Page 1 (6) Our Ref: PSE, Bernt Andersson OPTIPOW 105 OPTIPOW 105, the compact pulse valve for the Optipulse fabric filters of different types: is a result of many years of experiences within the fabric filter technology area, experiences from the former used membrane type of pulse valve and extensive testing in the SEATC laboratories. is an ALSTOM patented product (two patents) is quick acting with high efficiency has small dimensions, allows valve spacing down to 160 mm. is primarily designed to be used in combination with circular pressure tank. is easy to install and make service to has a very robust design, designed for normal use at air pressure up to 600 kpa (6 bar) but static designed for 1500 kpa ( 15 bar) the figure 105 stands for the dimension of the plunge OPTIPOW 105 ; MAIN PARTS Fitting and hoses not included in standard delivery 6 5 2 1 1. Valve house 2. Pilot cover 3. Rubber disc 4. Plunge O-ring 3 5. Pilot membrane 6. Solenoid valve 4
Page 2 (6) OPTIPOW 105 ; MAIN PARTS Design data : Design static pressure 15 bar (1500 kpa) Design temperature 100 C Normal operating pressure < 6 bar Normal operating pressure variation 3 bar unlimited nos Normal operation temperature 50 C Pos 1, valve house, is die-casted in material SS 4250 (equal to DIN 1725 GD-AlSi9Cu3). After machining, the house for maximal wearing resistance and low friction is hard-anodised including a PTFE-treatment. The house is bolted to the pressure tank with four bolts M10. For sealing between pressure tank and ambient there is an O-ring at the outside of the valve house. Pos 2, pilot cover, is die-casted in material SS 4250 (equal to DIN 1725 GD-AlSi9Cu3). The cover is fixed to the house with four bolts M5x30mm. For sealing there is an O-ring between the cover and the pilot membrane. Pos 3, rubber disc, is made from Urethane-rubber and acts as a damper for the forces from the plunge that is transferred into the house but do also reduce the deceleration forces on the plunge. The rubber disc is pressed into the bottom of the valve house. Pos 4, plunge, is injection moulded in glass-fibre reinforced polyamide material PA 6.6, acid resistant and withstanding gas temperatures up to 150 C. The outside diameter as well as the sealing part of the bottom is machined. Pos 5, pilot membrane, is made of rubber from a standard membrane quality. Pos 6, solenoid valve, is a 3-way valve. At non energised valve the pilot air is connected to the volume above membrane (pressurised). At energised valve the volume above membrane is connected to ambient (evacuated) via the slot in the pilot cover. As standard the solenoid valve is delivered for 24 V DC.
Page 3 (6) OPTIPOW 105 ; FUNCTION Volume A is via the slot between the valve house and the plunge connected to the pressure tank i.e. there is same pressure in the volume A as in the pressure tank. Due to the larger pressurised surface of the plunge in volume A the plunge is pressed towards the pulse pipe and sealing between the pressure tank and the pulse pipe. The volume B is via the solenoid valve connected to the pilot air. The area is larger on pilot air side so the pilot membrane is pressed down towards the top of the valve house and seals off the volume A from the ambient. Closed valve Volume B Volume A Tank Opening When cleaning is initiated the solenoid valve closes the connection (a) and opens to ambient (b) which means that volume B is evacuated. The membrane is pressed upward (c) and the volume A is evacuated through the 2 ports at the outer side of the valve house. The plunge is rapidly moving upwards by the pressure difference over the plunge. The compressed air in the pressure tank is released through the pulse pipe as a pulse and further on to a row of filter bags. Closing The solenoid is closed to ambient and opened to the pilot air. Pulse pipe Open valve a b c The pilot membrane is pressed down towards the seat. Via the slot between the plunge and the house the pressure above the plunge will be equalised to the tank pressure and the plunge moves down to the pulse pipe and ends the cleaning pulse. The time for a sequence (start opening to closed valve) is to some extent depending on process requirements but generally it is in the range of 100 200 msec.
Page 4 (6) OPTIPOW 105 ; ASSEMBLAGE INSTRUCTION The assemblage of the complete pulse unit (pressure tank+pulse valves) should normally take place in workshop. Detailed instructions for the manufacture as well as mounting and testing of the unit are given in a separate QUALITY ASSURANCE PRESSURE TANK UNIT FOR FF TYPE LKP distributed 1999-12-21. The OPTIPOW valve is as standard made for vertical installation. When the valve shall operate horizontally an extra internal spring has to be used. By that the plunge will always be in closed position when pressurising the cleaning system. The OPTIPOW is normally delivered as one unit in a special package. For detailed instructions regarding erection of separate parts see OPTIPOW assembly drawing. Unpack the valves at first when mounting them. Check that there are no visible damages on the valve. Check that there are no foreign materials inside of the valve. Check that the top of the pulse pipe is smooth without any deburrs. Position numbers below refers to sketch on page 1. Put the plunge (pos 45) on the top of the pulse pipe. Oil or wet the O-ring on the outer side of the valve house (pos 1) and match the house to the plunge. Turn the house so that the solenoid is pointing in right direction. Screw the four bolts with fingers as long as possible and make then the last setting with tool crosswise to avoid damages to the O-ring. OPTIPOW 105 ; PILOT AIR CONNECTION On-off valve Non-return valve The pilot air for the solenoid is taken from the incoming tube to the pressure tank. The pipe for the pilot air is common for all valves in one tank and is connected upstream the main onoff valve of respective tank. The pipe should have an on-off valve and a non-return valve which ensures that pressure is kept also if pressure decreases during pulsing. Note: If a separate feeding pipe for the pilot air is used the pressure for the pilot air should be approx equal to pressure in tank. A too high pressure will give a remaining deformation to the membrane, which will reduce the lifetime and have a reducing effect on the function of the pulse cleaning.
Page 5 (6) OPTIPOW 105 ; SPECIFICATION AND SPARE PARTS LIST Pulse Valve OPTIPOW 105 Complete unit V1617803-0100 24 V DC (standard) V1617803-0200 110 V 60 Hz V1617803-0300 110 V 50 Hz V1617803-0400 120 V 60 Hz V1617803-0500 220 V 50 Hz Plastic pipe dia 8/6 mm Fittings connection G1/8 Note not included in delivery Bolt M4x70 12.9 Locking washers 4.3x9.0x1.8 Plate V3630524-0100 NOTE: Orientation of washers Solenoid valve V3611471-0100 (24 V DC) Other voltage see above NOTE: Letters A (B) on this side opposite to notch in pilot cover Bolts (4 pcs) M5 x 30 mm Pilot cover V3630501-0100 Pilot membrane V4549902-0100 O-ring Dim 64,5 x 3 mm Valve house V1585320-0100 Bolts (4 pcs) M10 x 30 mm O-ring Dim 114,5 x 3 mm Rubber disc V3630526-0100 Plunge V3630527-0100 For increasing the locking of all bolts use LOCTITE 477 or similar.
Page 6 (6) OPTIPOW 105 ; UP-GRADING Upgrading older versions of the OPTIPOW is possible. Note however that the rubber disc due to different machining of the inside of the valve house has to be slightly different. The thickness of the disc is 8 mm and there are a number of notches made. See sketch. Recommended details for upgrading are : Locking of solenoid valves consisting of 1 pc plate V3630524-0100 2 set Locking washers Nordlock 4,3x9x1,8 2 pcs Bolt hex socket M4x70 12.9 Pilot cover V3630501-0100 Membrane V4549902-0100 Rubber disc V3630530-0100 Most details are stored in a small quantity at SEENS. Notches this side Rubber disc OPTIPOW 105 ; DIMENSION SKETCH Outside dia 153 Outside thread G1/8 (Solenoid) Pitch dia 135 (4 x M10) Approx 140 85 Inner dia connection 120 H9