ISO 4126-1, VdTOV leaflet 100, AD2000-A2 and TRD 421 Application letter D/G and F Figure 945-948 -VaTOV leaflet 100, -100/4, TRD 721, DIN EN 12828. Application letter D/G/H and D Series 950/960: DN 15 - DN 25 (G 1/2"-G 1") ENJS1049, 1.4581 PN 100 Approval ace. to: Figure 951-953 - DIN EN ISO 4126-1, VaTOV leaflet 100, AD2000-A2. Figure 961-963 Application letter D/G and F Accessories: Stainless steel bellow for back-pressure compensation; elastomer bellow; soft sealing disc; lock bush; proximity switch; heating jacket; test gag; rupture disc; support tongues; removable lifting ei Page 6 Rey. 0040401000 2704 | | | |— Operating and installation instructions eS SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 4.5 Marking FigeNtJType Safety valve (TOV) pets Mewcuer 7 \ Xe | A CE-marking Fol ‘must remain open as a matter of principle, although in the case of Group I fluids { (PED 97/23/EC) a nonisolatable pipeline must be connected to remove the medium safely (without back pressure if the bellow seal is damaged. Ventilation must not be blocked by any leak detector used. - No pipe sections or screws must protrude into the spring bonnet through the inspection connection. Blockage hazard! - The drainage system shall be adequate fo remove the condensate. ~ Blockage of the drainage system by dirt or foreign bodies shall be avoided. - Freezing, sticking or blocking of the safety valve must be avoided at all costs. if necessary use a heating jacket and/or stainless stee! bellow with or without a rupture disk. ~ Safety valves shall be installed with upright spindle, not series 950 when marked, ‘Einbau nur horizontal (Installation only horizontal)’, then they must be Installed horizontelly. | - Flange gaskets shail be fitted concentrically and not restrict the flow cross section. - Keep the shaft of the spindle-unit free from paint (open bonnet / cap). | ~ Blow-off ines shail be laid with gradient. Page 8 Rev. 0040401000 2704Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS - The ratio pao/po shall be taken into account when dimensioning the system. - Safety valves shall be equipped with support tongues to absorb high reaction forces. - Pressure losses in the line to the safety valve shall not exceed 3%. - Ensure that adequate drip pans are used if setting media in Fluid Group pursuant to PED 97/23/EC. ~ Planners / construction companies or operators are responsible for positioning and installing products. - Refer to appropriate TRD 421, AD2000-A2, DIN, ASME Code rules for piping and installation. - Remove transport fasteners and protective caps for inlet and outlet immediately before installation. - Water shall be drained from the safety valve and blow-off line via the blow-off line (drainage points always at the lowest point). fig. 4 cd wy =e S tk Rev. 0040401000 2704 Page ®Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS. Ror a. @> 6.0 Putting the valve into operation AN @) ‘ATTENTION ! ~ Before putting the valve into operation, check material, pressure, temperature and direction of flow. ~ Regional safety instructions must be adhered to. - Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage. ~ Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media temperatures can cause injury. Affix warning notice or protective insulation as appropriate! - Before putting the valve into operation, check material, pressure, temperature, direction of flow and also check that the data of the valve are correct for the nt ienrio type test plate) ~ Remove any test gag from cap and close opening with stopper. ~ Remove protective caps and lever lock before putting the valve into operation - Freezing, sticking or blocking of the safety valve must be avoided at all costs. If necessary use a heating jacket and/or stainless steel bellow without a rupture disk. (Note point 5 “Insfailation’). - When operating without a blow-off line, medium may spurt from the valve outlet. Injury hazard! - Blowing off may generate loud flow noise. ~ Medium may be discharged from the ventilation or inspection hole in the spring bonnet (safety valves with stainless stee! bellows and heating valves) Injury hazard! - Hot vapour may be discharged if the spring bonnet is open, Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that: - All works has been completed! - The valve is in the correct position for its function. - Safety devices have been attached. Page 10 Rey, 0040401000 2704Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 7.0 Care and maintenance Maintenance and maintenance-intervals have to be defined by the operator according to the requirements. ‘ATTENTION I ~ Too frequent lifting for test purposes can increase wear of the sealing surfaces! - The safety valve must be lifted from time to time in line with current regulations to ensure that the valve works correctly. (The intervals at which this must be done depends on various factors so that no generally applicable interval can be specified) - Original parts only should be fitted as spares as a matter of policy. - In safety valves with an open spring bonnet there is a danger of being crushed between the spring windings during lifting and setting. - Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due to particles between the seat and disc. = If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been damaged. ‘This can only be rectified at our works or by an authorised contractor. - With valves corresponding to Figures 901, 921 and 941, the lever must always be returned to the original position after lifting the safety valve. - With Fig. 951 and 961 the lift button must be pressed down again after lifting, - The manufacturer accepts guarantee liabilities only if tampering by third parties is. prevented. 7.1 Setting instructions ‘ATTENTION? The following work must only be carried out by authorised specialist workshops orat the operator’s own responsibility with monitoring by an independent agency (eg. TOV). 7.4.1 Removing the cap ‘ATTENTION If there is back pressure or during setting/lifting, medium may be discharged from | the open bonnet, or into the adjusting screw area if the bonnet is closed. ‘Open caps - Remove slit pin (pos. 40), bolt (pos. 39) ~ Extract lifting lever (pos. 41). ~ Remove screw (pos. 38). ~ Unscrew cap (pos. 29). Glosed caps ~ Press lifting lever (pos. 36) towards bonnet (pos. 11) and against stop. - Unscrew cap (pos. 28). Glosed cap series 960/950 Remove spring type straight pin (pos. 68) ~ Remove lift button (pos. 67) or lifting lever (pos. 36) - Unscrew cap (pos. 28) Rev. 0040401000 2704 Page 11Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 7.4.2 Changing the set pressure “without” spring change ATTENTION T | - When changing the set pressure in a pressurised system bear in mind vapour | discharge if bonnet is open, in adjusting screw area if bonnet is closed. | = Note spring setting range. ~ Check the spring range. le (pos. 14) mi rat ~ Loosen lock nut (pos. 21). - Tum adjusting screw (pos. 17) clockwise to increase and anticlockwise to reduce the set pressure. ~ Secure spring setting by tightening lock nut (pos. 21). - Assemble lifting device. 7.1.3 Changing the set pressure “wi ” spring change ~ ATTENTION I A - Depressurise the system before dismantling or opening the safety valve. -For removing the cap referto 7.1.4. - Extract parallel pin (pos. 20) and liftoff the spindle cap (pos. 19). ~ Slacken locknut (pos. 21) and relieve spring (pos. 37) by turning adjusting screw (pos. 17) anticlockwise, - Unscrew nuts (pos. 8) at flange connection and remove bonnet (pos. 11/42). Fig. 940: loosen coupling (pos. 61) Fig, 950/960: loosen bonnet (pos. 11) ATTENTION I - With higher set pressures, the two nuts (pos. 8) on the longer studs (pos. 3) must be removed last and simultaneously! ~ Remove top spring-plate (pos. 26) and spring (pos. 37). ~ Extract spindle (pos. 14) with disc (pos. 12/12a), guide plate (pos. 4/4a) and bottom spring-plate (pos. 26). ~ Clean seat (pos. 2) and disc (pos. 12). ~ Insert spindle (pos. 14) with disc (pos. 12), guide plate (pos. 4), spring-plate (pos. 26) and different spring (pos. 37). Page 12 Rev. 0040401000 2704L Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS. it work hol ATTENTION I - Torques must be observed: ee I 100Nn mia 3040Nim | —[eorewed seat BROAD 180m ™ié]7080Nm] [bonnet BRASO/EED 60 Nm ‘mao | 480-175 Nw ~ Check spring marking in accordance with manufacturer's data. - Note spring setting range. - Change seals. - Fit bonnet (pos. 11/42) and reset the set pressure; make sure spring setting range is appropriate, ~ Secure spring setting by means of lock nut (pos. 21). ~ Assemble lifting device, ~ If necessary, replace both spring plates (pos. 26) and use longer studs (pos. 3) when fitting a spring for a higher set pressure. ~ Further information obtainable from the manufacturer. Only for series 900 ATTENTION When changing the set pressure and fitting a new spring, note that safety valves. with set pressures between 0.2 and 1.5 bar have a greater lift. Therefore: Set pressure in the range | Spring change only in the range 0.2 to 1.5 bar 02to15 bar > 1.5 bar > 1.5 bar Only for series 950: ATTENTIONT Safety valves for horizontal application, must also to be set in a horizontal position (< 4.9 bar). Rev. 0040401000 2704 Page 13Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS Eos @, 7.2. Representatio1 pL! El fib bilcoig @ lb a9) 1d iicsiug>Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 8.0 Troubleshooting In the event of malfunction or faulty operating performance check that the installation and adjustment work has been carried out and completed in accordance with these Operating Instructions. ATTENTION ! AN Itis essential that the safety regulations are observed when identifying faults. lf malfunctions cannot be eliminate with the help of the following table “9.0 troubleshooting table’, the supplier or manufacturer should be consulted. 9.0 Troubleshooting table ATTENTION I - read point 10.0 and 11.0 prior to dismantling and repair work! ~ read point 6.0 before restarting the plant ! Fault Possible cause [Corrective measures Safety valve does not | Flange covers not removed, respond, Ino flow [Remove flange covers. Test gag sill in place. Spring blocked. Remove pipe or screw projecting into bonnet through inspection connection. Set pressure too high Reset (point 8.) or replace the safely valve. Stainless steel bellow defective, Replace the safety valve. no backpressure compensation. [Back-pressure not taken into account. |Reset (point 8.1) or, ifnecessary, replace the safely valve. The use of a stainless steel bellow to | compensate for backpressure should Ibe considered. Medium visoous or sticky Use bellow / heating jacket. Insert rupture disc upstream if necessary. The valves and piping must be Heating ! protected agains! freezing and solidifying media. [Stem cannot be lifted. | Pressure less than 85% of set It must be possible to lif the spindle at pressure. lover 85% of the set pressure. [Safety valve seat leaking. |Working pressure higher than 90% of | Working pressure must be less than set pressure. }20% of the set pressure. [At iow pressures: lever not in neutral [Press lever into neutral position | Position with closed cap. (towards bonnet). Safety valve flattering Refer to separate point Flattering’ Medium contaminated; foreign body — Raise spindle briefly or, if necessary, between seat and disc. replace safety valve. Use of a soft sealing disc should be [considered Rev. 0040401000 2704 Page 15-® e Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS point. Valve drainage inadequate or not ited. Fault [Possible cause [Corrective measures Flange broken [Damage during transport. Replace safely valve. Flange bots not evenly tightened. | Replace safety valve. Transfer of forces such as bending or install fee of tension. torsional forces. Pressure surges. Safety valve not installed at highest | install safely valve at highest point. Install drainage system a required by regulations. Valve constantly blows off. [Transport fastening not removed. Remove transport fastening (red screw [above cap, Figure 990), Spring corroded by medium and Replace safety valve. broken. in the case of vapour, select open cap Jor bonnet if possible. Injury owing to medium. [Danger ofinjury from medium (e.g. | Replace safely valve, liquids) emerging from valve. Select design with closed bonnet and cap. install a guard if necessary. injury from vapour discharge instal guard ifnecessary {open bonnet / cap) Flattering. [Pressure loss >3% in ine to valve. | Reduce resistance by chamifering or radius in connection socket. Select iarger line if necessary. Poor welding (root pass), gaskets at [Change conditions. niet and outlet fanges too small or not concentric. [Safety valve capacity too high. Insiall smaller safety valve. [Burner capacity too low. Install smaller safety valve. Biow-offjine too long or diameter too |Use larger diameter or back-pressure small [compensation by stainless steel below. Inlet and/or outlet socket too emall. install with dimensions larger than ON of niet and outlet tines. Back-pressure higher than 10%. Install stainless steel bellow for pressure compensation, Sapay oto] Sty vanes a apie nee Soe anda use oy | plant conditions. valves. Safety valve not applied in fine with [Adjust conditions. Page 16 Rev. 0040401000 2704Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 10.0 Dismantling the valve or the top part ATTENTION! — A The following points must be observed: - Pressureless pipe system. ~ Medium must be cool. - Plant must be drained. | - Purge piping systems in case of caustic, inflammable, aggressive or toxic | media. 11.0 Warranty / Guarantee ‘The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself. @ “) We guarantee freedom of faults in compliance with state-of-the-art technology and the ~~” confirmed application, No warranty claims can be made for any damage caused as the result of incorrect handling or disregard of operating and installation instructions, datasheets and relavant regulations. This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements. Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us. No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is excluded. The warranty shail not cover maintenance work, installation of external parts, design modifications or natural wear. Any damage incurred during transport should not be reported to us but rather to the ‘competent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated, ‘The manufacturer will accept warranty lability only if there has been no third party tampering. GERMAN QUALITY VALVES ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo& Holte-Stukenbrock Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159 Internet: http:/Avww.ariarmaturen.com E-mail: info.vertrieb@ari-armaturen.com Technology for the Future. Rev. 0040401000 2704 Page 17Operating and installation instructions SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS 12.0 EC declaration of conformity / Manufacturers declaration ARI-Armaturen Albert Richter GmbH & Co. KG, Mergelheide 56-60, 33756 Schlo& Holte-Stukenbrock eae EC declaration of conformity as defined by the Pressure Equipment Directive 97/23/EC Herewith we deciare, that according to the above mentioned Pressure Equipment Directive (PED) the below listed products comply and have been approved according to Module H1 and also EC type test according to module B+D through LLOYD'S REGISTER QUALITY ASSURANCE (NB-No. 0525), ‘Ménckebergstr. 27, 20095 Hamburg. Certificate-No: 5003/2 Safety valves SAFE series 900 Type 901,911,912,902,903,904,990 Applied standards = DIN EN ISO 4126-4 AD 2000 Code of Practice A2 ‘AD 2000 Code of Practice A4 Cast iron with spher. graphite - Cast sieel TRD 424, TRD 721 \VdTOV 100, DIN 3840 ASME Code Section VIIl-Div. 1 Safety valves SAFE-TC series 940 Type 941,942,943,945,946 Applied standards : DIN EN ISO 4126-4 ‘AD 2000 Code of Practice A2 ‘AD 2000 Code of Practice A4 ~ Cast iron with spher. graphite ~ Cast steel TRO 421, TRD 721 \VaTOV 100, DIN 3840 Safety valves SAFE-P series 920 Type 921,922,923,924 Applied standards : DIN EN 1S0 4126-4 ‘AD 2000 Code of Practice A2 ‘AD 2000 Code of Practice Ad - Cast steel TRO 424, TRD 721, VeTOV 100, DIN'3840 Safety valves ‘SAFE-TCPITCS series 950/960 ‘Type 951,952,953, 961,962,963 Applied standards DINEN ISO 41264 AD 2000 Code of Practice A2 ‘AD 2000 Code of Practice Ad = Cast iron with spher. graphite - Cast steel \VaTOV 100, DIN 3840 Manufacturers declaration as defined by the Machinery Directive 98/37/EC Herewith we deciare, that the listed products as supplied are intended for installation in a machine or system and that the machine / system must not be started up until it has been established that the machine / system complies with the provisions of the EC Machinery Directive 98/37/EC. ‘SchloB Holte-Stukenbrock, 12.07.2004 Cele “(Grechmafn, Managing director) Page 18 Rev. 0040401000 2704STOBU® Stop valve with gland seal ) ARI-STOBU® - Stop valve with gland seal ARI-STOBU?® Globe valve with flanges + TRB 0! Nods (capt cat ion) ++ German "TA-Luft TOW-Test-No, 922-8204866 (optonay ARESTOBU® Globe valve with flanges + Genman Ta Lu TOV Test No, 9225204886 (optional) ARI-STOBU® Globe valve wav fanges + TRB aot Nods a approls TOA/TOVAR. 167.00 rman TAL TOV Test No, 22-2204866 (eter) ARL-STOBU® Globe valve with flanges: sTrB 001 Neds * Geen TAL TOV TstN. s22.e24868 Silene! (pinay ‘BR OGE Pages ARISTOBU® Globe valve Leal vi Saft weld ends + Proven tectotogy TREAD ann + Sold ply mede of tint mata + Test approvals TO.ALTOV. 00 ++ Solid stem made of stainless material + German “TAL! TOV-Testa, 922-6004868 Forged steel (optonay, ‘BR 005 Page S + Sold seat mae of tiless material —_— + Stan wh hadeed ead ARI-STOBU® Globe valve ornnss Wi Butt weld ends + Bamiched se f sTRe6o1 + Hlge ten lard packing “Tostappols TOATOVAR 187-00 O ++ German “TA-Luft” TOV-Test-No. 922-9204868 ‘Cast staal cee (enor) RODS aged nota see forgo sta and staness tek + Bone ap wi treated sing ARLSTOBU? Y. lobe valve + Pivot mounted bots var anag stpbat teas * Geena “Tutt TVTest a 2.204886 Sides ste ||_— | (opto) Sani — ARESTOBU® Angle pattern globe valve win tanger + TRB 801 No4S axcopt cat ton) ed * Gorman "iLut? TOV-TestNo. 22-9004865, 7 we Noten : Bronmen7 LL," Pages ARLSTOBU® attern globe valve ‘mianges +778 01 Noss O + Test approvals TO. *Gegnan ToL TOV Cast et on (cpio BR TOT4 preston = Stop valve with gland seal, made of cast iron and nodular iron ros E Puss ENLIOW DN E06 ee © [zscos [a8 BR S06 Win made of RAS (CuZnBsNcWs2AbP, CW7IOR code number 2 ‘CuSat-Cu, CO4B0K code number 08) Tesi DWTS ope Geman Tut TOV Tat Na S22CH85S (ero page 16) ‘Selecon of poss applcaons: sinsty + Roxy ies + Ponersaons + Stipbuldng + Fiue gas puriication plant ++ General plant manufacturing + Vapour tastes PN2s ENNSIO@ ON 15-160 thr eppcations on request- Weights (kg) 2006, 12.06 35 | 40 | 60 | 68 [ 93 | t22/ 180 | 248) 350/ 550 | 770 [145020019410] ~ | ~ | ~ [esos (2506 ‘38 [48 | 54 [70 | 95 | 128] 184] 248 [360] 560] wo fio] - | ~ | ~ | - | — ARF-STOBU® - Stop valve with gland seal, made of cast steel BR 208 Trim made of RGAS (Quznsstiaur2n, CW7H0R. code number 02 (CuSt0-Cu, COAEOK code number 08) ect SRDS BH TE-400 aR TBToO 585.005 ON 15.200 (AR 187-00 DN 18-300 opal: Goran "TALut”TOV-Test No. 922-9204866 (fet page 14) ‘Selection of possible aplcations: ee a 5 edusty ‘+ Reoytng eos + Powerstatons + Shipbulking ; + Fue g2s puritan pant Genera plant mandating Lf A ‘Vapour facts + ctr applcatons on equest- 84 [63 | 70 | 103 | 138 | 210] 275 | 400 0 [1600 2850137701510, | 7600 | 1850) 4 a i eae Ran DISTO}ESID| 2 ‘Editon 0708 -Dala subject io aerationARI-STOBU® - Stop valve with gland seal, made of cast stee! “ite | Pus 0518N —_DN15-600, [BR 07: Trin made of RGIUS. (CuzrS6hioMr2APy, CW710R code runbor 2 CuSa10Cu, C6480K code ruber 03) Test 94007 ON 16-00 TOLAMTOVAR 187-05 ‘$5007 ON 15150, TUATUVAR 187.09 ‘DN15-900opfonat_ Geman TAL TUV-Tost No. - 822-2046 ero page 14) | Sslecton of possible apleaons: sloty Rane tts | = Powers + Siplrg *Fuegespuiesn pit Geral plant mandating pours i & - be aplaton on oes i Weights (ks) | amma a ea LEK a fos z i é ion 0a - Data ebjecioeoatonee ((Q)_-Dimensions, kvs- and zeta-values oe i | wT a a oa a i oan ce 2s ot | te “ a | 2s rn at me ~ a aol ae a 980 | 425, 116 | 640 ~ [27750 46 30 tet a ee rags oa Kr ess BON ETS. ra yn AS tsa angus pag ofa gk ns i chal RE Gl ves wth fag ‘tos dent FT ei org ON NS ONSI soe Fi Yatongtevaterntn tage, Panlotednen Tels wen BO EE (ON ee) Agata tne: Fate son CF cfs Scr DENS (820 2) Gl abe tbl ne Fetes dann ETE ies madi OE 86% (ON 28 er) 4 es cas —— us§ — as — oem Figure |12.007 |2ale8.007 |3486.007 128088907 | 29728,307 |34/96.307 | 45.006. |82/54,/55.009 es ereocen Pepa (aver fornia uy 1 [Body Lion [ENISTOES | ogiaenl JENGIL29 [aiseo-ieuIT |1.08tgN |1.0460 1-2 1.4408 Bee: Dice ow ce io reat Sec. omen (rag, [SEEM HEH lovnian Jevsionen liao” lrawan {tase oO (Bee: fave fous” (LSE [eibtestt fovea [roee” [aie ak = jeracan, aaa, laxgonuors a i oat ra, 1ae i a lec Je foun onc revortanihes for, cwssioremenbuts unites [rae fisonMer tated ii Be [6 | Gland packing Pure graphite [8 [Hexagon nuts ‘C3SE, 1.1181 i" ‘CS6E, 1.1181 At Head pee aero 7 i pear io fewer sees [reir ones PERM i en Ea abe WONT Informations /restictions of technical rues have tobe observed! Operating insrectons canbe ordered on request by phone (495207) 40 or fax (49 5207) 9945819, (Yestes mate of astrn are not alond to be operated in ystems scoring a TAD 10, \..draduetion allowance according to TRE 801 No, 45 exists (eccording to TRB! No 5 cation is not allowed). sp) The engines, designing a system or plan irecponsibe forthe selection ofthe corel va. Edlion 01706 - Daia sibjecito aeralion @ | i | |General informations ‘Alternative description according to DIN 3356 ,valves* Pressuretemperature-atings large hikes cnc co ON 2598 /DI 2544/2545 {seston en 0022 FENILI040.-/16 = ‘tar ‘aba tester Ti2ter| aster] — | | ENust049 x e [25 | onrenest 25ber 243tar| Zow [2iRbar| 20ber| i7star] — | — ace. to DINEN 1082-1 5 fy 23;3bar| 21,7 bar] 184bar] 17,8bar| 16,1 bar) 1Sbar | 144bar| 139 25 ‘23a 21,7 bar] 194¢bar] 17.8bar| 16,1 ar] 1Sbar | 144bar) 10bar 14 9bar 18sbar] 124 bar] 11,7bar} 11 bar | 0,7bar| 102ber) ‘7 abar] 8a] 3,1 bar] 283bar| 276 bar| 26,7 bar] 256 ba intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart. * Sus and nuts made of A470 a operates below 10°C) Fiange dimensions acid ‘xi a8 4x18 ‘8x16 3x22 385 | 12x25, 20 [470 | 16x25 715 [680 | 20x00 ‘Butt weld ends according to DIN EN 12627 -4 (lero page 7) Please indicate when ordering: Dinersonsin in 4. FigueNo, $8. Nonna dametar ‘eights nig 2. Nomina pressure 4 Special design acessories bar 108? 0,1 1a| Sample: Kvsina| Figure 3006; nomial pressure P40; nominal meter D100 with toting plu, psiion Inet wits loking devive. ths 1160" (U5) Eaiton O16 - Daa sibocto atorton 3Operating and installation instructions Stop valve with gland seal STOBU® Contents 4.0 General information on operating 5.4 Instaling valves with limit switches Instructions. 416 6.0 Putting the valve into operation ... 2.0 Notes on possible danger 16 7.0 Care and maintenance... 2.1 Significance of symbols. --16 8.0 Troubleshooting. 2.2 Explanatory notes on safety information.......-18 9.0 Troubleshooting table . 3.0 Storage and transport .. 4.0 Description 4.4 Scope of applications 4.2 Operating principles. 4.3 Diagram nnn 44 Technical data - remarks. a 5.0 Installation... {5.1 General notes on installation. {6.2 Installing valves with butt weld ends. 65.3 installing valves with balancing plugs 17 44.0 Warranty | Guarantee .. 16 10.0 Dismantling the valve or the top part page 1Operating and installation instructions STOBU® Peewee 1.0 General information on operating instructions These operating instructions provide information on mounting and maintaining the fittings. Please contact the supplier or the manufacturer in case of problems which cannot be solved by reference to the operating instructions. ‘They are binding on the transport, storage, installation, start-up, operation, maintenance and repair. The notes and warnings must be observed and adhered to. ~ Handling and all work must be carried out by expert personnel or all activities must be supervised and checked. {tis the owner's responsibility to define areas of responsibility and competence and to monitor the personnel ~ In addition, current regional safety requirements must be applied and observed when taking the fittings out of service as well as when maintaining and repairing them. ‘The manufacturer reserves the right to introduce technical modifications at any time. These Operating Instructions comply with the requirements of EU Directives. 2.0 Notes on possible dangers 2.1 Significance of symbols A ATTENTION ! | Waming of general danger. 2.2 Explanatory notes on safety information In these Operating and Installation Instructions dangers, risks and items of safety information are highlighted to attract special attention. {information marked with the above symbol and “ATTENTION!” describe practices, a failure to comply with which can result in serious injury or danger of death for users or third parties 6 in material damage to the system or the environment. Its vital to comply with these practices and to monitor compliance. Al other information not specifically emphasised such as transport, installation, operating and maintenance instructions as well as technical data (in the operating instructions, product documentation and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to persons or damage to property. 3.0 Storage and transport ATTENTION | ] A - Protect against extemal force (like impact, vibration, etc.). - Valve mountings such as actuators, handwheels, hoods must not be used to take extemal forces, ¢.g. they are not designed for use as climbing aids, or as ‘connecting points for liting gear. - Suitable materials handling and iting equipment should be used. See catalog sheet for weights. ~At-20°C to +65°C. ~ The paintis a base coat to protect against corrosion during transportation and storage. Do not damage paint protection. Page2 Rev. 0040102000 2103stallation instructions STOBU® Operating ani 4.1 Scope of applications Valves are used for ,shut-off and/or throttling of media’. ‘ATTENTION T LN - Refer to the data sheet for applications, limits on use and possibilities. ~ Certain media require or preclude the use of special matorials. = The valves are designed for standard operating conditions. If conditions exceed these requirements, 0.g. aggressive or abrasive media, the operator should state the higher requirements when ordering. - Valves made from GG-25 are not authorised for use in systems subject to TRD 110, ‘The information complies to the Pressure Equipment Directive 97/23/EC. Itis the responsibility of the machine planner to ensure compliance. ‘The special markings on the valve must be taken into account. Refer to the catalogue sheet to see which materials are used in standard versions. Please contact the supplier or the manufacturer if you have any questions. 4.2 Operating principles The valve is closed by tuming the hand wheel clockwise (valve plug/seating function). ATTENTION VAN Do not use tools to increase the torque on the hand wheel. ‘The valve spindle is sealed by a bellow and an outer safety stuffing box. Tighten the stuffing box if required. Rev. 0040102000210 Page 3Operating and installation instructions STOBU® 4.3 Diagram fig. 3: STOBU straight through fig. 4: STOBU-straight through GG-25/G66-40.3 shoed butt weld ends 1.0619+N. Refer to the data sheet for information about materials with designations and figure numbers. Page 4 ‘Rev. 0040102000 2103Operating and installation instructions STOBU® 44 Technical data - remarks ~ Principal dimensions -Pressure-temperature-ratings - Valves with butt weld ends, etc. refer to datasheet. 4.5 Marking Detalls of the CE-marking on the valve: CE CE-marking 0525. Notified body <@> Manufacturer Address of manufacturer: Typ Type refer to item 11.0 Warranty / Guarantee Year of manufacture According to the Pressure Equipment Directive appendix 2 diagram 6 valves without safety function are only allowed to bear the CE-marking DN32 onwards. 5.0 Installation 5.1 General notes on installation ‘The following points should be taken into account besides the general principles governing installation work: ATTENTION! - Remove flange covers if present. ~ The interior of valve and pipeline must be free from foreign particles. - Note installation position with reference to flow, see mark on valve. ~ Steam line systems should be designed to prevent water accumulation. - Lay pipelines so that damaging transverse, bending and torsional forces are avoided. ~ Protect valves from dirt during construction work. - Connection flanges must mate exactly. - Valve mountings such as actuators, handwheels, hoods must not be used to take extemal forces, e.g. they are not designed for use as climbing aids, or as connecting points for lifting gear. - Suitable materials handling and lifting equipment should be used. See data sheet for weights. - Valves can be installed with the spindle pointing in any direction, but the prefered spindle position is vertical. - Valves should be installed upside down only, if the medium being handled is clean. - Keep the thread and shaft of the spindle free from paint. = Centre gaskets between the flanges. Rev.0040102000 2103 Page 5Operating and installation instructions STOBU® Eo - Lockable stop valves must be installed in such a way that the spindle is vertical and the flow agent enters under the taper. if the valves are installed in pipelines in positions other than specified, they must be fitted with a closing spring. - 188 A plug damper should be used in critical applications, immediately downstream ‘of pumps, compressors, etc., where severe turbulence and pulsating pressure ‘surges may occur. Through the damper function of the loose plug, the negative influence of pressure shocks and high turbulences, are nof transferred onto the valve. - Planners / construction companies or operators are responsible for positioning and installing products. 5.2 Installing valves with butt weld ends Please note that only qualified persons using appropriate equipment and working in accordance with technical rules are allowed to install fitings by welding. ® ‘The responsibility for this lies with the system owner. Refer to the data sheet for information about the shape of the butt weld ends. > 4 Page 6 Rev. 0040102000 2103,Operating and installation instructions sTOBU® 5.3 Installing valves with balancing plugs ATTENTION f A ARI stop valves must be equipped with pressure balancing plugs if the differential pressures listed in the table below are exceeded in the closed state. Valves with pressure balancing plugs should be installed so that the pressure of | __the medium acts on the plug ( 3). ‘ATTENTION T Note direction of flo fig. 5 Valves with pressure balancing plugs have to be installed with medium flowing over the plug (3) as indicated by flow direction arrow on valve body. Working principles: When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug (3.1) off the larger balancing plug (3). This allows the medium to pass through the plug and ‘equalizes the pressure of the medium under the plug (3). After the pressures have been equalized within the values stated in the table below, the valve can be opened by turing the valve further. Balancing plog DN [125 [1s0_ [300 Jao [a0 [aso [400 [500 Pressure diference [AP _[25bar |2tbar |t4bar [Sbar__{@bar |4Sbar /S.Sbar [15 bar ~ Pressure balancing plugs are fully effective only in closed line section. - The pressures of the medium on either side of the plug cannot be equalized if the medium is discharged into ‘open air’. + Ifadequate pressure equalisation cannot be achieved using a pressure balancing plug, other design solutions must be used instead (e.g. a bypass line). 5.4 Installing valves with limit switches ‘The valves with limit switches must be connected up as shown in the plans of the plant on the basis of their working principles. Rev. 0040102000 2103 Page 7Operating and installation instructions sTOBU® ro) o 6.0 Putting the valve into operation ATTENTION | AN ~ Before putting the valve into operation, check material, pressure, temperature and direction of flow. - Regional safety instructions must be adhered to. - Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage. - Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media temperatures can cause injury. Affix warning notice or protective insulation as appropriate! Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that: - All works has been completed! - The valve is in the correct position for its function. - Safety devices have been attached. 7.0 Care and maintenance Maintanance and maintenance-intervals have to be defined by the operator according to the requirements. fig. 6: Pattern with hinged bolts ~ Observe safety instructions! - Keep the spindle well greased! Page 8 ev. 0040102000 2103Operating and installation instructions STOBU® ~ Lubricant: e.g. Klberpaste HEL 46-450 (at valves for oxygen: Oxigenoex FF 250) toorder at: Kldber Lubrication MUnchen KG, Postfach 701047, D-81310 Miinchen ‘or a lubricant wich is suitable for the application. ATTENTION ! VAN Pay attention, that the lubricant is suitable for the media. - Ifthe valve spindle (4) leaks, gradually tighten the stuffing box seal (6) evenly in increments by means of the hex. nuts (19) until leaking stops. ATTENTIONT LAN = Retighten the stuffing box packing if required and re-pack it in good time. = For safety reasons we recommend that valves only be repacked when depressurised. = Refer to point 10.0 and 11.0 before dismantling the valve. = Replace stuffing box packings only after the system has cooled down and the pressure in the plant has been relieved. In the case of corrosive or aggressive mediums, drain and ventilate the valve before replacing the packing. - Valve service life can be improved by leakage checks. When cutting the new packing from the roll, make sure that the ends are cut with a stant fig. 7: Split packing ring ‘Mounting of the bonnet: ~ Before reassembling the unit, remember that the bearing surface must be cleaned and 2 new gaskets (9) must be inserted. - Set the cover in place ~ Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise. = Tightening torque's for hexagon nuts / screws: DN hexagon nuts / Torque hexagon screws (Nm) 15-32 M10 15-30 40-65 = M12 35-50 80-100 «M16 75-100 125-150 M16 80-120 200 M20 150-200 250-400 M24 340-410 500 M27 340-410 Rev. 0040102002103, Page 9 iOperating and installation instructions sTOBU® 8.0 Troubleshooting In the event of malfunction or faulty operating performance check that the installation and adjustment work has been carried out and completed in accordance with these Operating Instructions. ATTENTION! Z\ It is essential that the safety regulations are observed when identifying faults. If malfunctions cannot be eliminate with the help of the following table “9.0 troubleshooting table’, the supplier or manufacturer should be consulted. Page 10 Rev, 0040102000 2103,© EN Operating and installation instructions sTOBU® 9.0 Troubleshooting table ~ ATTENTION T = read point 10.0 and 11.0 prior to dismantling and repair work! = read point 6.0 before restarting the plant 1 Fault Possible cause [corrective measures No ow Valve closed. Open valve. Fiange covers not removed, ~~ |Remove flange covers. (25; fig.1-2; page 4) (25; fig.1-2; page 4) Title tow Valve not sufficiently open. [Open valve, Dirt sieve clogged. [Clean replace sieve. Piping system clogged, [Check piping system. Valve dificult to move or Spindle (4) dry (ig. 6; page 6) [Grease spindle (4) (ig. 6; 90 8) [cannot be opened (Lubricant: see page 9) [Stufing box too fight (6; fig. 1-4; page | Slacken hex. nuts of stufing box gland 4) (15) slighty, but not sufficiently to [cause leakage (fig. 1-4; page 4) | Wrong direction of rotation Turn in correct direction (anticlockwise to open valve). Valve spindle leaking | Stufing box gland (16) slack Tighten stuffing box gland (16) unt (ig. 1-4 page 4). leakage stops. 1-4; page 4) jecessary, renew packing in stufing box seal (6). Observe warnings (Fig. 6; page 8) Teakage across valve | Valve not propery dosed [Pul hand whosl ight wihout tool, seat. | Seat (1-2) / plug (3) damaged by for- | Replaced valve, consult suppliedman- | eign partctes. facture. (9. 1-4; page Pressure difference too high. ° (see point 5.3). Medium contaminated (suspended sol- | Clean valve. ids). instal dirt screen upstream of valve, Valve with trotling pag |Locking device has been lghfened. | Release locking device. Postion indicator + tock- ing device cannot be opened. Ralting “banging Nominal damoter ofthe valve i com | Choose smaller nominal Gameter lof the plug design with [pliance to the flow rate is to big Use a plug damper execution: see loose plugé medium high flow turbulences; ~~Talter the system — -the valve with loose plug is mounted Use a plug damper execillon: 606 ly by a centrifuged pump; medium pressure reduction stations; hind pipe elbows; -in compact plants; - expansion joints are missing; - the pump is not mounted on a damper; - there is no flow stabilizing pipe length, - there is no start-up bypass fine Flange broken between | Bolls ightoned unevenly. Re-align piping and ft new valved valve and piping. Mating flanges not property aligned. Rev.0040162000 2103 Page 11Operating and installation instructions sToBU® Ree 10.0 Dismantling the valve or the top part ‘ATTENTION T ZN The following points must be observed: - Pressureless pipe system. = Medium must be cool. - Plant must be drained. - Purge piping systems in case of caustic, inflammable, aggressive or toxic media. 11.0 Warranty / Guarantee ‘The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert Richtor GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself. We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed application. No warranty claims can be made for any damage caused as the result of incorrect ‘handling or disregard of operating and installation instructions, datasheets and relavant regulations. ‘This warranty also does not cover any damage which occurs during operation under Conditions deviating from those laid down by specifications or other agreements. Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us. No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is excluded. The warranty shall not cover maintenance work, installation of external parts, design modifications or natural wear. ‘Any damage incurred during transport should not be reported to us but rather to the competent cargo-handiing depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated. Technology for the Future. GERMAN QUALITY VALVES ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo8 Holte-Stukenbrock Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159 Intemet: http:/ww.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com Page 12 Rev, 0040102000 2103@ @ Operating and installation instructions STOBU® Few 12.0 EC declaration of conformity ARI-Armaturen Albert Richter GmbH & Co. KG, Mergelheide 56-60, 33756 Schlof Holte-Stukenbrock EC declaration of conformity as defined by the Pressure Equipment Directive 97/23/EC Herewith we deciare, ‘that according to the above mentioned Pressure Equipment Directive (PED) the below listed products comply and have been approved according Module H through LLOYD'S REGISTER QUALITY ASSURANCE (BS-Nr. 0525), Monckebergstr. 27, 20095 Hamburg. Certificate-No: 5003/1 ‘Stop valves with gland seal STOBI ‘Type 005, 006, 007, 009, 017, 306, 307 Applied standards: DIN 3230 ‘DIN 3840 AD 2000 leaflet A4 ~ Cast iron with spheroidal graphite ~ Cast steel - Forged steel Schlo® Holte-Stukenbrock, 20.08.2002 Rev. 0040102000 2103 Page 13 i |AALBORG INDUSTRIES ‘Type: ‘© Straightway control valve with electric actuator ‘+ 23.470 PREMIO Size: ‘* Nominal diameter: DN 50 Application: ‘+ For steam and/or fluid flow Material: + Body: GGG 40.3 DIN -Material No. 0.7043 ‘© Seat: X20 Cr13 DIN Material No. 1.4021.05 ‘+ Dise: X20 Cr13 DIN Material No. 1.4021.05 + Stuffing box: PTFE-V-ring unit (-10°C to +220°C) ‘Technical data, valve: Nominal pressure: PN 25 Position ratio: 50:1 Flow characteristic: Equal percentage Standard K, value: 16 m’/h Stroke: 20 mm Plug type: Parabolic shaft guided Flanges according to DIN Technical data, actuator: + Voltage: 230V — 50/60 Hz ‘Thrust: 2.2 kN Closing pressure: 19.2 bar Power input: 11.7/14 W Protection: IP 65 Ambient temperature: - 20°C up to + 70°C Operating time: 53/44 sec Cable glands: 2 x PG 11 Technical data: © Weight: 24 kg incl. actuator Installation: ‘© Only as shown in the picture sol od eo ora Fae Fab sete XG vafejela| ‘WE (S3) Lins sich fora the stroke ‘stancetn opening aresson ‘Type No.: 6050 Control valve, straight way, with electric actuator, DN 50, PN 25 6050 000064 Language UK. Page 1/1STEVI® 470/471 with electric and pneumatic actuators © Straight through control valve with post guided plug DN 15-150 Fig. 470/471 Electric Actuator AREPREMIO ‘ Endosure cles P65, + 2cque switches T +1 ravel nich r *Handhes “Additonal device avaliable, 29. poteniometer Fig. 4707471 Electric actuator AUMA SAR + lets mut actor atl of tics esses Qe? -Eetoresunerer ~ +2teque otches + 2a vices + andshoo + Overheating pct or motores standard + Adlon does sil, 9, polnionetr + Bplsion proc version evaeble Fig. 470/471 Pheumatic actuator DP + Rosersble pnoumate sctutor “+ Aa wth ling eephag + Airsuply peassre mss Bar + tem protcton by below *Maintenance-tee Oving sat + Assembly of adtonal davies aps, to DIVIEC 605348 OO Features: * Compact design + Pacson guided stem + Burnished stom “Tape oat int + Replaceabl seat ag and pig + Sorowed seat cing ‘ Kessalues duce up to 6 tos + Rangeabiiy 50:1 + Pot guided pg + Sping lod PTFE-Vaing packing uit + Twopiybolows seal + ive etor Ss ® Eon 0604 Data subject to aeration — ~ Data sheet 04700015 STEVI® 470 / 471 Smee ene aes QD tuawiaanargue ra ‘ori ical dua cr part) 22-58 «etsn50 || | Rati 2200075 y | —22.7 220 5 x ty of — 22:2 227 228 x 222 | 295 226 ~223 | | -22.4 —_ i Away " a7, | ¢ L i ao : 2) Fig. 470 Fig. 471 anise} war49|tearcalenae alates dasd|scans| sus? | 7002 | save ars | 186 [rae Tata [pw 16/Pn25-40 (a ae es [sanz] rane. asaez 7 aro rea afen za aa pews oscza} scan ear ee em pw 16 25-40,> a @y STEVI? 470/471 Closing pressures with ARFPREMIO | Cosing peso Operating time i mes cing a emacs | Ss [seat (ne) 30 Operating tne 2 ($55 B a | (Op. speed 0,36 mms) | 7 ” n my ca prssue = me E aa A Operating time ® (5) 1 * Opera i CY sa | 0 ® 2 7% 7 [1] 7] 12 Cosing presse Cperating ne (5 len sreeco7emay)| | E lasing presse i ES Sa [zai Operating me ® (3) | (On 20038) ” * i 0: PTFE Weingut TL Fig a0: PTE [pe rope pac Wig Ai Balows seat Motor votage: 2500 SoHe Spactlvotages: DAV SOF; 115V SOBGH;250V 60H “Techical data for actuator reer to data sheet AR-PREMIO. 2) incatod operating ins wih 50 2. ° Not or periorated pl (presentation re. lo page 18). Kvswalves acc. to .Solcsion STEVI, rte to techn, annex. ion 1200 Data subject aloraon aSTEVI® 470/471 Closing pressures with DP ie Editon 1208 - Dae Saat aoraon zy [2] 3, pape ss |<] ea} |e] 6 [Travel {ra @ a) ae aay | T ase [ae Ha wr : ult ssa] a aso | as Pas as © 7. 7 [as [a6 | es] ae ie t pele leas) oma | ate F |g 8 es a a | a | we) 9 ae ue [a2 | ss | asap av Pace] at t fee Perper aie @| o) 0, a] o/s ie) ee ee pele pee pepe pepe wpe peperpe teeta T o i “Beis te a © fit : 2 - £(-t c sft © : z z : t | eit = - ‘I = a = - | 1] a [aoa | 4a |e [aig [Wa [Me | a | Bia | a] Wa] Wa | Wa] He | Baral Bio |eATal Wo | Maal Waal Ba] \ [1 [es | es ee ae] ae of al We eel wa we] wu we Be [aT al Ber Ube asa Taal To W {27a Fa| Mita eb 27 9 Bika) TOSel 9a] AP) TOBe) HeSal 12a] Tal Tre | Wal Wa [05a] Ta] TSA Bal | T a aq] | Ws | | Wa | ware att : Bs “ea a] wr 0] 4] 0s [sal a 3 |_ [ee] ea] wa wa | ao | ws | wa au | Ws wo wal wel wal wal wel el we fa wn PSA ait : ws a\s fr oa] iit 1 of aa = oa oe 5 + ae SENSE SESE z(t | _ sit = i @ ac 7 a I of : t 1 i 1 | T = i ra | ule | Fara | c SaaS ia] { isa i aa i 2 i ect oe | zie i a i aL = a i ico | | ae ' | ale te ' e| fe | | g t Fk t { 1a porate pig resetion erage 16) | © t swale act Salaton STEV!, rt techn. | T amet. | Ie fe = | Mics ©) (Fig. A70: PTFEAng ant TL Fig. 47 PTFE: pare graphitepactings TWFg. a7: Bellows seat | ) Tasty pees ao pia airs Eat lessor mex ital ake" alSbar__—t)4Sbar_cidbwr aber _o) tar | i‘max. permissible closing pressures io parchoo pig on ow t-open P= 0 ‘Spring opens on ai failure [Obsave, ro its on page 17_Ph STEVI 470 / 471 Closing pressures with DP ign ac. oSelecton STEVI leach. ana Ses ‘ poy presen ba) ‘A spy rss BIE Se wa BP ‘Ba [74 Sate ‘ae SEhee annex. nv DPT refer to separate data sheet. {| i 4 4 Not for paoratd plug (presentation refer o page 18) + Neelus au. o Selection STEVI, rl techn. = | Haer cso pressure for DN125-150 combina os} a SmaI ao 1 Fig. 470 PTFE Wing unl 1 Fig a Tp grap packng: 1 Fig. 77 alos sal eu presse max of paamais acute OF ar lAcsup pressure max tntofconil vee: a)Sbar___—B)AShar_ bar )OSbar_o)Sbar 0 208 - Daa subject aterason @Control valves, type 470/471 1 General This type of control valve is suited to regulate fluids, gases and steams. The valve plug is normally a parabolic plug, but can also be supplied in a perforated design. Both types of plugs can have either linear or equal percentage flow characteristic. The flow direction for parabolic plugs is always against the closing direction. , However, with perforated phags for steam and gases, it isin the closing direction. If a valve with a perforated plug is operated by means of a pneumatic actuator with the flow in the closing direction, the pneumatic actuator should have a stronger thrust force. This is necessary to prevent thumping near to the closing position. All control valves can be fitted alternately with manual-, pneumatic-, electric- or hydraulic operation devices. IMustration of control valves type 470 and 471 Control valve, type 470 Control valve, type 471 n os 151 “a woes" samy Figure 1 vald7x.tif Language UK Page 158 d twoustaies Designation Designation Gis a Sins Screw fin Hexagon nu Mounting Bonet Spindle gun Hexagon nus ‘Mounting bonnet Stuffing box Spring: ine saiahtpia Guiding bush Srfing-box pac Seti Py Gackt Bellow hous Sind Gasket Bellow ui Sri Stud Tablet 2 Operation ‘The valve should be inserted so that the spindle has a vertical position together with the actuator. The valve can also be tilted to a maximum horizontal position if the installation point does not allow any better condition. To guarantee a disturbance free function of the control valve, the inlet and outlet stretches of the piping should be of straight piping length (min. two times the pipe diameter by inlet and six times by outlet). The piping should be rinsed to clear out any pollution, welding beads, rust, etc. before inserting the control valves. A strainer should be fitted in front of the control valve to catch the remaining particles. Bolts should be tightened after taking into operation, ‘The flow direction is signalled by an arrow on the valve body. The valves should be insulated against high temperatures to guard the actuator. 2.2 Actuator assembly 7 The control valves are normally delivered with actuators already fitted. For alterations or maintenance of actuator, the assembly should occur in accordance with the operation instructions for the actuator. 23 Setting into operation ‘When the piping system is filled, the spindle sealing should be checked for leakage and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as the spring tension maintains the necessary force. The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter than itis necessary for the sealing. Flange connection bolts should never be loosened or tightened when the valve is under temperature or pressure even if a leakage may arise. For actuators please see to the appropriate actuator operation instructions. Language UK Page 205(oreo N= Rdg TAO Seal 3 tenance Before any maintenance of the control valve is carried out, the piping system must be shut off and pressure free. 3.1 Exchange of the stuffing-box packing A leak stuffing-box packing should initially be carefully tightened to stop the leakage. If this does not help, a new layer should be inserted, or the complete packing should be replaced. 3.1.1 Additional packing layer Step A: Open the valve fully and unscrew the hexagon nuts (17). Step B: Lift the gland flange (7) and the spindle guiding (8) upwards. Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting at 180° to avoid overlapping). ‘Step D: Fix the hexagon nuts (17) properly. 3.1.2 Exchange ‘Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the hexagon nuts (17) from the studs (15). ‘Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing ‘box (10) and clean the packing compartment. Step D: Clean the valve spindle and check for damage and if necessary replace. If the damaged spindle is not replaced, the new packing will leak after a short period. ‘Step E: Insert the new packing rings (split ring-displacement, splitting at 180° to avoid overlapping). ‘Step F: Fix the hexagon nuts (17) properly. Note: Strenuous tightening will prevent leakage, but will also have a brake effect on the spindle which aggravates the movement of the spindle. 3.2 Exchange of a PTFE-V-ring sealing unit A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good ‘seal even by low operation pressures. It is replaced as mentioned above. ‘The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing lips must face against the pressure direction. Tanguage UK Page 35Inpustetes Note: Special eare should be given to the spindle surface. Rough surfaces wear the sealing lips enormously and can be due to failure of the packing unit. 3.3 Exchange of the bellow unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the screw joint (7.1) Step C: Unserew the hexagon nuts (17) and remove the bellow housing (25). Dismantle the plug as described in the next section, ‘Step D: Unserew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1). Step E: The bellow unit (26) is removed from the bellow housing (25). Step F: Replace the two gaskets (14.1) and the gasket (14), ‘Step G: When the bellow unit (26) is replaced, the proper position of the anti- twisting device must be observed. ‘Step H: The set pins (21) have to drive within the slots of the anti-twisting device. Check for friction-free movement. Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1) crosswise. 3.4 Exchange of the plug-spindle unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the gland flange (7). 3.4.2. Control valve type 470 Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3). Step B: Pull out the plug with the spindle and exchange this unit. Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6). Step D: Replace the old parts and assemble it. Step E: Drill a hole through the plug shaft and insert a new pin. Step F: Replace the gasket (14) and assemble the mounting bonnet (3). Step G: Tighten the nuts (17) evenly, crosswise. Language UK Pagesr foro INDUSTRIES 3.4.3 Control valve type 471 ‘Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with plug (5). ‘Step B: Drive the spindle in the bottom position and remove the spring-type straight pin (19) Step C: Unscrew the plug. Step D: Screw a new plug at the spindle and drill through the shaft. Drive the spring-type straight pin (19) into the hole. Step E: Replace the gasket (14). Step F: Assemble the bellow housing (25) with plug (5) together with the body (1) and fix it by screwing the hexagon nuts (17) crosswise. ‘The spindle can only be completely replaced together with the bellow. 3.5 Changing the seat ring The seat ring is screwed into the valve body. The seat ring can be obtained after removing the bonnet and can then be refinished or replaced as required. ‘Step A: Clean and lubricate the thread and conical sealing surface before insertion. Language UK Page 5/5AALI BORG @) INDUSTRIES Electrical actuator, type Premio 1 General ‘These operating instructions contain information necessary to install and operate the ‘thrust actuator both safely and effectively. If problems arise which cannot be solved with the aid of this operating instruction, please contact Aalborg Industries for farther information. 1.1 Qualified personne! This refers to personnel possessing corresponding qualifications and familiar with the processes of installing and assembling the product as well as with putting the product into service and operating the same, e.g. — Training, instruction, or authorisation to switch on and off electric cireuits and equipment/systems and to disconnect, ground, and identify the same in accordance with VDE 0100, the regulations stipulated by the local electricity ‘generating boards as well as technical safety standards. — Insiruction and obligation to comply with all regulations and requirements : periaining to use as well as regional and in-house regulations and requiremeats. — Training or instruction in accordance with technical safety standards in the use and mainienance of pertinent safety equipment including job-safety equipment. 4.2 Handling O = 4 '* Storage temperature: -20°C to +70°C dry, free of dirt. + Donot damage packing. A desiccant or heating to prevent condensation is necessary in damp rooms. ‘Transport © Transport temperature: -20°C to 470°C. ‘© Protect against external force (impact, vibration, ete). © Donot damage packing. Handling before installation '* Protect against atmospheric conditions e.g. wetness. © Correct handling protects against damage. * Do not soil or damage type identification plate and wiring diagram on the controller.INDUSTRIES Description 2.1 Field of application ‘The PREMIO linear thrust actuators are employed to actuate control or shutoff valves requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 KN to 15 KN. The thrust actuators are set to the thrust forces specified in the technical data. If supplied with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve. Selection of the proper actuator version in alignment with the corresponding fitting as well as use of the thrust actuator in accordance with the specified technical data is the responsibility of the systems engineer. Attention: Any use of the thrust actuator beyond the specified technical data ‘or improper use of the actuator is deemed to be not for the intended purpose. The ambient conditions have to be conformed to the actual electromagnetic compatibility directives. Additional the compatiblity to this directive has to be ‘maintained in case of expansion or other changing of the ambient conditions. 2.2 Method of functioning ‘The thrust actuator, fitted with a yoke or columns, is mounted to the valve. Transfer of force is affected via @ coupling safeguarded against torsion. The torsion s ling feature also serves as a lift indicator. The lift settings can be read off on @ lift dial attached to the yoke or between the 2-ear clamps mounted to the column. ‘The electrical components are accommodated separately from the gearbox ‘undemeath a sealed hood, thus being protected against operating and environmental effects. Following removal of the hood, easy access is provided to the switch gear and indicating feature. ‘The rotary motion of the motor is transmitted to the spindle mut by means of spur gear. The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thus performs a pull or push motion depending on the sense of rotation. In the final positions of the valve, the spindle mut is pressed against a set of springs so as to produce closing force. ‘The motor is switched off by means of two load-dependent switches and one stroke- dependent switch. The load-dependent switches will also switch off the motor if foreign bodies have lodged themselves between the valve seat and cone. The load-dependent switches serve to protect the valve and thrust actuator against damage. ‘The technical date for the thrust actuators is appears from Table 1. Actuator agrams are illustrated in Figure 1 and Figure 2 and the part list is shown in Table 2. Finally a dimension drawing can be found in Figure 3. Page 221AALBORG INDUSTRIES [te — coms ‘at ce] 2 cS 139 Stoke eee a ea w Saaifoton macoranes STOR aay es T= ay dasifaion 311007 uy cle 54204 ayy 1200 oh ey SE ‘Control speed [meso] 025___|_ 038 | 038 io wo | _0st Ma vlge OVS) DHE Ba sit | 250 VSO Teo ‘Power consumption [W] 103 [7 [353 52.9 109, L 96. Tena 7 aly paraenty Wad swiciag ey Fp PSY wel re srisbng Ponty SOV arr T a poate wed sing capac pee penal ed IDA ISON ting aut 16 ASV _~ | idomensco—— 3 ee B= are re “Hand wheel ‘Yes (rotating during operation) “Yes (can be engage) nt an we ay capone uN nol be papeiad Goward Ors Kiba NOUS Una ear hvizae Kier Unger LA 02 or sina tod Kltbe NensopKR25 0 Sau [Weight fice) ~ Sa [60765 TOs [Aecessories ‘ional ave ais 7 ial eels BT, Gay TA TTT ‘Aol evel switches Tr Tow" | —Zaditenl ened svicies set socal wit nl copes ote Sey ‘eget, Oa A 30 va ee Sn ay hmm 0.206, STORET SW ‘0@)-10 V, 0 (@)~ 20 mA only 1 potentiometer possible. letronie position indicator RI21 Using the temperature coirolle, installation is only posible i the control caine. Hens poston oar ES T()=0V, 0 @) 20 mA~ only Tyron poustle i No: compat ar we wit tpn contol, Bea ea (Gi at sng) OV = SO He 11S = STE, = DE SW SO 24 50160 avant 24v-s0o ue v- ‘Adina volugs/ ues 24 S060 He Tioveoe| SY" soo He Lesv ne =e 250v.se erga aca 1 tava svc, 2 pote, foe feo wiring, swiching capacity 10 A,250°0~ Lawvtngeomasdiontond — | Zorg wi ga commc, owing opel te, (Glesronie syste), NA See wing vith Teper eonler (Gree pont iwoTG) iio proces NOI Thre-septenpentur-contallr fn micoprocesoehncogy Intagatdtenperture-consollee | Contol ange: 200°C to 880°C (rience temomet) TRON 16.1 YVatiage:24V, 115 V, 0230 VSW60 Fx Compatible wid resistance themoners and themocotples(rvidd by cisomen), standardised ative cent orvolngeegals ‘Standard-voltage connection PA “etaaior with 100 V—30 Hz and | Integrated reversing contactor = 440V 60 He. Only 1 electronic module possible. ‘Only in addition with integrated Phase contol rely 7 ™ Control speed and power consunnpsion are 200 higher at Requency of 60 Ha ‘TabletDiagram for actuators type 2. ‘Yoke Version aot | Figure 1 Language UKAALBORG INDUSTRIES ) J 5 al a8 a oR ! \ : | 3 g g il 3 a \ i ; Z| 2 XQ ¢ Page S721 Language UKOy teoustares ee ve se ee = ie eee Se |e ee es Se a oat ee ne en sw [ai feats eed 50.101 | Connector, 8-5 Table 2 Dimensions diagram Cement 8) motions ore eed or oo “enor ood. ‘heme ogi or recom aac Figure3 premio 3.tif Language UK Page 621Nia ten esa Installation ‘Note: Safe operation of the actuator is only ensured if itis installed, put into operation, and maintained by qualified personnel. In addition, care must be taken to ensure that the general equipment and safety regulations for electrical lines and installations are complied with and that tools and protection devices are used professionally. The operating instructions for the electronic actuator must be observed when carrying out all work on and when handling the electronic actuator. Disregard of these instructions can result in injury to persons or damage to property. 3.1 General installation notes Tn addition to general installation guidelines, the following points are required to be observed: — Existing operating instructions for valve. — Complete valve with cross-arm. — Valve cone approximately in mid lift position - on no account supported inside a seat. — Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricity generating board. — Conductor cross-section selected to correspond to the given drive power and ‘existing line length. — Mains fuse rating max. 6 A. — Circuit breakers to EN 6035-1 in the plant to cut off the mains supply to the actuator. — Conformity of technical data on thrust actuator with field conditions. — Mains voltage in accordance with data specified on rating plate of thrust actuator. — Thrust actuator complete with yoke or distance columns and coupling parts ‘intended for mounting to the corresponding valve, — Qualified personnel possessing knowledge of the regulations pertaining to the erection of power installations. — Ease of access to installation site and adequate clearance space above the thrust actuator for removing the hood, — Install where there is protection against high-energy heat radiation, — The ambient temperature must not exceed +70°C. — In case of widely fluctuating ambient temperatures and high atmospheric humidity, user is recommended to install a heating resistor to minimise condensation build-up in the actuator. 3 @O £ Page 721w AALBORG tnoustaies — Thrust actuator mountable in any position except in downward suspended position. — If installed with a horizontal connecting rod, the thrust actuator must be ‘mounted so that both legs of the yoke or columns are on top of one another in ‘the vertical plane. 3.2 Manual operation For actuators type 2.2-5.0 KN With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the hand wheel firmly meshed with the gear. Proceed as follows: Step A: Swing out lever (50.12.1) from hand wheel (50.12), see Figure 4. — Tuming in clockwise direction —> closes valve. — Tuming in counter-clockwise direction > opens valve. ‘Hand wheel operation (actuator type 2.2 ~5.0 kN) igure 4 In the manual operating mode pay careful attention in the final positions that the hand wheel is only turned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator. Since the hand wheel always follows during motor-driven operation (running indication), never operate by hand while the motor is running potential injury hazards. For actuators type 12.0 -15.0 KN ‘With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the engage able hand wheel. Proceed as follows: ‘Step A: Fold the tuming handle out of the hand wheel (A), see Figure 5. ‘Step B: Turn the hand wheel slightly and push in the engaging button for manual mode (B) -> the button engages. — Tuming in clockwise direction -> closes valve. — Turing in counter-clockwise direction —> opens valve. ‘The motor is no longer in mesh when the hand wheel is engaged. The hand wheel is automatically disengaged when the motor starts and the hand wheel is once more in mesh. “Language UKAALBORG INDUSTRIES Figure 5 In the manual operating mode pay careful attention in the final positions that the hand wheel is only tuned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator. 3.3 Installation instructions for mounting to valves 3.3.1 Mounting for valve-tift up to 30 mm (yoke version) ‘To mount the thrust actuator to a valve having a nominal lift of up 10 30 mm, proceed as follows (Fig. and position mumbers refer to Figure 6): ‘Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). ‘Step B: Set valve cone position to approximately mid lift position. ‘Step C: Tum flat hexagon mut if not present on valve spindle (Fig. A). ‘Step D: Slip coupling (50.27) over valve spindle (Fig. A-B). ‘Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (¥) and lock with hexagon nut. Setting dimension (¥) for fitting-projection (X) are 60 and 83 mm= 102 mm. Step F: Place thrust actuator (50) on valve (Fig. C). Mount thrust actuator on fitting with two T-head bolts (50.19), two washers (50.20), two spring washers (60.21), and two hexagon nuts (50.22), Step G: Swing out hand wheel lever (5012.1) and use it to move out the thrust ‘actuator until the driving spindle (50-30) comes to rest on the threaded bush (50.87), (FIG. D-E). Step Hi: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure in place using grub screw M6 (50.35), (Fig. F). Step I: Run valve to lowest position. Step J: Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is in alignment with tip of arrow mark on lift dial. Page 921lis, RG $ INDUSTRIE Step K: Run valve to both final positions and check to ensure that these are safely reached. Step L: Carry out electrical connection (see section 3.4) and set travel switch $3 (see section 43), Mounting for valve-lft up to 30 mm (yoke version) B Cc D E T A WT Til {I Figure 6 premio 6.tif 3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version) ‘To mount the thrust actuator to a valve having a nominal lift of over 30 mm to 80 ‘mm, proceed as follows (Fig. and position numbers refer to Figure 7): Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). Step B: Set valve cone position to approximately mid lit position. Step C: Tum flat hexagon nut if not present on valve spindle (Fig. A). Step D: Slip coupling (50.27) over valve spindle (Fig. A-B). Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (¥) and lock with hexagon mut. Setting dimension (Y) for fitting-projection (X) is 83 mm = 102 mm or 98 mm = 116mm. Step F: Slip 2-car clamp (50.26) onto a distance column (50.24) press on very lightly Fig. C). Step G: Screw distance column with 2-ear clamps on opposite side of hand wheel into the flange in such a way that one of the 2-car clamps is situated above the torsion safety feature (50.32) and the other below. Step Hi: Screw the other distance column into the flange likewise. Page 10721@, 2) iil, AALBORG INDUSTRIES ‘Mounting for valve-tift o Step I: Place thrust actuator (50) with distance columns onto valve and fix into position with two self-locking hexagon nuts (50.25). Step J: Fold out turning handle of hand wheel (50.12.1), slightly tum the hand ‘wheel and press in the engaging button for manual mode (only 12- 15 KN) (button engages). Having done this, move out the thrust actuator until driving spindle (50.30) comes into contact with threaded bush (50.87), (Fig. DE). Step K: Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grub screw M6 (50.35), (Fig. F). Step L: Move the valve to the lowest position. ‘Step M: Press 2-ear clamps (50.26) into position according to the stroke so they ‘cannot slip, with the bottom clamp in the lowest valve position located directly below torsion safety feature (50.32) and the top clamp in the ‘highest valve position located directly above the torsion safety feature. Step N: Move the valve to both travel positions and check that it reaches them reliably. Fold turning handle of hand wheel (50.12.1) back in. ‘Step O: Make the electrical connection (see section 3.4). The engaging button for ‘manual mode (only 12- 15 KN) disengages when the motor starts up. ‘Step P: Set standard travel switch 83 (see section 4.3). mm to 80 mm (column version) B Cc D E F co 2 sas 5035 s130-f ral nxt Figue7 0 SSOSOS™~””””””SCp reo ‘Language UK Page 1121, | | | |ey 3.4 Electrical connection Figure 8 and Figure 9 illustrate the wiring diagrams for actuators type 2.2 ~ 5.0 KN and actuators type 12.0 — 15.0 KN respectively. To connect the thrust actuator up to the electrical power supply, proceed as follows: Step A: Run the thrust actuator a few mm out of the lower final position applying the manual mode, ‘Step B: Loosen countersunk screw in hood, carefully remove hood in upward direction. Step C: Screw out one of the two cable inlets and re-assemble in the same way without the supplied blank flange. Step D: Insert the connection line through this cable inlet until sufficient conductor Jength is available up to the corresponding terminals. Then tighten the cable inlet until the connecting cable is clamped in place inside it. Step E: Strip connecting cable approx. 1 ~ 1.5 cm above cable inlet. Step F: Strip the individual conductors approx. 5 mm away from the end and fit ‘with conductor end sleeves. Step G: Connect protective conductor of connecting cable up to protective ‘conductor terminal of thrust actuator. Step H: Connect neutral N/MP conductor of connecting cable up to terminal 1/N of ‘thrust -actuator terminal strip, Step 1: Connect pulse line for move-out connecting rod up to terminal 11 of thrust- ‘actuator terminal strip. Step J: Connect pulse line for move-in connecting rod up to terminal 14 of thrust- actuator terminal strip. ‘Step K: Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screw and rubber gasket. Step 1L: Connect supply line to mains and run thrust actuator to each of the final positions so as to check whether the final-position travel switches effect switching off, also checking to see whether the direction of movement on the thrust actuator corresponds to the desired direction. Step Mz If the directions of movement are contrary to those desired, the pulse lines governing the move-in and move-out connecting rod will need to be exchanged. Page 12721Page 13/21 premio 8.tif ry ind a w is fal 2 re S ¢ fe O fn 4 7 Wiring diagram for actuators type 2.2 ~5.0 kN ‘Language UK2 rn i i & rf Fa Fc 2 ELEC ‘Wiring diagram for actuators type 12.0 15.0 kN 9. Figure 9 Page 14/21@ O AALBORG INDUSTRIES Settings 4-1 Torque and travel switches -standard feature ‘Thrust actuators are as standard equipped with a load-dependent travel switch for the closing direction ($1), a load-dependent travel switch for the opening direction ($2), and a stroke-dependent travel switch for the opening direction ($3). The load- dependent travel switches (S1, $2) switch off the motor as soon as the factory-set thrust force is attained, Note: The settings of the load-dependent travel switches must on no account whatsoever be changed. ‘The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke is attained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent travel switch S3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximum valve-lift is attained. If the thrust actuator is supplied om a three-way valve, the trip cam belonging to travel switch $3 is set in the opening direction in the trip stide to such a downward extent that the ‘upper final position of the valve is attained prior to travel switch S3 being reached, thus causing the load-dependent travel switch S2 to switch off the motor. For this function, all three switches reveal interlock-controlled cireuitry on the board. If the standard travel switches are to be integrated directly into the facility control system, the standard board can be replaced by optional boards PA or NA (only 2.25.0 kN). 4.2 Connection boards PA or NA (only 2.2 - 5.0 KN) ‘On connection boards PA or NA, the standard travel switches S11/S21, S12/S22, and $13/823 do not reveal inteslock-controlled circuitry and can be ‘integrated individually into the facility control system. The 3 contacts on each of the switches $11/821, $12/S22, and $13/S23, designed as double-throw contacts, are, in the case of these boards, brought out on terminals 40 - 48 and can be freely connected. ‘The switches on the PA optional board (standard-voltage connection board) are designed for switching capacities of up to 10 A, 250 Vac. The switches on the NA ‘optional board (low-voltage connection board) are designed for switching capacities of up to 0.1 A, 4 ~ 30 V (gold contacts). The optional boards may only be installed at the factory due to the switching points of the load- dependent switches having to bbe reset following installation of these boards. ‘Note: When using optional boards PA or NA, it must be warranted -due to the operator's individual cireuitry- that, when switching the load-dependent travel switches $11/21, $12/S22, and S13/S23 the motor of the thrust actuator comes to a standstill without delay. This function is not provided for on the optional boards PA and NA in the supplied state, Langage UK Page 15/21@ On delivery of the thrust actuator, the standard travel switch (S3) is already set to the existing valve-ift and the setting spindle for the travel switch ($3) is sealed with sorew glyptal. This setting needs no changing for normal operation. If reinstalling the thrust actuator on a straight-way valve, the travel switch ($3) needs to be set as follows: ‘Step A: Move valve out of the lowest position so as to run valve-lift to up position. Step B: Using a screw driver, proceed to tum setting spindle for switch ($3) until the trip cam arriving from below trips the switch (audible click). Step C: Run thrust actuator briefly in closing direction and then in opening direction ‘once more, checking to see whether the thrust actuator is switched off at the desired point (nominal lift). Step D: Ifneeded, correct the setting as described. Af reinstalling the thrust actuator oii a three-way valve, the travel switch ($3) needs to be set as follows: Step K: Run valve in both final positions and check in each final position whether the valve switches off via the load-dependent switches, Step F: Carry out a check in the top final position the see whether, after switching off the thrust actuator, the trip cam of the travel switch (S3) is situated below switch (S3) and has not tripped the latter. If the trip cam is situated above the travel switch (S3) or trips the same, the setting spindle governing the travel switch ($3) needs to be turned until the trip cam is situated below travel switch ($3) without tripping it. ‘Step G: Run the thrust actuator in both final positions once more and check whether thrust actuator switches off in both final positions via the load-dependent switches. Step HE: Ifneeded, correct the seiting as described above. 4.4 Potentiometers ‘The potentiometers are used for electrical position acknowledgement on the facility ‘control system or for the options, electronic position controller ES11 or electronic position indicator RI2Z1. A maximum of 2 potentiometers can be installed (= 1 double potentiometer). The potentiometers can be supplied with different resistance values. For the electronic position controller ES11 and the electronic position indicator RI21 use must be made solely of 1000 ohm potentiometers. Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by means of transmission determined in respect of each valve-lift between the toothed rack on the trip slide and the pinion on the potentiometer shafl. Use must only be made of the pinion specified for the valve-tift. Language UK Page 16/21