installation and maintenance manual pneumatic valves type

M/VTOP-P/E

05 2020

Installation and Maintenance Manual

Pneumatic Valves Type 20VT RA-DA / Type 50VT RA-DA

WWW.CONFLOW.IT

Servicing Department

E-mail: [email protected]

VTop Control Valves M/VTOP-P/I ed. 01 2020

WWW.CONFLOW.IT Page 1

Summary

1 – GENERAL SAFETY INFORMATION ....................................................................................................... 2

2 - GENERAL ASSEMBLY INSTRUCTIONS .................................................................................................. 2

2.1 – ASSEMBLY ON THE SYSTEM (GENERAL NOTES) .................................................................................... 2

3 – PNEUMATIC VALVES TYPE 20VT RA-DA /50VT RA-DA ......................................................................... 2

3.1 – COMMISSIONING (GENERAL NOTES) ................................................................................................... 3

3.2 – PNEUMATIC CONTROL VALVES COMMISSIONING ............................................................................... 3

3.2.1 – PNEUMATIC VALVES WITH “DA” MANUAL HANDWHEEL COMMISSIONING ................................ 4

3.2.2 – PNEUMATIC VALVES WITH “RA” MANUAL HANDWHEEL COMMISSIONING ................................ 4

3.2.3 – PNEUMATIC VALVES WITH LUBRICATOR COMMISSIONING ASSEMBLED ON BONNET ................ 4

3.3 – CALIBRATION ........................................................................................................................................ 5

3.3.1 – PNEUMATIC CONTROL VALVES ..................................................................................................... 5

3.3.2 – ON-OFF PNEUMATIC VALVES ........................................................................................................ 6

3.4 – MAINTENANCE ..................................................................................................................................... 7

3.4.1 – BODY GASKET REPLACEMENT ....................................................................................................... 7

3.4.2 – PACKING REPLACEMENT................................................................................................................ 9

3.4.3 – TRIM REPLACEMENT .................................................................................................................... 11

3.4.4 – SOFT SEAL REPLACEMENT - TRIM ................................................................................................ 13

3.4.5. – INVERSE ACTION ............................................................................................................................. 14

4 OPERATING ANOMALIES ............................................................................................................... 15

5 – RISK ANALYSIS ................................................................................................................................ 16

6 – ATEX DIRECTIVE 2014/34/EU .......................................................................................................... 17

6.1 – LABEL DATA REGARDING SAFETY ....................................................................................................... 17

6.2 - ASSEMBLY INSTRUCTIONS - CALIBRATION AND MAINTENANCE ........................................................ 19

6.2.1 – VALVE GROUND ........................................................................................................................... 19

6.3 – Additional RISK ANALYSIS ................................................................................................................... 19

6.4 – HEALTH AND SAFETY .......................................................................................................................... 20

6.5 – PRECAUTIONS FOR USE ...................................................................................................................... 20

7 – LIST OF RECOMMENDED SPARE PARTS ............................................................................................ 20

7.1 – COMPONENTS SUGGESTED FOR COMMISSIONING AND START-UP .................................................. 20

7.2 – COMPONENTS AFTER 2 YEARS OF OPERATION .................................................................................. 20

8 – DECLARATIONS OF CONFORMITY ACCORDING TO DECLARATIONS IN FORCE …………………………… 21-24

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1 – GENERAL SAFETY INFORMATION

ATTENTION THIS PRODUCT WAS DESIGNED FOR USE IN THE MANUFACTURING

INDUSTRY WITHOUT MILITARY PURPOSE. IT IS STRICTLY FORBIDDEN TO USE CONFLOW PRODUCTS FOR THE PRODUCTION OF WEAPONS OF MASS DESTRUCTION. OTHER USES MUST BE APPROVED IN ADVANCE BY THE MANUFACTURER.

CONFORMITY REQUIREMENTS

THE IMPORT-EXPORT OF CONFLOW PRODUCTS FROM ONE COUNTRY TO ANOTHER IS REGULATED BY SAFETY AND TRADE LEGISLATION IN THESE COUNTRIES. BEFORE SENDING THE PRODUCT TO A THIRD COUNTRY, CHECK THE PRODUCT DOES NOT CONFLICT WITH THE REGULATIONS OF THAT COUNTRY.

Before installing the valve, remove the plastic guards covering the flanges and the connection couplings.

ATTENTION During commissioning of the valve or during operation, do not touch the body which could

conduct heat if the fluid used is at high temperature.

ATTENTION During operation, do not touch the stem as it is in movement, it may be hot and could catch

your finger or clothing.

ATTENTION Before starting any maintenance operations, ensure the valve is not pressurised and/or hot.

ATTENTION Do not remove the descriptive label fastened to the yoke since it reports the serial number,

data which is indispensable for tracking the valve over time.

Please refer to this number for supply of spare parts Do not remove the stroke label which is the main reference for valve calibration

Non-compliance with the main safety information, the standards in force and the assembly instructions can:

Cause danger for the safety of those carrying out manoeuvres or for third parties.

Damage the valve or adjacent objects.

Compromise the efficient operation of the valve.

2 - GENERAL ASSEMBLY INSTRUCTIONS

2.1 – ASSEMBLY ON THE SYSTEM (GENERAL NOTES)

Before assembling the valve, accurately clean the tubing with compressed air, water or another blowing fluid to eliminate foreign bodies, welding waste and various dirt that could damage the sealing surfaces of the valve.

ATTENTION Assemble the valve with the direction arrow imprinted on the body in the same direction

as the tubing fluid.

Assembly is however recommended of a “Y” filter (our “FY” series) on the tubing, upstream of the valve. Assembly of the valve can be carried out in the vertical or horizontal position. You are however advised to assemble vertically to prevent wear of the trim due to the weight and relevant rubbing. For safety reasons, vertical upside down assembly is not recommended.

ATTENTION It is forbidden to weigh the valve down with foreign objects. It is compulsory to protect the

valve from external stress.

3 – PNEUMATIC VALVES TYPE 20VT RA-DA /50VT RA-DA

If the valve is fitted with a reducer filter, it is preferred that it is assembled vertically to promote condensate drainage using the specific deaerator.

ATTENTION If the valve is fitted with instrumentation (pilot positioner, etc.) pay particular attention to assembly of the piping since each strike could cause damage to the accessories or they could lose calibration.

ATTENTION If the valve is fitted with a case handwheel for emergency manual control, ensure that during

automatic operation it is in the complete standby position, to avoid mechanically obstructing the stroke of

the valve that could be limited.

The Actuator is connected to the air source using a 4x6 mm diameter pipe. This diameter can be increased the more the distance between the air source and the valve. The pneumatic connections are Ø 1/8” GAS F




DA input = upper part of case RA input = lower part of case

Ambient temperature - 20 °C / + 70 °C std diaphragm EPDM

If you have ordered the product with “Low temperature” execution, you can install it with the following

temperature limits - 50 °C / + 80 °C diaphragm VMQ60

If the upper coupling has a vent, protect it with a specific joint or with a curved pipe, to avoid releasing liquids and/or atmospheric agents in the case.

3.1 – COMMISSIONING (GENERAL NOTES)

The valves are supplied calibrated and tested, ready to work in the conditions requested by the client during the order phase. Having ensured all warnings have been respected, slowly open the shut-off valves upstream and downstream of the valve.

THE PACKING IS MAINTENANCE-FREE.

ATTENTION After the first working hour, check tightening of the nuts on the body unit according to the

“Nut tightening forces” table

ATTENTION Comply with the values in the “Nut tightening forces” table each time maintenance

operations are carried out.

ATTENTION If the valve is equipped with a BELLOWS seal, never rotate the stem for any reason.

A possible wrong manoeuvre could cause torsion and breakage of the bellows.

3.2 – PNEUMATIC CONTROL VALVES COMMISSIONING The standard control air pressures are: 3-15 psi 6-18 psi 6-30 psi

The maximum pressure on the diaphragm of the Actuator must never exceed the value 35 psi - 2,5 bar The same should be used for valves with ON-OFF service The air used must be strictly dry, without oil or condensate that could damage the Actuator diaphragm or the accessories possibly assembled on the valve. NUT TIGHTENING FORCES table

ATTENTION Always comply with the tightening valves on each maintenance

DN NUT DESIGNATION KEY SIZE Nm

15-20 M8 No. 4 13 15-20

25 – 32 M8 No. 6 13 15-20

40 – 50 M12 No. 6 19 25-30

65-80 M16 No. 6 24 55-60

100 M16 No. 8 24 70-80

125 M16 No. 10 24 Spiral wound 60-65

PTFE 65-70

150 M20 No. 10 30 Spiral wound 60-70

PTFE 70-75

200 M20 No. 12 30 Spiral wound 60-70

PTFE 70-75




3.2.1 – PNEUMATIC VALVES WITH “DA” MANUAL HANDWHEEL COMMISSIONING

Ensure the handwheel ref. 1 in the standby position (automatic operation) is fully up. By default, nut ref.5 is blocked in this position. To manually activate the valve, ensure there is no air in the Actuator, then unscrew the safety nut ref..5, bringing it upwards and rotate the handwheel.1. By doing so, the handwheel acts as a piston and closes the valve.

3.2.2 – PNEUMATIC VALVES WITH “RA” MANUAL HANDWHEEL COMMISSIONING

Ensure the handwheel ref. 1 in the standby position (automatic operation) is fully screwed down. The stem ref.2 during automatic operation goes up and down. To manually activate the valve, ensure there is no air in the Actuator, then rotate the handwheel ref.1 anti-clockwise. The handwheel acts as an extractor and raises the stem, opening the valve.

3.2.3 – PNEUMATIC VALVES WITH LUBRICATOR COMMISSIONING ASSEMBLED ON BONNET

During automatic operation, the lubricator must remain closed, turn the handwheel clockwise ref. 7 To grease the packing, proceed as follows: Close the main plug with the handwheel ref. 7 Unscrew the handwheel of the loader ref. 5, load with grease, screw back in the handwheel ref. 5 only by a few rotations. Open the main plug using the handwheel ref. 7, screw in the handwheel ref. 5 after loading the grease inside the packing and close the main packing again using the handwheel ref. 7. The greasing operation is recommended every 600 working hours or when the stem moves in a linear manner. You are advised to use anti-seize, molybdenum disulfide grease for temperatures > 200 °C

OPENS CLOSES

OPENS CLOSES




3.3 – CALIBRATION

The valves are supplied calibrated and tested, ready to work in the conditions requested by the client during the order phase.

3.3.1 – PNEUMATIC CONTROL VALVES If the adjustment valve must be calibrated again, the following tools will be necessary: - a Bourdon spring gauge with scale 0-40 psi - a pressure reducer filter or an air manipulator which can be finely adjusted in the range 0-35 psi Having applied the reducer filter to the compressed air line, connect its output to the gauge and then the Actuator to the valve to calibrate. Check the calibration valve of the springs indicated on the descriptive label affixed to the yoke, “signal” field. For DIRECT ACTING valves (DA=air closes), Figure of example “20VT DA” slowly adjust the reducer by registering it

at the start value of the valve. For example, if the signal planned is 3-15 psi, the valve must start to move at 3 psi and at 15 psi it must have executed the entire stroke, reaching the compartment in the closure position. If the start signal is under 3 psi, you must: Loosen the nuts ref. 17 tightening the union block ref. 18 to the lower stem ref. 7, also loosen nut ref. 19 locking the diaphragm plate stem ref.20 screw in the union block ref. 18 to increase the start signal. If the start signal is over 3 psi, you must: Loosen the nuts ref. 17 tightening the union block ref. 18 to the lower stem ref. 7, also loosen nut ref. 19 locking the diaphragm plate stem ref.20 unscrew in the union block ref. 18 to reduce the start signal.

“20VT DA”

Attention! During the calibration phase, ensure the valve

executes the full stroke. This operation can be visually inspected by observing the indicator plate formed by the union block ref.18 sliding on the indicator label of the stroke ref.22. Repeat the opening/closure or closure/opening operation until the right values are obtained.




For REVERSE ACTING valves (RA=air opens), Figure of example “20VT RA” do as above.

For example, if the signal planned is 3-15 psi, the valve must start to move at 3 psi and at 15 psi it must have executed the entire stroke, reaching total opening. If the start signal is under 3 psi, you must: Loosen the nuts ref. 17 tightening the union block ref. 18 to the lower stem ref. 7, also loosen nut ref. 19 locking the diaphragm plate stem ref.20 unscrew in the union block ref. 18 to increase the start signal. If the start signal is over 3 psi, you must: Loosen the nuts ref. 17 tightening the union block ref. 18 to the lower stem ref. 7, also loosen nut ref. 19 locking the diaphragm plate stem ref.20 screw in the union block ref. 18 to decrease the start signal.

“20VT RA”

Attention! During the calibration phase, ensure the valve

executes the full stroke. This operation can be visually inspected by observing the indicator plate formed by the union block ref.18 sliding on the indicator label of the stroke ref.22. Repeat the opening/closure or closure/opening operation until the right values are obtained.

3.3.2 – ON-OFF PNEUMATIC VALVES On-off pneumatic valves are supplied already calibrated according to the control signal, chosen by the client, and based on the input pressure of the fluid. On-off valves do not require any calibration control operations.




3.4 – MAINTENANCE

3.4.1 – BODY GASKET REPLACEMENT

ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL, CONSIDERING THE COMPLEXITY OF THE

OPERATIONS FOR BODY GASKET/S REPLACEMENT, YOU ARE ADVISED TO CONTACT OUR SUPPORT SERVICE.

For DIRECT ACTING valves (DA= air closes), Fig. “20VT DA” – “50VT DA” , proceed as follows:

unscrew the locking nuts ref. 12 that tighten the bonnet ref. 9 for version 50VT unscrew the lower nuts also ref. 12 that tighten the lower flange ref. no. 1, at the same time remove the overall Actuator with the bonnet and trim connected, remove the old gasket ref. 8 and clean the compartment carefully, replace the gasket/s ref. 9, then proceed to assembly by carrying out the previous operations in the reverse order.

“20VT DA”

“50VT DA”




ATTENTION BEFORE CARRYING OUT ANY MAINTENANCE OPERATION, SUPPLY AIR TO THE ACTUATOR

(1 bar ) TO COMPRESS THE SPRINGS. FROM NOW ON (always keeping air in the Actuator) YOU CAN EXTRACT

THE YOKE-ACTUATOR AND EACH COMPONENT CONNECTED WITHOUT THE POSSIBILITY THE SPRINGS REMAIN

WITHOUT COMPRESSION. For REVERSE ACTING valves (RA= air opens), Fig. 20VTRA – 50VTRA, to replace the gasket of the body, proceed as above, taking care however to unscrew the locking nuts ref. 12, to supply air, at pressure that allows the valve to execute a few millimetres of stroke, to distance the plug from its compartment.

“20VT RA”

“50VT RA”




3.4.2 – PACKING REPLACEMENT

ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL, CONSIDERING THE COMPLEXITY OF THE OPERATIONS FOR

PACKING AND BELLOWS REPLACEMENT, YOU ARE ADVISED TO CONTACT OUR SUPPORT SERVICE.

The operation to replace the packing involves dismantling the lock on the bonnet + trim + Actuator.


unscrew the locking nuts ref. 12 that tighten the bonnet ref. 9, at the same time remove the overall Actuator with the bonnet and trim connected and then proceed as follows: unscrew the nuts ref. 17, unscrew and remove the entire stem ref. 7, unscrew the packing bush ref. 16,with a hooked iron tool gently extract the packing rings ref. 15, the packing washer ref. 13, the packing spring ref. 14 , blow and clean the packing chamber found on the bonnet ref. 9. When the packing is changed, the body gasket must also be changed, see 3.4.1 Then proceed to assemble the new packing following the previous operations in the reverse order, see Fig. “PACKING”.

“20VT DA”

“50VT DA”

Fig. “PACKING”




For REVERSE ACTING valves (RA= air opens), Fig. 20VT – 50VTRA, proceed as above, taking care however to unscrew the locking nuts ref. 12, to supply air, at pressure that allows the valve to execute a few millimetres of stroke, to distance the plug from its compartment.

When the packing is changed, the body gasket must also be changed, see 3.4.1 “20VT RA”

“50VT RA”

Fig. “PACKING”




3.4.3 – TRIM REPLACEMENT

ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL, CONSIDERING THE COMPLEXITY OF THE OPERATIONS FOR

TRIM REPLACEMENT, YOU ARE ADVISED TO CONTACT OUR SUPPORT SERVICE.

VTop valves were designed with a “QUICK CHANGE TRIM” – “EASILY REPLACED INTERIOR”, the compartment is not screwed to the body, but rests with a seal gasket and pressed by the cage system, see Figures “TRIM DN15-50” – “TRIM DN65-200”.


tighten the locking nuts ref. 12 tightening the bonnet ref. 9 simultaneously remove the overall Actuator with the bonnet and trim connected, then proceed as follows, extract in sequence: the cage ref. 4, the compartment ref. 2 with gasket ref. 3 fitted. As for the first operation, clean the compartment and replace the compartment with the new gasket. Unscrew the nuts ref. 17, unscrew and remove the entire stem ref. 7 combined with the plug ref. 5, replace the trim with the complete spare part – profile ref. 5 + stem ref. 7 connected to the pin ref. 6. For the DN65-200 valves, the piston ref. 5 with all its compartments is always firmly on the stem ref. 7 In this case, it will be forced/precise inside the cage to guarantee sealing of the rings EK3245.

When the trim is changed, the body gasket must also be changed, see 3.4.1

“20VT DA”

“50VT DA”

Fig. “TRIM DN15-50”





For REVERSE ACTING valves (RA= air opens), Fig. 20VT – 50VTRA, proceed as above, taking care however to unscrew the locking nuts ref. 12, to supply air, at pressure that allows the valve to execute a few millimetres of stroke, to distance the plug from its compartment.

When the packing is changed, the body gasket must also be changed, see 3.4.1

“20VT RA”

“50VT RA”






3.4.4 – SOFT SEAL REPLACEMENT - TRIM

ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL, CONSIDERING THE COMPLEXITY OF THE OPERATIONS FOR SOFT

SEAL REPLACEMENT, YOU ARE ADVISED TO CONTACT OUR SUPPORT SERVICE.

ATTENTION TO OPEN THE VALVE, PROCEED AS DESCRIBED IN POINT 3.4.1

For the DN 15-50 valves Fig. “SOFT TRIM DN15-50”, proceed as follows:

unscrew the locking nuts ref. 5f – remove the washer ref. 5e – remove the profile 5d – remove the seal ring 5c. Carefully clean the compartments and proceed to replace the ring 5c, then tighten the nuts according to the table indicated in the figure. For the DN 65-50 valves Fig. “SOFT TRIM DN65-200”, For the DN65-200 valves, it is forced/precise inside the cage to guarantee sealing of the rings EK3245, pay attention during removal

unscrew the locking nuts ref.5k – dismantle the bottom ref. no.5j – remove the seal ring 5i Carefully clean the compartments and proceed to replace the ring 5i, then tighten the screws according to the table indicated in the figure. When the soft seal is changed, the body gasket must also be changed, see 3.4.1

Fig. SOFT TRIM DN15-50 Fig. SOFT TRIM DN65-200

SEAL TIGHTENING FORCES TABLE

DN 15-20 DN 25-32 DN 40-50 DN 65-100 DN 125-200

6/7 Nm 8/9 Nm 9/10 Nm 8/9 Nm each screw 9/10 Nm each screw




3.4.5. – INVERSE ACTION

The inverse action operation can be carried out with the valve assembled on the piping.

Ref. Fig. “ACTION” proceed as follows: - Invert the parts as displayed in the drawing - The tightening force of the screw ref.29 must be 20Nm.

ATTENTION check the signal function if the springs are compatible, e.g. you want

to pass from a RA version 6-18 psi to a DA version 3-15 psi, contact our After-Sales Service to check the spring type.

Fig. “ACTION”

DA VERSION RA VERSION




4 OPERATING ANOMALIES

Some problems are outlined below which can occur during operation of the valves and the measures to implement.

PROBLEMS FOUND CAUSE MEASURE

The stem does not run the entire stroke and/or stroke incomplete

1. Air leak in connection pipe between the case and the control tool and/or the air source

1. Localise and eliminate the leak

2. Air leak from actuator perimeter 2. Tighten the perimeter nuts of the actuator

3. Air leaking from actuator - broken diaphragm

3. Replace the diaphragm

4. Waste deposits between compartment and plug

4. If seizure not generated, remove deposits

5. Indicator label movement compared to index

5. Reposition the stroke reference based on index

6. The instrumentation does not supply the correct signal and is necessary to execute stroke

6. Search the causes on the instrumentation

7. The positioning unit on the valve needs re-calibration

7. Proceed to “setting” the positioner in compliance with the relevant manual

The stem moves in jolts 1. Stem seized and/or damaged 1. If possible, polish the stem, otherwise replace the “trim”

2. Sediment in packing chamber 2. Replace the bonnet with packing

Heavy seal compartment/plug leak

1. Soft seal class VI damaged 1. Replace the soft seal class VI

2. Metal seal class IV or V damaged 2. If possible, grind the cone of the plug with the edge of the compartment with “grinding paste” Otherwise, replace the trim

3. Differential pressure between upstream and downstream of the valve too high

3. Contact our Servicing to ask for a quote for replacement, if possible, of the actuator

Packing leak 1. Worn rings or seals 1. Replace the bonnet with packing

2. Soft seal broken 2. Given the complexity of the operation, contact our Servicing




5 – RISK ANALYSIS

This document assesses the risks relating to the equipment indicated above, which can arise during its use, installation or movement, in compliance with the provisions of the Directive PED 2014/68/EU. The provisions are also indicated to comply with to avoid them arising. The classification of the SOLUTIONS implemented is as follows: 1. Solution to eliminate and/or reduce the risk. 2. Application of the appropriate safety measures against the risks which cannot be eliminated 3. Information for users

CAUSE EXCESS PRESSURE OVER THE MAXIMUM PERMITTED PRESSURE “PN”

EFFECT Broken body, cracks, permanent deformations

DANGER Projection of metal parts, leaking fluid

SOLUTION 1. The body unit is constructed with due safety margins. 2. The system must be fitted with the “Safety Accessories” planned by the Decrees in place

in the country of origin. 3. The label outlines the maximum permitted pressure “PN”

CAUSE EXCESS PRESSURE OVER THE MAXIMUM PERMITTED TEMPERATURE “TS”

EFFECT Internal excess pressure

DANGER Breakage or deformation of the body, leaking fluid

SOLUTION 1. The body unit is constructed with due safety margins. 2. The system must be fitted with the “Safety Accessories” planned by the Decrees in place

in the country of origin. 3. The maximum temperature is declared on our “data sheet” specifications and must be

checked by whoever sizes and/or chooses the valve

CAUSE REACTION FORCE TO EXTERNAL STRESS

EFFECT Deformation, structural failure

DANGER Breakage or deformation of the body, leaking fluid

SOLUTION 1. Check there are not external loads, it is compulsory for the installation technician to protect the valve from external stress.

2. This manual, in section 2 point 2.1 describes the indications in point 1 and 2. 3. The installation technician must check the valve is free of hazards due to external reaction

forces and/or stress.

CAUSE WORKING TEMPERATURES

EFFECT Metal parts at high temperature

DANGER Burns

SOLUTION 1. Install the valve in a protected area or insulate the valve. 2. The user must signal the hazard using suitable signs indicating the parts can reach high

and dangerous temperatures. It is indicated in section 1 of the manual. “General safety information”

3. Wear adequate personal protection

CAUSE INSTALLATION AND/OR USE NON-COMPLIANT WITH THE PROVISIONS, THE DIRECTIVES IN FORCE AND NATIONAL LEGISLATION

EFFECT Inappropriate installation, breakage of the valve

DANGER Poor system operation, leaking fluids

SOLUTION 1. The installation technician and/or user must install the valve in compliance with the Directives in force and national legislation

2. Not applied 3. In this manual, it is described in point 1. “General safety information”




CAUSE VALVE MAINTENANCE WITH SYSTEM PRESSURISED

EFFECT Incorrect maintenance

DANGER Poor operation of the system, danger of projection of pressurised parts, danger of leaking fluids

SOLUTION 1. Maintenance activities must be carried out with the valve shut off. 2. The valve must be free of hydrostatic pressure. 3. The valve must be shut off as described in this manual in point 1. “General safety

information”

CAUSE EXTERNAL ENVIRONMENT, ADDITIONAL LOADS (Wind and Earthquake not applicable)

EFFECT Deformation, structural failure

DANGER Breakage and/or deformation of the body, leaking fluid

SOLUTION 1. Support all the connection tubing that weighs on the valve with specific structures and/or supports.

2. The valves do not allow external loads 3. The support structures and the relevant anchorage and/or foundation tie rods must be

calculated in advance.

6 – ATEX DIRECTIVE 2014/34/EU

The ATEX 2014/34/EU certified valves are intended for use in AREAS WITH PRESENCE OF POTENTIALLY EXPLOSIVE ATMOSPHERES!

ATTENTION The materials not yet used on the system must be stored in areas that maintain all the technical characteristics intact of the equipment and compliance, up to installation, therefore they must be kept in places that are protected, clean and dry. All plugs used to cover the fluid inlets and the air connections should be kept and maintained intact up to installation.

6.1 – LABEL DATA REGARDING SAFETY

The additional ATEX label outlines the following data:

II 2 GD = equipment for surface systems in the presence of: Gas, vapour or mist CAT. 2, suitable for zone 1 and 2 dust CAT. 2, suitable for zone 21 and 22

Exh IIB T6…T1 Gb (GAS group IIB) Exh IIIC T6…T1 Db (DUST group IIIC )

STAINLESS STEEL LABEL

-20°C ≤ Ta ≤ +70°C -50°C ≤ Ta ≤ +80°C

Standard Diaphragm Low Temperature Diaphragm

T6 T5 T4 T3 T2 T1

85 °C 100 °C 135 °C 200 °C 300 °C 450 °C

ATTENTION The temperature does not depend on the equipment, but mainly on the operating conditions, therefore the marking relates to the maximum operating temperatures of the body unit of the valve or the maximum design temperature of the valve body. THE USER MUST COMPARE THE TEMPERATURE OF THE ATEX ZONE WITH THE TEMPERATURE CORRESPONDING TO THE HEAT TRANSFER FLUID USED.




ATTENTION Ensure the valve was chosen with the seals for the fluid contained in the body unit

(TYPE OF PACKING-SEAL) and also check the unit for substances in the air, the relevant ignition temperature and compare with the temperature class of the equipment. The ignition temperature of the gaseous mix must always be higher than the maximum surface temperature. Basically, a safety margin is considered of 15/20% between the ignition temperature and the marking temperature. For a cloud of dust, you must know the composition and determine the ignition point, taking into consideration that a layer can cause an explosion of the cloud above. Therefore, for preventive purposes, determine the exact composition and the possible layer that could form on the equipment.

The VTop Series Valves – “Non-Electrical Equipment” are constructed with non-electrical type protection for constructional safety “c” – EN 80079-37

TYPE OF PACKING - SEAL

PACKING SEAL - MAINTENANCE-FREE - LOCKED PACKING ADJUSTMENT

BELLOWS SEAL MAINTENANCE-FREE

Valid for Heat Transfer fluids: STEAM – OVERHEATED STEAM - WATER – HOT WATER – OVERHEATED WATER COMPRESSED AIR AND INERT GASES

Valid for: DIATHERMIC OIL HAZARDOUS LIQUIDS GAS GROUP II ( IIA – IIB)

ATTENTION It is the installation technician and/or user’s task to take all the measurements necessary to insulate the body unit and the bonnet that conduct heat and that determine the maximum surface temperature.

To determine the type of dust, the maximum surface temperature must be known and compatible. To prevent ignition of dusty atmospheres, limit the maximum surface temperature. This must be under the lowest of these two values:

- 2/3 of the auto-ignition temperature of the cloud of dust considered. - at the auto-ignition temperature of a layer of dust 5mm thick, reduced by 75 °C.

Also, for dust regarding the stem exiting the valve body, ensure you have correct blowing or periodic cleaning, SINCE THE PART CANNOT BE INSULATED.

ATTENTION The user is responsible for checking the packing seal. When the BELLOWS SEAL is used for GAS GROUP II, as soon as its breakage is determined, the packing will only work as an emergency seal for a few hours, THEREFORE SECTION AND REPLACE THE VALVE.

ATTENTION The ambient temperature (specified on the label) in which the pneumatic actuator of the valve can work is between:

- 20 °C / + 70 °C std diaphragm EPDM

- 50 °C / + 80 °C std diaphragm VMQ60

Obviously, the maximum surface temperature is the ambient temperature




ATTENTION DO NOT OPEN THE EQUIPMENT IN AN EXPLOSIVE ATMOSPHERE.

BEFORE OPENING, ENSURE THE EQUIPMENT FLUID INSIDE IS NOT PRESSURISED AND THAT IT HAS APPROPRIATELY COOLED. Carry out every maintenance operation, according to the manual, in total safety!

6.2 - ASSEMBLY INSTRUCTIONS - CALIBRATION AND MAINTENANCE

For assembly, see section 2 For calibration see section 3 - point 3.4 For maintenance see section 3 - point 3.4

6.2.1 – VALVE GROUND Connect the ground as indicated in the figure. The same valve should be grounded on the system.

6.3 – Additional RISK ANALYSIS

This document assesses the risks relating to the equipment indicated above, which can arise during its use, installation or movement, in compliance with the provisions of the Directive ATEX 2014/34/EU. The provisions are also indicated to comply with to avoid them arising. The classification of the SOLUTIONS implemented is as follows: 1. Solution to eliminate and/or reduce the risk. 2. Application of the appropriate safety measures against the risks which cannot be eliminated 3. Information for users

CAUSE HIGH SURFACE WORKING TEMPERATURE IN ACCORDANCE WITH SUFFIX “T” T6…T1

EFFECT

Metal parts at high temperature, Danger of Explosion

DANGER The surface temperature of the body unit can reach (not considering heat dissipation caused by the body) high values that may not be compatible with the fluid in the source body.

SOLUTION Check the ignition temperature of GASEOUS and/or DUST mixes and compare them with the maximum surface temperature of the valve.

Insulate the body unit, BODY AND BONNET, using suitable and appropriately

thick material to reduce the surface temperature and set it at a limit 20% under the ignition temperature of the GASEOUS and/or DUST mix formed in the environment. For dust, reduce the surface temperature by 2/3 of the auto-ignition temperature of the cloud or reduce the surface temperature by 75°C of the auto-ignition temperature of a 5 mm layer of dust. Ensure adequate personal protection

Terminal 1

Terminal 2




6.4 – HEALTH AND SAFETY

ATTENTION Comply with all the health and safety standards planned for the site (classified area) where the equipment is installed in strict compliance with the employer's risk analysis.

ATTENTION Wear the planned personal protective equipment.

ATTENTION Do not remove or carry out maintenance on the valve, without having firstly completely depressurised it and, where necessary, cleaned the residue of any toxic, explosive or flammable substances away.

ATTENTION Do not handle valves that were used in the presence of harmful substances, unless they

were completely decontaminated and certified as safe for handling

ATTENTION Ensure that potentially flammable dust is reduced to a minimum through accurate and

frequent cleaning and/or using suitable guards.

ATTENTION Never use a valve for conditions that exceed the working conditions. Contact our technical

office for further information. Never change or alter the valves without

6.5 – PRECAUTIONS FOR USE

To guarantee full compliance with the requirements of the ATEX Directive 2014/34/EU, fluids compatible with the external environment must be used as heat transfer fluids.

7 – LIST OF RECOMMENDED SPARE PARTS

7.1 – COMPONENTS SUGGESTED FOR COMMISSIONING AND START-UP

- BODY UNIT GASKETS SET composed of : No. 1 compartment gasket No.2 body gaskets (no. 1 Type 20VT – no. 2 Type 50VT ) No.1 packing package

- PNEUMATIC ACTUATOR GASKETS SET composed of : NO.1 diaphragm No. 1 yoke gasket No. 1 upper air tight ring No. 1 “O” ring

- PLUG SEAL CLASS VI SET composed of: No. 1 soft seal ring

7.2 – COMPONENTS AFTER 2 YEARS OF OPERATION

- COMPLETE TRIM composed of: No. 1 compartment No. 1 trim-plug with stem with any seals No. 1 complete body gaskets set No. 1 packing package No. 1 pneumatic actuator gaskets set


8 - DICHIARAZIONI di CONFORMITA’ 4/3 DN15-25 SERIE VTop – Declaration of Conformity 4/3 DN 15-25 VTop Series / Ed. 11 2019

A. Descrizione / Description: Valvola Serie VTop - Valves VTop Series

Numeri di matricola / Serial Numbers: vari – various

Riportato/i sulla targhetta identificatrice / marked on identification plate

Materiali Materials Temperatura Progetto °C Design Temperature °C

EN-GJ-L250 – 5 + 200

GP240GH+N – 20 + 400

ASTM A216 M16 WCB – 20 + 425

ASTM A351M-16 CF8M – 196 + 425

B. Tabella 6 – Tubazioni di cui all’art. 4, paragrafo 1, lettera c) punto i) primo trattino – GRUPPO 1 Table 6 - Piping reffered to in Article 4 (1) (c) (i), first indent – GROUP OF FLUID 1

PN 16 PN 40 ANSI 150 – PN 20 ANSI 300 – PN 50

DN 15 – 25

4/3

C. Procedure di valutazione di conformità utilizzata - Conformity Assessment procedures followed :

Buona Prassi di Ingegneria

SEP

CERTIFICATO DI CONFORMITA’. I prodotti sono stati verificati e ispezionati rispetto al nostro Sistema Controllo Qualita' UNI

EN ISO 9001. Noi certifichiamo che questo prodotto corrisponde alla Vostra richiesta e che le sue caratteristiche sono in

conformita' con le nostre specifiche tecniche.

CERTIFICATE OF CONFORMITY This product has been manufactured, tested and inspected in accordance with our Quality Assurance System UNI EN ISO 9001. We certify that it contents correspond to the order placed and its performance is in conformance with our technical specifications.

Data di Rilascio / Date of Issue

06/12/2019

DICHIARAZIONE DI CONFORMITA’

AI SENSI DELL’ALLEGATO IV DIRETTIVA EUROPEA “PED” N° 2014/68/UE

Declaration of conformity according to PED DIRECTIVE N° 2014/68/UE annex IV

Via Lecco 69/71 20864 AGRATE BRIANZA (MB) - ITALY

8 - DICHIARAZIONI di CONFORMITA’ B+C2 DN32-200 SERIE VTop – Declaration of Conformity B+C2 DN 32-200 VTop Series / Ed. 11 2019

A. Descrizione / Description: Valvola Serie VTop - Valves VTop Series

Numeri di matricola / Serial Numbers: vari – various

Riportato/i sulla targhetta identificatrice / marked on identification plate

Materiali Materials Temperatura Progetto °C Design Temperature °C

EN-GJ-L250 – 5 + 200

GP240GH+N – 20 + 400

ASTM A216 M16 WCB – 20 + 425

ASTM A351M-16 CF8M – 196 + 425

B. Tabella 6 – Tubazioni di cui all’art. 4, paragrafo 1, lettera c) punto i) primo trattino – GRUPPO 1 Table 6 - Piping reffered to in Article 4 (1) (c) (i), first indent – GROUP OF FLUID 1

PN 16 PN 40 ANSI 150 – PN 20 ANSI 300 – PN 50

DN 32 – 50 CAT.I°

DN 32 – 200 CAT. II°

DN 32 – 50 CAT. I°

DN 32 – 100 CAT. II°

DN 65 – 200 CAT. II°

DN 125 – 200 CAT. III°

DN 65 – 150 CAT. II° DN 125 – 200

CAT. III° DN 200 CAT. III°

C. Conformity Assessment procedures followed - Procedure di valutazione di conformità utilizzata :

Modulo B+C2 - MODULE B +C2

Modulo B : Esame UE del Tipo di Produzione - Module B: EU-Production Type

N° TE-A-B-PZ-202/19 Rev. 0 of 09/12/2019 Modulo C2 : Conformità al tipo basata sul controllo interno della produzione unito a prove delle

attrezzature a pressione sotto controllo ufficiale effettuate a intervalli casuali – by TECNO Module C2 : Conformity to type based on internal production control plus supervised pressure equipment checks at random intervals – by TECNO

TECNO Srl – Via A. Colla 7/2, 17014 CAIRO MONTENOTTE (SV) - ITALY

Organismo Notificato con N° 1214 - Notify Body N° 1214

CERTIFICATO DI CONFORMITA’. I prodotti sono stati verificati e ispezionati rispetto al nostro Sistema Controllo Qualita' UNI

EN ISO 9001. Noi certifichiamo che questo prodotto corrisponde alla Vostra richiesta e che le sue caratteristiche sono in

conformita' con le nostre specifiche tecniche.

CERTIFICATE OF CONFORMITY This product has been manufactured, tested and inspected in accordance with our Quality Assurance System UNI EN ISO 9001. We certify that it contents correspond to the order placed and its performance is in conformance with our technical specifications.

Data di Rilascio / Date of Issue

06/12/2019

DICHIARAZIONE DI CONFORMITA’

AI SENSI DELL’ALLEGATO IV DIRETTIVA EUROPEA “PED” N° 2014/68/UE

Declaration of conformity according to PED DIRECTIVE N° 2014/68/UE annex IV


8 - DICHIARAZIONI di CONFORMITA’ ACCESSORI SERIE VTop – Declaration of Conformity Accessories VTop Series / Ed. 11 2019

Gli eventuali accessori montati a bordo valvola sono conformi alle seguenti Direttive: Eventually accessories on valve board are conformed to following Directives:

Posizionatore elettropneumatico Serie EPL analogico – Serie SS2/SS3 SMART 2014/30/UE Electropneumatic Pilot Positioner Series EPL analogic – SS2/SS3 SMART

Filtro riduttore Tipo AFR35 –2014/68/UE Air filter regulator Type AFR 35 -

Box fine corsa per attuatori lineari Tipo LSB1000 2014/30/UE - 2014/35/UE Position monitoring linear switches Type LSB1000.

Box fine corsa per attuatori lineari Tipo LSB3000 2014/30/UE Position monitoring linear switches Type LSB3000

Sensore induttivo Tipo FCE/I2 – FCE/I4 Inductive proximity switches Type FCE/I2 – FCE/I4 2014/30/UE, DIN EN 50032 IP 68 IEC 68-2-14, approvato “US SAFETY SYSTEM” (UL)

Elettrovalvole Tipo EV3 24V CC - 24V – 110V – 220V 50/60 Hz 2014/30/UE Solenoid valves Type EV3 24V CC – 24V – 110V – 220V 50/60 Hz

Nei manuali di ogni singolo accessorio è presente la Dichiarazione di Conformità corrispondente The corresponding Declaration of Conformity is included in the manuals of each individual accessory Tutti gli accessori conformi alla Direttiva ATEX 2014/34/UE sono oggetto di certificato di conformità a parte The conformity certification of all accessories conformed to ATEX 2014/34/UE Directive are supplied separately

Date of Issue / Data di rilascio

06/12/2019


8 - DICHIARAZIONI di CONFORMITA’ ATEX SERIE VTop – Declaration of Conformity ATEX VTop Series / Ed. 12 2019

A. Descrizione / Description : Valvole Pneumatiche Serie VTop Tipo : Pneumatic Valves VTop seriesType :

TIPO-TYPE 20VT RA-DA

DN 15 - 100 TIPO-TYPE 50VT RA-DA

DN 15 - 200 Numero/i di matricola / Serial number/s : Vari - Various riportato/i sulla targhetta identificatrice / marked on identification plate

B. CLASSIFICAZIONE secondo Allegato I : Gruppo 2 Categoria II 2 GD

CLASSIFICATION according ANNEX I : Group 2 Category II 2 GD

MARCATURA / MARKED : II 2 GD Exh IIB T6….T1 Gb Exh IIIC T6….T1 Db

T = T6 T5 T4 T3 T2 T1

85 °C 100 °C 135 °C 200 °C 300 °C 450 °C TEMPERATURA AMBIENTE ATTUATORE AMBIENT ACTUATOR TEMPERATURE

Membrana EPDM - EPDM Diaphragm Membrana VMQ60 - VMQ60 Diaphragm

-20 °C ≤ Ta ≤ + 70 °C -50 °C ≤ Ta ≤ + 80 °C

C. Procedure di valutazione di conformità utilizzata : Capo 1, Articolo 13, lettera b), lettera ii) ALLEGATO VIII – Modulo A Conformity Assessment procedures followed : Chapter 1, Article 13, section b), section ii) ANNEX VIII – Modul A

D. Riferimenti a norme armonizzate applicate alla Serie : EN 80079-36 / EN 80079-37 References to harmonized standards applied to the Series : EN 80079-36 / EN 80079-37

E. Nome e Numero dell’ente che detiene il fascicolo tecnico N° VTOP/ATEX/ REV.00: Name and Number of Notified Body where is manteined the technical documentation N°VTOP/ATEX/ REV.00 :

1370 – BUREAU VERITAS ITALIA S.p.A – MILANO - ITALY RICEVUTA NUMERO / RECEIPT NUMBER : BVI/ATEX/ITA/19/104

Per quanto esposto si dichiara che le valvole descritte al punto A, classificati secondo il punto B e verificati in accordo ai punti C,D,E soddisfano i requisiti essenziali di sicurezza previsti nell’allegato II della Direttiva 2014/34/UE e ad essa applicabili. We declare that the equipments mentioned on above point A, classificated according to point B, valuated according to point C,D,E are conformed to the most essential safety requirements as required by Directive 2014/34/UE annex II.

Prendere visione del Manuale N°M/VTOP-P/I/E che contiene tutte le prescrizioni in ambito ATEX Take a look at the N ° M / VTOP-P/I/E Manual which contains all the ATEX prescriptions

Date of Issue / Data di rilascio

16/12/2019

DICHIARAZIONE DI CONFORMITA’ AI SENSI DELLA DIRETTIVA EUROPEA “ATEX” 2014/34/UE ( Allegato VIII )

Declaration of conformity according to ATEX DIRECTIVE 2014/34/UE ( Annex VIII )


Dichiarazione di Incorporazione

ai sensi dell’Allegato IIB “DIRETTIVA MACCHINE” N° 2006/42/CE

Declaration of Incorporation according Annex IIB to “MACHINE DIRECTIVE” N° 2006/42/EC


La Dichiarazione di Incorporazione Allegato IIB Direttiva Macchine 2006/42/CE è disponibile su richiesta

presso l’uffico vendite. Mail : [email protected], va compilata con i dati di commessa – ordine cliente – Tipo

Valvola – Tipo Attuatore – Serial N° The Declaration of Incorporation Annex IIB to Machine Directive 2006/42/EC is available on request from the sales office. Mail: [email protected], must be completed with the order acknoledgemnt - customer purchase order - Valve type - Actuator type - Serial No.

mailto:[email protected]


Servizio Assistenza – Servicing Department

Via Lecco, 69/71

20864 AGRATE BRIANZA (MB) – ITALY

Tel: +39 - (0)39 - 651705 / 650397

Fax: +39 - (0)39 – 654018

E-mail: [email protected]

Web: www.conflow.it



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