Chlorine ball-valve. Operating instructions. Read the operating manual! The user is responsible for installation and operation related mistakes!

Transcription

1 Chlorne ball-valve Read the operatng manual! The user s responsble for nstallaton and operaton related mstakes! Orgnal operatng nstructons Dosng Conveyng Control Lquds Gases Systems

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3 Table of Contents 1 Notes for the Reader General non-dscrmnaton Explanaton of the sgnal words Explanaton of the warnng sgns Identfcaton of warnngs Safety General warnngs Informaton about chlorne Hazards due to non-complance wth the safety nstructons Workng n a safety-conscous manner Personal protectve equpment Personnel qualfcaton Intended use Notes on product warranty Intended purpose Prohbted operatng condtons Prohbted dosng meda Product descrpton Scope of delvery Desgn and functon Ratng plate Mantenance Mantenance ntervals Mantenance accessores Preparng the system for mantenance Mantanng the ball valve Functon test of the drve Fnshng mantenance Troubleshootng Ball valve malfunctons Malfunctons of the drve Spare parts Ball valve wth handle Drve wth mountng hardware Declaraton of no objecton Warranty clam Index Techncal data Techncal data of the ball valve Techncal data of the drve Dmensons Ball valve dmensons Dmensons of the ball valve wth drve Installaton Installaton locaton Assemblng the ball valve Retrofttng a drve to the ball valve Connectng the drve Completng the nstallaton Installaton example Commssonng Check electrc connecton Inspectng the pressure system Operaton Operatng the ball valve Operatng the ball valve wth drve Adjustng the drve Shuttng down n an emergency Check ntervals Shutdown Short-term shutdown Long-term shutdown Storage...25 Subject to techncal changes Table of Contents 3

4 1 Notes for the Reader Ths operatng manual contans nformaton and behavour rules for the safe and desgnated operaton of the devce. Observe the followng prncples: read the entre operatng nstructons pror to nauguratng the devce. Ensure that everyone who works wth or on the devce has read the operatng manual and follows t. Mantan the operatng manual throughout the servce lfe of the devce. Pass the operatng manual on to any subsequent owner of the devce. 1.1 General non-dscrmnaton In ths operatng manual, only the male gender s used where grammar allows gender allocaton. The purpose of ths s to make the text easy to read. Men and women are always referred to equally. We would lke to ask female readers for understandng of ths text smplfcaton. 1.2 Explanaton of the sgnal words Dfferent sgnal words n combnaton wth warnng sgns are used n ths operatng manual. Sgnal words llustrate the gravty of possble njures f the rsk s gnored: 1.3 Explanaton of the warnng sgns Warnng sgns represent the type and source of a danger: Warnng sgn Table 2: Explanaton of the warnng sgns Type of danger Danger to lfe from chlorne posonng Danger to lfe due to electrc shock General danger zone 1.4 Identfcaton of warnngs Danger of damage to machne or functonal nfluences Sgnal word DANGER Meanng Refers to mmnent danger. Ignorng ths sgn may lead to death or the most serous njures. Warnngs are ntended to help you recognse rsks and avod negatve consequences. Ths s how warnngs are dentfed: WARNING CAUTION NOTE Table 1: Explanaton of the sgnal words Refers to a potentally hazardous stuaton. Falure to follow ths nstructon may lead to death or severe njures. Refers to a potentally hazardous stuaton. Falure to follow ths nstructon may lead to mnor njury or damage to property. Refers to a danger whch, f gnored, may lead to rsk to the machne and ts functon. Warnng sgn Descrpton of danger. Consequences f gnored. SIGNAL WORD ð The arrow sgnals a safety precauton to be taken to elmnate the danger. Instructon for acton dentfcaton Ths s how pre-condtons for acton are dentfed: ü Pre-condton for acton whch must be met before takng A resource such as a tool or auxlary materals requred to perform the operatng nstructons. Ths s how nstructons for acton are dentfed: è Separate step wth no follow-up acton. 1. Frst step n a seres of steps. 2. Second step n a seres of steps. 4 Result of the above acton. ü Acton completed, am acheved. 4 Notes for the Reader General non-dscrmnaton

5 2 Safety 2.1 General warnngs The followng warnngs are ntended to help you elmnate the dangers that can arse whle handlng the devce. Rsk preventon measures always apply regardless of any specfc acton. Safety nstructons warnng aganst rsks arsng from specfc actvtes or stuatons can be found n the respectve sub-chapters. DANGER Danger to lfe from chlorne posonng! Chlorne s posonous. In severe cases, breathng n chlorne may lead to death. It rrtates the eyes, the respratory system and the skn. ð Install a gas warnng devce. ð Use suffcent personal protectve equpment. ð When carryng out any work on the system, use a resprator mask wth a Type B gas flter that comples wth EN ð Always comply wth the accdent preventon regulatons that apply at the place of use. ð Get rd of leaks wthout delay. You must get rd of even very mnor leaks wthout delay. Together wth the humdty, chlorne forms hydrochlorc acd and corroson results n rapdly ncreasng leakage. ð Use only chlorne-resstant seals. ð Only use seals once. Reusng them leads to leaks. DANGER Increased danger to lfe from chlorne escape If chlorne gas escapes, a flter mask s neffectve, snce t s not a self-contaned breathng apparatus. ð If chlorne gas escapes, wear a Type 2 self-contaned breathng apparatus that comples wth EN 137. ð In an emergency, shut down the system n accordance wth secton 9.4 Shuttng down n an emergency on page 24. ð Gven a serous escape and nsuffcent equpment or qualfcatons, leave the work to professonal emergency servces personnel. Do not take any unnecessary rsks. WARNING Increased rsk of accdents due to nsuffcent qualfcaton of personnel! Chlornators and ther accessores must only be nstalled, operated and mantaned by personnel wth suffcent qualfcatons. Insuffcent qualfcaton wll ncrease the rsk of accdents. ð Ensure that all acton s taken only by personnel wth suffcent and correspondng qualfcatons. ð Prevent access to the system for unauthorsed persons. NOTE Damage to the plant due to the formaton of hydrochlorc acd Chlorne gas s hghly hygroscopc. Ths means that humdty enters the system at any open connecton on devces or ppes, whch results n the formaton of hydrochlorc acd and contamnaton. thus nevtably causng damage to the unts. ð Keep all connectons (ncludng n the vacuum system and on all devces not currently n use) closed at all tmes. 2.2 Informaton about chlorne Chlorne s a hazardous substance. The chemcal element chlorne s a greensh-yellow, toxc gas wth a pungent odour, whch can be detected n the ar at concentratons below 1 ppm (= 1 ml/m³). Chlorne s 2.5 tmes heaver than ar and accumulates at ground level. Chlorne s extremely toxc for water organsms. The reason for the toxcty of chlorne s ts extraordnary reactvty. It reacts wth anmal and vegetable tssue and thus destroys t. Ar wth a chlorne gas content of 0.5-1% leads to a quck death n mammals and humans, as t attacks the respratory tract and the pulmonary alveolus (formaton of hydrogen chlorde or hydrochlorde acd). NOTE Faults due to nsuffcent chlorne qualty Impurtes n the chlorne gas form deposts n devces and valves and can attack the components chemcally. Ths can lead to malfunctons. ð Only use techncally pure chlorne that meets the followng requrements: - Mass content of chlorne at least 99.5% - Water content max. 20 mg/kg Chlorne that comples wth EN 937 meets these requrements. Subject to techncal changes Safety General warnngs 5

6 2.3 Hazards due to non-complance wth the safety nstructons Falure to follow the safety nstructons may endanger not only persons, but also the envronment and the devce. The specfc consequences can be: Falure of mportant functons of the devce and of the correspondng system, Falure of requred mantenance and repar methods, Danger to persons, Danger to the envronment caused by substances leakng from the system. 2.4 Workng n a safety-conscous manner Besdes the safety nstructons specfed n ths operatng manual, further safety rules apply and must be followed: Accdent preventon regulatons Safety and operatng provsons, Safety regulatons on handlng hazardous substances, Envronmental protecton provsons, Applcable standards and legslaton. 2.5 Personal protectve equpment Based on the degree of rsk posed by the dosng medum and the type of work you are carryng out, you must use correspondng protectve equpment. Read the Accdent Preventon Regulatons and the Safety Data Sheets to the dosng meda fnd out what protectve equpment you need. You wll requre the mnmum of the followng personal protectve equpment: Personal protectve equpment requred Resprator mask Wear the followng personal protectve equpment when performng the followng tasks: Installaton, Commssonng, All work on gas-bearng sectons of the plant, Changng the chlorne tank, Shut-down, Mantenance work, Dsposal. 2.6 Personnel qualfcaton Any personnel who work on the devce must have approprate specal knowledge and sklls. Anybody who works on the devce must meet the condtons below: Attendance at all the tranng courses offered by the owner, Personal sutablty for the respectve actvty, Suffcent qualfcaton for the respectve actvty, Tranng n how to handle the devce, Knowledge of safety equpment and the way ths equpment functons, Knowledge of ths operatng manual, partcularly of safety nstructons and sectons relevant for the actvty, Knowledge of fundamental regulatons regardng health and safety and accdent preventon. All persons must generally have the followng mnmum qualfcaton: Tranng as specalsts to carry out work on the devce unsupervsed, Suffcent tranng that they can work on the devce under the supervson and gudance of a traned specalst. These operatng nstructons dfferentate between these user groups: Specalst staff Thanks to ther professonal tranng, knowledge, experence and knowledge of the relevant specfcatons, specalst staff are able to perform the job allocated to them and recognse and/or elmnate any possble dangers by themselves Traned electrcans Protectve clothng Protectve gloves Due to ther professonal tranng, knowledge and experence as well as knowledge of specfc standards and provsons, traned electrcans are able to do the electrcal work assgned to them and to recognse and avod any potental dangers by themselves. They are specally traned for ther specfc workng envronment and are famlar wth relevant standards and provsons. They must comply wth the legally bndng regulatons on accdent preventon Traned persons Safety shoes Table 3: Personal protectve equpment requred Traned persons have receved tranng from the operator about the tasks they are to perform and about the dangers stemmng from mproper behavour. Traned persons have attended all tranngs offered by the operator. 6 Safety Hazards due to non-complance wth the safety nstructons

7 2.6.4 Personnel tasks In the table below you can check what qualfcatons are the pre-condton for the respectve tasks. Only people wth approprate qualfcatons are allowed to perform these tasks! Qualfcaton Specalst staff Traned electrcans Traned persons Table 4: Personnel qualfcaton Transportaton Assembly Actvtes Hydraulc nstallatons Commssonng Control Takng out of operaton Fault rectfcaton Mantenance Repars Dsposal Electrcal nstallaton Rectfyng electrcal faults Electrcal repars Storage 3 Intended use 3.1 Notes on product warranty Any non-desgnated use of the devce can mpar ts functon and the protecton provded. Ths leads to nvaldaton of any warranty clams! Please note that lablty s on the sde of the user n the followng cases: The product s operated n a manner that s not consstent wth these operatng nstructons, n partcular wth the safety nstructons, handlng nstructons and ntended purpose. f people operate the product who are not adequately qualfed to carry out ther respectve actvtes. No orgnal spare parts or accessores of Lutz-Jesco GmbH are used. Unauthorsed changes are made to the product by the user. The user uses dfferent dosng meda than those ndcated n the order. 3.2 Intended purpose The chlorne ball valve descrbed below s used for shuttng-off a ppe, whch carres lqud or gaseous chlorne. The use of the valve as a control valve does not comply wth the ntended purpose. 3.3 Prohbted operatng condtons The product s only ntended for the applcatons accordng to Secton 3.2 "Intended purpose". The detals regardng the operatng condtons accordng to the "Techncal data" (page 10) must be observed. The product must not be operated f protectve equpment has been removed or has not been properly nstalled or s not fully functonal. 3.4 Prohbted dosng meda The devce must not be used for the followng meda and substances: All meda apart from lqud and gaseous chlorne. Not techncally pure chlorne wth a mass content of less than 99.5%. Subject to techncal changes Intended use Notes on product warranty 7

8 4 Product descrpton 4.1 Scope of delvery Please compare the delvery note wth the scope of delvery. The followng tems are part of the scope of delvery: Ball Valve Assembly accessores for flanges DN 25 / PN 40 (optonal) 4.2 Desgn and functon The ball valve s a shut-off devce that uses a perced ball (1) as the shutoff body. The fttng s desgned wth a floatng ball. Ths means that the connecton between the ball and the control rod (2) s "loose" so that the ball can press tself nto the seal (3) n the closed valve poston by the medum pressure alone wthout exercsng any pressure on the control rod. The control rod opens and closes the ball valve. The control rod s operated ether va a manual handle (fgure 1) or an electrcal drve / actuator (fgure 2). The connecton between the ball valve and ppelne s made wth a housng flange (5). Ths flange s attached to the ball valve n order to provde a connecton for drves or stop pns (6), whch are to lmt the swtch travel. 4 Actuatng torques DN Requred Maxmum permtted 8* Table 5: Actuatng torques for ball valves In order to take certan nfluences, such as contamnaton or ageng of the ball valve, nto consderaton, we recommend an actuatng torque of 1.5 tmes the requred torque value. The ball valve has a housng flange (4) for the fastenng of stop pns (5), whose task s to lmt the swtch travel, or for the connecton of drves. The connecton dmensons for drves depend on the nomnal wdth of the ball valve (see Table 9 n Secton 6 "Dmensons"). Possble drves are electrcal swvel drves. The drve (1) s connected wth the ball valve (4) va a metal brdge (2) and an adapter (3). Fgure 2 shows such a ball valve Fg. 1: Ball valve wth nternal thread Furthermore, ball valves are categorsed by the dameter of the ball bore. If the dameter of the ball bore corresponds to the nomnal wdth (DN) of the connected ppe, the ball valve s called a ball valve wth full passage. If the ball bore s smaller by one nomnal wdth step, the ball valve s called a ball valve wth reduced passage. Ball valves wth reduced passage have the advantage that they requre a smaller torque for actuatng the control rod compared to ball valves wth full passage. Table 5 shows the requred and maxmum permtted actuatng torques for brand new ball valves dependng on the nomnal wdth of the connected ppe. Wth the excepton of ball valves for very small nomnal wdths (*), all ball valves, to whch these operatng nstructons apply, have a reduced passage. Fg. 2: Ball valve wth drve The swvel drve s ftted wth a manual emergency gear. In the event of a power cut, the control rod can be manually operated usng a handle (5). An operatng mode selector lever (6) for togglng between automatc operaton (AUTO) and manual operaton (MAN) s located on the drve sde. 8 Product descrpton Scope of delvery

9 Drve unt The drve has a ratng plate wth nformaton about the safety and functonalty of the product. The ratng plate must be kept legble for the entre servce lfe of the product (B) MAN (A) AUTO Fg. 3: Vew of the connectors Also on the drve sde are the connectors for the power supply (7) of the drve and the end poston (lmt) feedback (8). An operatng lght (9) ndcates the operatonal readness of the drve or the actvaton of the manual operaton. Fg. 4: Drve ratng plate No. Descrpton As an opton, the swvel drve can be ftted wth a rechargeable battery system. In the event of a power cut, the drve moves the ball valve nto the closed poston usng the battery power supply. The battery ncludng the charger electroncs s already ntegrated n the drve housng. The falure of the battery system NOTE The battery system can only work f the battery has been charged. Always charge the battery before commssonng the drve. (For nformaton about the chargng tme please refer to Secton 5 "Techncal data".) ð Make sure that the motor s also suppled wth voltage n the closed poston. The battery charges n both postons. 1 Model (s composed of the voltage varant and operatng torque n Nm) 2 Detals regardng the seres 3 Voltage range 4 Actuatng tme 5 Temperature range 6 Detals regardng the possble flange varants for the desgn acc. to DIN EN ISO Start-up tme (100% = 10 mnutes) 8 Protecton class Only n AUTOMATIC OPERATION does the battery move the ball valve nto the closed poston. 9 Detals regardng the support's female square n mm 10 Maxmum torque (not the operatng torque) 4.3 Ratng plate Ball Valve 11 CE markng 12 Seral number Table 6: Drve ratng plate The ball valve does not have a ratng plate. Instead, the followng detals have been punched nto ts metal body: Materal number of the housng flanges Works number of the housng body Desgnaton of the seres Maxmum permssble pressure Nomnal wdth of the ball valve Seral number CE markng Year of bult Subject to techncal changes Product descrpton Ratng plate 9

10 5 Techncal data 5.1 Techncal data of the ball valve Connecton type Informaton DN 8 - DN 25 DN 25 Value Internal thread Flange wth groove and sprng accordng to EN 1092 shape C and D Operatng pressure PS 40 Max. pressure PS 100 Housng Steel (1.0436) Ball Monel 400 Materals Control rod Steel (1.4404) Housng seal Ball seat PTFE PTFE wth 25% glass Ambent temperature 0 C - 60 C Weght DN 8 DN 15 DN 20 DN 25 (thread) DN 25 (flange) 0.75 kg 0.95 kg 1.7 kg 2.3 kg 4.5 kg Table 7: Techncal data of the ball valve 10 Techncal data Techncal data of the ball valve

11 5.2 Techncal data of the drve Descrpton Value Flange connecton acc. to DIN EN ISO 5211 F 03 F 05 Torque Actuatng tme for 90 wthout load Voltage Current consumpton: Protecton class Operaton Maxmum 20 Nm 25 Nm 11 s V AC/DC 0.01 A 0.21 A IP65 Start-up tme 75% Temperature range C Load capacty of the lmt swtch 250 V AC, 3 A Servce lfe journeys or 3-5 years Maxmum number of runs before rechargng s requred 5 Chargng tme after battery run 8 mn Rechargeable battery system (optonal) Chargng tme before commssonng 28 h Battery capacty 100 ma Consumpton (drvng) 6.2 W Current consumpton (chargng) 40 ma/h Weght Wthout battery Wth battery 1.4 kg 1.6 kg Table 8: Techncal data of the drve Subject to techncal changes Techncal data Techncal data of the drve 11

12 6 Dmensons All dmensons n mm 6.1 Ball valve dmensons E B G A1 A2 4xØ K G C E D Ø J Fg. 5: Dmensonal drawng of the ball valve wth nternal thread (wthout stop pns) Nomnal wdth DN 8 DN 15 DN 20 DN 25 Dm. A Dm. A Dm. B Dm. C Dm. D Dm. E Dm. F Dm. G Internal thread H ¼" NPT ½" NPT ¾" NPT 1" NPT Flange code pursuant to DIN EN ISO 5211 F03 FO3 FO3 FO4 Dm. Ø J Dm. Ø K M6 M6 M6 M6 Table 9: Dmensons of the ball valve wth nternal thread (wthout stop pns) 12 Dmensons

13 Ø Ø 85 Fg. 6: Dmensonal drawng of the ball valve wth flange (wthout stop pns) Ø Dmensons of the ball valve wth drve ~126 ~ ~196 Fg. 7: Dmensonal drawng of the ball valve wth nternal thread and drve Subject to techncal changes Dmensons 13

14 7 Installaton Danger from too hgh a pressure! DANGER Under the nfluence of heat, lqud chlorne expands consderably. An mpermssble hgh pressure can occur f a ppe lne or a system component s flled wth lqud chlorne and all nputs and outputs are closed. Ths can cause system parts to burst, causng chlorne to escape. ð In each secton of the system where lqud chlorne can be trapped, nstall an expanson system. ð In ths case, relef may only be performed nto a safe envronment, e.g. n an expanson tank made of steel. The contaner should be brand-new and must be capable of accommodatng at least 20% of the lne volume. DANGER Danger to lfe from chlorne posonng! Chlornators wthout gas warnng devces are an ncreased safety rsk, snce t s not possble to detect escapng chlorne gas n good tme or at all. ð Install a gas warnng devce. WARNING Increased rsk of accdents due to nsuffcent qualfcaton of personnel! Chlornators and ther accessores must only be nstalled, operated and mantaned by personnel wth suffcent qualfcatons. Insuffcent qualfcaton wll ncrease the rsk of accdents. ð Ensure that all acton s taken only by personnel wth suffcent and correspondng qualfcatons. ð Prevent access to the system for unauthorsed persons. NOTE Damage to the system due to ncorrect nstallaton The falure to observe nstallaton nstructons (e.g. use of unsutable tools, ncorrect torque) can damage the system parts. ð Use sutable tools. ð Note the specfed torque. 7.1 Installaton locaton The room must fulfl the followng mnmum requrements: secured aganst access by unauthorsed persons, protected aganst weather condtons, protected aganst frost, protected aganst exposure to drect sunlght, permssble ambent temperature adhered to (see Secton 5 "Techncal data"), room of suffcent sze to allow trouble-free assembly as well as nspecton and mantenance of the devce at all tmes, good ventlaton of the room the room must comply wth the locally vald prescrptons 7.2 Assemblng the ball valve The flow drecton can be freely chosen. It may be necessary to adjust the poston of the stop pns on the housng flange for ball valves wth a handle. The equpment s supported by the ppelne. Make sure that the ppe s securely fastened. The mechancal assembly s dentcal for all varants. However, t dffers wth regard to the connecton type. The followng pre-condtons for acton must always be fulflled: ü When routng the ppelnes to the ball valves make sure that they are free from tenson. ü The nsde of the ppes and ball valve are clean and dry Assembly usng a flange connecton PN 40 flanges wth a groove and sprng accordng to EN 1092, shape C and D, are ftted to the ends of the ball valve. The approprate counter-flanges must be used n order to make the flange connectons. Precondton for acton: ü The transport protecton of the equpment s removed. ü The flange sealng faces are free from contamnaton and damage. ü The flange seals must be clean, undamaged and dry. ü Bolts, nuts and washers are clean and undamaged. ü The dstance between the ppe flanges equals the length of the ball valve. ü The ball valve s fully open. Any bolts, nuts and washers that are removed durng nstallaton must be replaced wth new ones. Used bolts, nuts and washers may only be nstalled f they are n new condton. 14 Installaton Installaton locaton

15 Assembly usng a threaded connecton Organc sealng materals must not be used for assemblng the fttngs and ppes. For ths purpose, only Teflon tape or specally approved sealng agents (such as anaerobc sealng compounds) may be used. Precondton for acton: ü The transport protecton s removed. ü The threads are metallc brght. Perform the followng workng steps: Fg. 8: Installng the flange connecton Perform the followng workng steps: Lubrcate the sldng faces and thread of bolts, nuts and washers e.g. usng fttng grease or PTFE grease. 2. Place the flat seal (2) nto the groove of the connecton flange (3). Assemble the seal n dry condton. 3. Mount the tongue flange (1). Make sure that the flat gasket (2) does not slp. 4. Ft the bolts (4), washers (5, 6) and nuts (7) by hand. 5. Tghten the bolts evenly alternately crosswse n three stages: 20 Nm, 35 Nm, 50 Nm. After ths, retghten all the bolts to the full target tghtenng torque (50 Nm). 6. Settng the seal (adaptng to the flange seal surface) can make t necessary to retghten the bolts. For ths reason, retghten the bolts to 50 Nm after a few hours. ü Flange connecton assembled 1. Clean the thread wth a fat-dssolvng cleanng agent, e.g. alcohol. 2. Allow the thread to dry completely. 3. Apply the thread sealant to the external thread n a crcular moton to the start of the thread. Leave the frst thread clear. Apply the thread sealant all the way down to the root of the thread to thoroughly grease the thread flank. Fg. 9: Seal n the thread 4. Insert the threaded pn nto the nternal thread and apply a lttle thread sealant to the nternal thread. Screw the parts by hand. Thread Tghtenng torque ¼" NPT up to 50 Nm ½" NPT up to 100 Nm 1" NPT up to 150 Nm Table 10: Tghtenng torques for threaded connectons 5. Remove excess thread sealant wth a cloth. NOTE Leakage due to ncorrect nstallaton To ensure that the connecton s correctly algned, t s necessary under certan crcumstances to turn the thread antclockwse. When the connecton s loosened, bubbles form n the adhesve, whch can lead to leakages. ð Only turn the thread ant-clockwse. ð If the orentaton s not correct after the connecton has been tghtened, repeat steps 1 5. Allow the bond to harden for at least 12 hours pror to the leak test. ü The ppelne wth a threaded connecton has been assembled. Subject to techncal changes Installaton Assemblng the ball valve 15

16 7.3 Retrofttng a drve to the ball valve At the pont of delvery, the drve s already pre-nstalled at the ball valve. However, there s an opton of retrofttng a drve to a manual ball valve. In order to do ths, the handle and stop pns must be removed. When selectng the drve, the techncal data of the ball valve (see Secton 5) and the drve manufacturer's nstructons must absolutely be observed Mechancal connecton of the supply lne and control lne The provded DIN connectors must be used for connectng the drve. When makng the connecton, make sure that you observe the correct cable cross-secton (see table 13) n order to ensure leak-tghtness. 7.4 Connectng the drve WARNING Danger of electrc shock! Lve parts can nflct fatal njures. ð Work of whatever knd on the drve may only be carred out by qualfed personnel and only after the power supply to the equpment has been dsconnected. ð All local laws and regulatons must be observed when selectng the mans power cables. Fg. 10: DIN connectors NOTE Damage due to ncorrect mans voltage The drve wll get damaged f you connect t to the ncorrect mans voltage. ð Observe the nformaton about the mans supply that s gven on the drve's ratng plate. Please observe the followng ponts when connectng the drve: The drve must be sngle-phase connected. Make sure that the left-hand rotaton and rght-hand rotaton of the drve are not actvated at the same tme. Ths must be guaranteed by provdng an external fuse. Electrcal consumers must not be swtched parallel to the drve. Connector colour / sze Use Mn / max cable cross-secton Grey / large Voltage supply Ø 8 x mm Black / small End poston feedback Ø 5 mm Table 11: Cable dameter Perform the followng workng steps: 1. Remove the connector's fxng screw (5). 2. Open the connector by pullng the termnal block (2) out of the housng (4). 3. Insert the cable that s to be connected nto the cable screw connecton (7) at the housng (4). 4. Connect the cable accordng to the wrng dagram. ü Drve connected 16 Installaton Retrofttng a drve to the ball valve

17 V AC Lmt swtch N PE L L N close open closed open PE Grey plug Black plug Fg. 11: Exploded vew of a DIN connector Fg. 12: Crcut dagram Poston Descrpton 1 Seal 2 Termnal block 3 Cable clamp 4 Housng 7.5 Completng the nstallaton After the nstallaton has been completed, you need to check that all the connectons are leak-proof (see 8.2 "Checkng the pressure system" on page 19). Furthermore, all cable screw connectons must be securely tghtened to guarantee the IP protecton class. 5 Fxng screw 6 Seal 7 Washer 8 Cable connecton Table 12: Key of the DIN connector Electrcal connecton of the supply lne and control lne Perform the followng workng steps: 1. Loosen the screws of the connectors and remove the connectors. 2. Connect the supply lne and control lne accordng to the wrng dagram. The wrng dagram s shown on the housng opposte the DIN connectors. Subject to techncal changes Installaton Completng the nstallaton 17

18 7.6 Installaton example A 7 12 B M M Fg. 13: Installaton wth a chlorne evaporator Poston Descrpton Poston Descrpton A Room for the chlorne supply 10 Pressure reducng valve B Dosng devce room 11 Mosture elmnator wth heatng collar 1 Chlorne barrel 12 Vacuum regulator 2 Chlorne barrel scale 13 Actvated carbon cartrdge 3 Manfold 14 Dosng devce 4 Expanson system for ppng 15 Motve water pump 5 Changeover swtch 16 Injector wth non-return valve 6 Chlorne evaporator 17 Gas warnng devce 7 Expanson system for chlorne evaporator 18 Gas sensor 8 Automatc ball valve 19 Horn 9 Chlorne gas flter 20 Entrance port of the chlorne elmnator Table 13: Desgnaton of components 18 Installaton Installaton example

19 8 Commssonng Precondton for acton: ü The nstallaton has been carred out correctly. 8.1 Check electrc connecton Ths only apples to ball valves wth a drve. Check that all electrcal connectons are correctly nstalled. 8.2 Inspectng the pressure system WARNING Increased rsk of accdents due to nsuffcent qualfcaton of personnel! If the leak-tghtness check s not carred out correctly, leakage may occur or the system may even get destroyed. ð Ensure that all acton s taken only by personnel wth suffcent and correspondng qualfcatons. ð Prevent access to the system for unauthorsed persons. ð Wear a resprator mask. Check the pressure system from the chlorne tank to the gas dosng system for leak-tghtness n two stages: 1. Leak test wth ntrogen, 2. Leak test wth chlorne Carryng out the leak test wth ntrogen You are strongly recommended to carry out ths nspecton before carryng out the leak test wth chlorne, snce t shows leaks n the pressure system wthout the rsk of chlorne escapng. As an alternatve, you can carry out the nspecton usng dry compressed ar. Precondton for acton: ü All the open connectons of the pressure system were closed correctly. ü All the shut-off valves n the ppe system were opened. ü A ntrogen cylnder wth a pressure reducer (0-25 bar) has been connected. Perform the followng workng steps: 1. Close the ntrogen cylnder's valve. 2. Apply soap soluton to all the potental leaks. 4 Bubbles form at leak locatons (wth a possble tme delay). 3. Close the outlet on the ntrogen cylnder's pressure reducer and observe the pressure gauge n the nstallaton. 4 The pressure must not drop wthn one hour. 4. Repar the leak. Allow any adhesve surfaces to harden suffcently and repeat the leak test wth ntrogen. NOTE Leakage at the control rod of the ball valve If the control rod shows any leakage, t can be made leak-proof by readjustng the control rod seal. ð Perform the followng workng steps Retghten the gland nut usng a sutable tool by turnng t clockwse for ¼ rotaton. Observe the tghtenng torques for glands n table Repeat ths process untl the control rod seal s leak-proof. 7. Make sure that the ball valve can stll be actuated easly wthout any need for force. DN DN8 DN15 DN 20 DN 25 Table 14: Tghtenng torques for gland nuts Tghtenng torque 10 Nm 10 Nm 20 Nm 25 Nm If t proves mpossble to correct the leakage at the control rod by readjustng the control rod seal, the control rod seal and the gland must be replaced (see Secton "Replacng the control rod seal" on page 27). ü Leak test wth ntrogen carred out. Resources Soap soluton or leak detecton spray Subject to techncal changes Commssonng Check electrc connecton 19

20 NH3 Chlorne ball-valve Carryng out the leak test wth chlorne gas DANGER Danger to lfe from chlorne posonng! If you start the leak test wth chlorne gas before the entre system has been nstalled and the njectors are ready for operaton, chlorne gas may not be extracted mmedately n the event of a leak. ð Make sure that all the components n the plant are nstalled correctly and the njectors are ready for operaton before startng the leak test wth chlorne gas. ð Put on protectve clothng before carryng out the leak test wth chlorne gas. NOTE Damage to the plant by the ammona soluton If the ammona soluton comes nto contact wth the plant, ths leads to corroson on the equpment. ð Make sure that you do not spll any ammona. Precondton for acton: ü The leak test wth ntrogen has been carred out successfully. ü All the open connectons of the pressure system were closed correctly. ü All shutoff valves n the ppng system have been closed. ü A chlorne tank has been closed (at the gas take-off of the chlorne tank). ü The njector s ready for operaton. Resources Cylnder wth ammona soluton Perform the followng workng steps: 1. Brefly open the chlorne contaner valve and close t agan. 2. Open the frst valve n the ppe lne, startng from the chlorne tank. 3. Carry out the ammona test at the ppelne secton up to the frst closed valve: Hold an open bottle contanng the ammona soluton close to the ppe and make slght pumpng motons wth the plastc bottle. Ammona steam wth chlorne forms a whte vapour and makes even very small leaks vsble. ü Leak test wth chlorne gas completed. Fg. 14: Leak test wth ammona 4. Open addtonal downstream valves n the ppe lne n sectons. In each case, let a lttle chlorne gas nto the system and close the valves agan. Then carry out the ammona test at ths ppe lne secton and the assocated fttngs. Proceed n ths manner untl all ppng and fttngs have been tested for leaks. If you fnd leaks: 1. Close the chlorne tank valve. 2. Use the njector to suck off the remanng chlorne. 3. Operate the chlornaton nstallaton for approx. 5 mnutes wth ntrogen or dry compressed ar at approxmately 5 bar. 4. Swtch off the njector at the booster pump. 5. Repar the leak. Allow any adhesve surfaces to harden suffcently and repeat the leak test. If you do not fnd any leaks: 1. Close the chlorne tank valve. 2. Depressurse the system usng the njector to evacuate the ppng. 3. Swtch off the njector at the booster pump. ü Leak test wth chlorne gas completed. 20 Commssonng Inspectng the pressure system

21 9 Operaton DANGER If the handle s removed, the dhedron ndcates the status. (The tap s open when the dhedron s parallel to the ppe axs.) Chlorne gas can escape due to systems that are leaky or not nstalled correctly! Chlornators consttute an ncreased safety rsk f they have not been properly nstalled, f an adequate leak test has not been performed or f the devces are not n good condton. ð Before placng the system nto operaton, have t checked by techncal personnel to ensure that t s n the proper condton and leaktght. ð The condton of the nstallaton must be checked for adequate tghtness on a regular bass. ð Ensure that all acton s taken only by personnel wth suffcent and correspondng qualfcatons. WARNING Danger of personal njury and materal damage! If the chlorne gas flow through the ball valve s restraned, the subsequent expanson nto the connected ppe wll result n a drop of the chlorne gas temperature. The temperature can drop to a pont when the chlorne gas wll condense. Ths means that downstream system parts, whch are only desgned for the use of chlorne gas, are damaged and that leakage may occur. ð Only use the ball valve for fully openng or closng the ppes. 9.1 Operatng the ball valve The ball valve does not requre any specal operatng technque. The valve can be opened or closed fully by movng the control rod, for example wth the handle (handle parallel to the ppe axs = open, handle perpendcular to the ppe axs = closed). We do not recommend that you use any ntermedate handle poston. 9.2 Operatng the ball valve wth drve Operatng modes Automatc operaton In automatc operaton, the drve moves the ball valve to the "fully open" or "fully closed" poston. The handle on the housng roof rotates wth the valve durng automatc operaton, thereby vsually ndcatng the poston of the ball valve. Dhedron Handle Handle Fg. 16: Top vew of the drve (top = open, bottom = closed) Fg. 15: Ball valve postons (top = open, centre = closed, bottom = ntermedate poston) Subject to techncal changes Operaton Operatng the ball valve 21

22 Manual mode The drve s ftted wth a manual emergency gear for actuatng the control rod n the event of a power cut. Move the operatng mode lever from the AUTO poston to the MAN poston. As a result, the motor s mechancally dsconnected from the gear. The drve can now be adjusted wth the handle Drve operatng lght The operatng state of the drve s ndcated by the LED n the cover. The flashng cycle s depcted n the followng table n the dsplay column. The tme amounts to 200 ms per bnary number. A notfcaton cycle conssts of 4 columns each wth 4 bnary numbers. The bnary numbers have the followng confguraton: 1 = LED on; 0 = LED off. Condton Tme Dsplay No voltage 100% Operatng ready 100% Operatng mode lever Protectve crcut actvated 200 ms Manual actuaton actvated 200 ms Battery actvated 200 ms (B) MAN (A) AUTO Battery empty 200 ms Table 15: Adjustng the drve Fg. 17: Togglng between automatc and manual operaton Returnng to automatc operaton 9.3 Adjustng the drve The drve contans an nternal functon that protects t aganst excessve motor operatng tmes. If the motor has swtched tself off, togglng from manual to automatc operaton solely by movng the operatng swtch from MAN to AUTO s no longer possble. Changng from MAN to AUTO before the motor s swtched off: è Move the operatng mode lever from the MAN poston to the AUTO poston. è Gently turn the handle n order to resynchronse the gear wth the motor. Changng from MAN to AUTO after the motor has been swtched off: è In the MAN swtch poston, turn the handle untl an end poston has been reached (open or closed). 4 The motor s reactvated. è As soon as the motor s runnng, move the operatng mode lever from MAN to AUTO. 4 The drve s agan ready for operaton. or è Move the operatng mode lever from MAN to AUTO. è Dsconnect the power supply for a bref perod of tme. 4 The drve s reset. After that t s agan ready for operaton. Mortal danger from electrc shock! Lve parts can nflct fatal njures. DANGER ð Work may only be carred out by qualfed personnel. ð Dsconnect the devce from the power supply. The drves are pre-adjusted. Dependng on the ntended use, any play or nsuffcent algnment of fttngs connectons or adapters may requre that you adapt the drve's travel to the respectve fttng or readjust the feedback dependng on the swtchng. Extended operatng tme and heavy vbraton may requre a readjustment Checkng the lmt swtches Deactvatng the motor The termnal connecton s ndcated on the motor housng. Perform the followng workng steps: 1. Move the operatng mode lever to the AUTO poston. 2. Electrcally move the motor to the CLOSED poston. 3. Check that the connected valve has been closed. 22 Operaton Adjustng the drve

23 4. Electrcally move the motor to the OPEN poston. 5. Check that the connected valve has been fully opened. End poston sgnals The termnal connecton s ndcated on the motor housng. Perform the followng workng steps: 1. Move the operatng mode lever to the AUTO poston. 2. Electrcally move the motor to the CLOSED poston. 3. The CLOSED poston feedback must be closed. 4. Move the operatng mode lever to the MAN poston. 5. Turn the handle counterclockwse. The contact must open after approx. ¼ rotaton. (¼ rotaton at the handle = 5 rotaton of the man shaft.) The servomotor's gear has some play. Ths means that the ¼ rotaton only begns wth the frst movement of the man shaft wth the poston ndcator. 6. Move the operatng mode lever to the AUTO poston. The motor returns to the CLOSED poston. 7. Electrcally move the motor to the OPEN poston. 8. The OPEN poston feedback must nterconnect. 9. Move the operatng mode lever to the MAN poston. 10. Turn the handle clockwse. The contact must open after approx. ¼ rotaton. Observe the notce regardng the gear play Adjustng the drve Requred actons: ü The housng has been opened. (In order to do ths, the handle and fastenng pn must be removed frst.) ü The handle has been replaced on the man shaft. Resources Settng tool W00037 Trgger cams D C B A B C D Mcroswtch Table 16: Adjustng the drve Motor deactvaton CLOSED Motor deactvaton OPEN End poston sgnal CLOSED Deactvatng the motor End poston sgnal OPEN Perform the followng workng steps: A+B lmt the travel C+D effect the poston feedback 1. Move the operatng mode lever to the MAN poston. Small connector Termnal 1+2 Small connector Termnal Move to the poston that s to be changed usng the handle. 3. Turn the trgger cam A or B on the man shaft usng the settng tool untl you can hear that the mcroswtch has been actvated. Move the trgger cam to the mcroswtch n the drecton of rotaton, n whch the man shaft wll move. 4. Re-establsh the electrcal connecton. Change the drve mode from MAN to AUTO and check the settng by electrcally movng to the poston. End poston sgnals Requred actons: ü The motor deactvaton has been checked or adjusted. ü The motor has been electrcally moved up to the motor deactvaton poston. Perform the followng workng steps: 5. Turn the trgger cam C or D on the man shaft usng the settng tool untl you can hear that the mcroswtch has been actvated. Move the trgger cam to the mcroswtch n the drecton of rotaton, n whch the man shaft wll move. Then turn t by another approx Check the contnuty at the connector. 7. Move the operatng mode lever to the MAN poston. 8. Turn the motor at the hand wheel n the drecton of the other poston. After approx. ¼ rotaton, the swtch opens the contact. (¼ rotaton at the handle = 5 rotaton of the man shaft.) A The servomotor's gear has some play. The ¼ rotaton only begns wth the frst movement of the man shaft. Fg. 18: Adjustng the drve 9. Re-establsh the electrcal connecton. Change the drve mode from MAN to AUTO and check the settng by electrcally movng to the poston. Subject to techncal changes Operaton Adjustng the drve 23

24 After the adjustment has been completed, carefully replace the cover. Make sure that the cables pass the shafts and motor wth suffcent dstance as t was orgnally the case so that malfuncton due to cables gettng caught s avoded. The cover must tghtly ft to ts base. If the cover doesn't close tghtly, you can use the screws and tghten them n a crsscross sequence. Then replace the handle and possbly the hand wheel and fx them. 9.4 Shuttng down n an emergency DANGER Increased danger to lfe from chlorne escape Chlorne s posonous. In severe cases, breathng n chlorne may lead to death. It rrtates the eyes, the respratory system and the skn. ð If chlorne escapes, leave the room mmedately. ð Use suffcent personal protectve equpment. ð If chlorne gas escapes, wear a Type 2 self-contaned breathng apparatus that comples wth EN 137. ð Only ntate counter measures after puttng on the protectve equpment. ð Gven a serous escape and nsuffcent equpment or qualfcatons, leave the work to professonal emergency servces personnel. Do not take any unnecessary rsks. The chlorne tank valves must be closed. The further procedure depends on the type of accdent and should be planned and executed by professonal personnel. For lqud chlorne systems, the ncorrect operaton of the ball valves can cause further damage. Ppes and equpment that are (s) flled wth lqud chlorne, can burst n the event of a temperature ncrease f no expanson systems are nstalled. 9.5 Check ntervals You must check the components of the chlorne system for leaks on a daly bass and after mantenance or commssonng work. The followng checks are to be carred out at the ball valve: Check the control rod seal for leak-tghtness. Check the housng seal and ball seal for leak-tghtness. 24 Operaton Shuttng down n an emergency

25 10 Shutdown 10.1 Short-term shutdown Perform the followng workng steps: 1. Close the chlorne tank valves. 2. Use the njector to suck off the remanng chlorne. 3. Swtch off the njector. ü Chlornator shut down for the short term Long-term shutdown Perform the followng workng steps: 1. Close the chlorne tank valves. 2. Use the njector to suck off the remanng chlorne. 3. Operate the chlornaton nstallaton for approx. 5 mnutes wth ntrogen or dry compressed ar at approxmately 5 bar. 4. Close all the connectons to protect the lnes and devces from humdty and drt. 5. Swtch off the njector. ü Chlornator shut down for the long term. We recommend mantenance after a longer standstll perod (see chapter 11 Mantenance on page 25) Storage Storng the devce correctly wll extend ts servce lfe. You should avod negatve nfluences such as extreme temperatures, hgh humdty, dust, chemcals, etc. Ensure deal storage condtons where possble: store the ball valves n the open poston, the storage place must be cold, dry, dust-free and generously ventlated, temperatures between -20 C and +50 C. 11 Mantenance The ball valve and drve are mantenance-free under normal operatng and ambent condtons. However, some parts are subject to operatonal wear. Ths means that regular vsual nspectons are necessary to ensure a long operatng lfe. Regular mantenance wll protect the devce from operaton nterruptons. DANGER Danger to lfe from chlorne posonng! Do not carry out mantenance or any other work on the chlornator untl the system has been decommssoned and all of the chlorne gas has been removed from the lnes. The falure to follow ths nstructon presents a sgnfcant rsk of njury. ð Pror to any mantenance work, prepare the system n accordance wth secton 11.3 Preparng the system for mantenance on page 26. WARNING Increased rsk of accdents due to nsuffcent qualfcaton of personnel! Chlornators and ther accessores must only be nstalled, operated and mantaned by personnel wth suffcent qualfcatons. Insuffcent qualfcaton wll ncrease the rsk of accdents. ð Ensure that all acton s taken only by personnel wth suffcent and correspondng qualfcatons. NOTE Damage to the system due to corroson Water n chlorne carryng system components combnes wth chlorne to form hydrochlorc acd and leads to corroson ð After completng mantenance work, remove all the water resdue from the system before returnng t to operaton. ð Keep the connecton of the contact vacuum meter closed so that humdty cannot penetrate Subject to techncal changes Mantenance Short-term shutdown 25

26 11.1 Mantenance ntervals To avod hazardous ncdents, chlornators must be regularly mantaned. Ths table gves you an overvew of mantenance work and the ntervals at whch you must carry t out. The next few sectons contan nstructons for carryng out ths work. Interval Mantenance 1 year Check the ball seal and housng seal and replace them f requred. Check the ball, ball cavtes and connecton ends for contamnaton and clean them f requred. Table 17: Mantenance ntervals Wth ball valves wth a drve. Functon test of the drve In some cases, regonal regulatons may requre shorter mantenance ntervals. Mantenance ntervals depend only on how frequently the equpment s used. Chemcal wear of seals, for example, begns wth the ntal contact wth the medum and contnues rrespectve of the usage type Mantenance accessores 11.4 Mantanng the ball valve The mantenance can also be carred out wthout havng to remove the fttng. Precondton for acton: ü The system has been prepared for mantenance n accordance wth secton 11.3 Preparng the system for mantenance on page 26. ü All feed and dscharge lnes have been depressursed Dsassemblng the drve The followng secton s based on the assumpton that the ball valve s a ball valve wth a handle. However, f the ball valve s ftted wth a drve, the drve must be removed for the mantenance work. Perform the followng workng steps: 1. Dsconnect the drve from the power supply. 2. Remove the four fastenng screws (4), whch connect the drve (1) ncludng the brdge (2) wth the ball valve (5). 3. Lft the drve off and put t to one sde. 4. Remove the adapter (3) from the control rod and put t to one sde. ü The drve has been dsassembled. DN Part number 1 DN 8, DN DN DN Table 18: Sealng sets Preparng the system for mantenance Perform the followng workng steps: Close the chlorne tank valves. 2. Use the njector to suck off the remanng chlorne. 3. Run the chlornator for approxmately fve mnutes wth ntrogen or dry compressed ar. 4. Swtch off the njector. 5. Close all connectons n order to protect the lnes and equpment aganst humdty. ü The system s prepared for mantenance. Fg. 19: Dsassemblng the drve 5 The centre part of the ball valve can be removed rrespectve of the desgn (nternal thread, flange) of the ball valve Replacng the ball seal and housng seal Perform the followng workng steps: 1. Close the ball valve by turnng the hand grp (1) dagonally to the drecton of flow. 26 Mantenance Mantenance ntervals

27 2. Loosen the bottom two hexagonal nuts (4) by approx. 2 to 3 turns. 3. Remove the top two hexagonal nuts, hexagonal screws (3) and spacer sleeves (2). 4. Remove the centre part of the ball valve (5) Clean the connecton ends, whch were left n the ppe, before assemblng the centre part of the ball valve. 11. Push the centre part of the ball valve between the connecton ends. Durng the assembly, make sure that the centre part rests on the spacer sleeves. 12. Close the ball valve so that the ball seals centre correctly. Tghten the hexagonal nuts n a crss-cross sequence. Comply wth the tghtenng torques lsted n Table 19 Tghtenng torques for housng screws. The nuts should be tghtened n 3 stages: a. In a crss-cross sequence wth 30% of the tghtenng torque. b. As above wth 60% of the tghtenng torque. c. As above wth 100% of the tghtenng torque. d. Tghten all nuts agan n a crcular sequence wth the full tghtenng torque. Ths process must be repeated untl the nuts wll not turn any further when the full tghtenng torque s appled. 4 DN Thread Ø Unon nut Tghtenng torque Fg. 20: Removng the centre part of the ball valve 5. Remove the ball seal and housng seals (6 and 8). Rsk of njury! WARNING In order to remove the ball, the control rod may need to be rotated. ð Never put your hands nto the nteror of the centre ball part n order to remove the ball as ths may result n serous njury! 6. Remove the ball (7) from the centre part. Carefully check the ball and ts cavtes for contamnaton. Remove any contamnaton wth the help of an alcohol-based solvent and a sutable cloth. 5 DN 8 M 8 20 Nm DN 15 M 8 20 Nm DN 20 M 8 20 Nm DN 25 M Nm Table 19: Tghtenng torques for housng screws ü The ball seal and housng seal have been successfully replaced Replacng the control rod seal Damage of the control rod NOTE The replacement of the control rod seal can lead to damage of the control rod. Therefore, we recommend that the control rod seal s only replaced n exceptonal cases. ð Only remove the control rod seal f ths s absolutely necessary. (For example f the control rod s leakng and f the leak cannot be corrected by readjustng the control rod. See also Secton ) Fg. 21: Replacng the ball seal and housng seal 7. Push the ball back nto the centre part of the ball valve. The lower dhedron of the control rod must rest n the ball's recess. You may need to rotate the control rod n order to do ths. 8. Close the ball valve by turnng the hand grp n parallel to the drecton of flow. 9. Insert the new ball seal and housng seal Perform the followng workng steps: 1. Carry out steps 1 to 6 n Secton Dependng on the verson, loosen the handle nut (1) and remove the washer (2) and handle (3). 3. Loosen the gland nut (4) 4. Tghten the control rod (7) on the upper flat edge n a bench vce. Rase the centre part to ts fullest extent and screw the control rod out of the housng. 5. Remove the control rod seal (8), the gland (6) and the metal rng (5) from the control rod. 6. Clean the nteror of the centre housng, the spndle and the gland nut usng an alcohol-based solvent and a sutable cloth. Check all parts for damage. Subject to techncal changes Mantenance Mantanng the ball valve 27