Danfoss PCVP DN 100-250 Operating guide [de]
Instructions
Pilot-controlled Differential Pressure Controller
PCVP DN 100-250, PN 16/25
English Page2
Einbau-, Bedienungsanleitung
Hilfsgesteuerter Differenzdruckregler
PCVP DN 100-250, PN 16/25
Deutsch Seite 16
© Danfoss | 2016.05
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Instructions Pilot-controlled Differential Pressure Controller PCVP
Table of Contents
1 Safety Notes ......................................................3
2 Definition of Application ............................3
3 Description .........................................................4
3.1 Construction ........................................................4
3.2 Mode of Operation ...........................................4
4 Technical Data ..................................................4
5 Scope of Delivery ................................... 5
6 Assembly ................................................ 6
6.1 Prior to Assembly ...............................................6
6.2 Installation Position, Installation Place ......6
6.3 When Installaling observe .............................. 6
6.4 Impulse Tube Installation ................................6
6.5 Insulation ..............................................................6
6.6 Installation Scheme ........................................... 7
6.7 Assembly Drawings, Dimensions ................ 8
7 Start-up ................................................. 10
7.1 Required static Pressure, Pressure
Difference .......................................................... 10
7.2 Leak and Pressure Test ................................... 10
7.3 Filling the System ............................................ 10
7.4 Start-up ................................................................ 10
7.5 Putting out of Operation .............................. 10
7.6 Adjustment of the Differential
Pressure ...............................................................11
7.7 Sealing .................................................................11
7.8 Function Test .....................................................12
8 Trouble Shooting ................................ 12
9 Replacement of Valve, Actuator,
Trims ..................................................... 13
9.1 Dismounting and Mounting
Actuator Valve ...................................................13
9.2 Replacement of Trim Valve VFG 2 ..............14
9.3 Dismounting, Mounting
Actuator AVP .....................................................14
9.4 Replacement of Trim Valve AVP ..................15
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Instructions Pilot-controlled Differential Pressure Controller PCVP
1 Safety Notes
MAINTENANCE
FREE
Prior to assembly and
commissioning to avoid injury
of persons and damages of the
devices, it is absolutely
necessary to carefully read and
observe these instructions.
Necessary assembly, start-up, and maintenance
work must be performed only by qualified,
trained and authorized personnel.
Prior to assembly and maintenance work on the
controller, the system must be:
depressurized,
cooled down,
emptied and
cleaned.
Please comply with the instructions of the
system manufacturer or system operator.
2 Definition of
Application
The controller is used for flow rate limitation of
water for heating, district heating and cooling
systems.
The admissible medium temperatures depend
on the design and comprise 5-150 °C,
5-200 °C.
The technical data on the rating plates determine the use.
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Instructions Pilot-controlled Differential Pressure Controller PCVP
Pilot controller AVP
T
only by DN150-250
3 Description
3.1 Construction
hrottling valve
3.2 Mode of Operation
The control unit consists of the PCV-VFG2
valve unit, installed in the main pipe, and the
differential pressure controller AVP installed as
pilot controllers in the bypass. In the bypass line,
a throttle element is installed in front of the pilot
controllers.
The controller keeps the differential pressure
across the corresponding section on a constant
level.
The valve and the pilot valves are pressurebalanced.
The setpoint for the differential pressure is
adjusted by pre-stressing the setpoint spring of
the pilot controller AVP.
The valve unit in the main pipe is opening on
rising pressure. The pilot controllers in the
bypass line are closing on rising pressure.
Throttling element
Valve unit PCV-VFG 2
Throttling valve
In case of small flow rates, the valve in the main
pipe remains closed through the pressure spring
in the actuator of the valve unit. The pressure is
exclusively controlled by the pilot controller.
If the flow rate in the bypass is increased, the
pressure in the throttle element (Venturi nozzle)
decreases.
The reduced pressure acts through an impulse
tube upon the lower chamber of the actuator
of the valve unit. The main valve is thus opened
shock-free and continuously.
If the flow rate is reduced, the pressure in the
throttle element raises and the main valve closes.
This sequential switching guarantees an
operation free of vibrations and a small control
deviation over a wide positioning range.
4 Technical Data Technical data, see rating plates and the PCV
data sheet.
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Instructions Pilot-controlled Differential Pressure Controller PCVP
5 Scope of Delivery
DN 100-125
Assembly kit valve unit PCV-VFG 2 Pilot controller AVP DN 25
AVP
Throttling element
Cu pipe Ø 6 × 1 × 1500 mm
Cu pipe Ø 10 × 1 × 3000 mm
DN 150-250
Assembly kit valve unit PCV-VFG 21 Pilot controller AVP DN 40
Throttling element
Cu pipe Ø 6 × 1 × 1500 mm
Cu pipe Ø 10 × 1 × 3000 mm
AVP
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Instructions Pilot-controlled Differential Pressure Controller PCVP
6 Assembly 6.1 Prior to Assembly:
Depressurized system before
any assembly work !
CAUTION!
• Clean pipeline system.
• Install strainer in front of the controller.
• Install shut-off units in front of and behind
the controller.
6.2 Installation Position, Installation Place
• Installation is only permitted in horizontal
pipelines with the actuators hanging in a
downward position.
• The controller may be installed in the supply
as well as in the return line.
6.3 When installing:
• Observe direction of flow.
• Design with welded ends:
• Loads on the valve body and the throttle
element by the pipes are not permitted.
6.4 Impulse Tube Installation
See installation scheme, section 6.6.
For CU pipes Ø 10 × 1, insert sockets 1 on both
sides.
1
Care for correct position of the cutting rings 2.
2
pin only
weld
do NOT
weld
6.5 Insulation
The diaphragm actuators must not be insulated
when insulating system parts.
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Instructions Pilot-controlled Differential Pressure Controller PCVP
V
P
)
lay impulse tube during mounting
V
P
lay impulse tube during mounting
6.6 Installation Scheme
Throttling valve
alve unit PCV - VFG2
ilot controller AVP
Installation in the Return Line
alve unit PCV - VFG2
ilot controller AVP
Throttling element
Throttling valve
(only by DN 150 - 250
Throttling valve
Throttling element
Throttling valve
(only by DN 150 - 250)
Installation in the Supply Line
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Instructions Pilot-controlled Differential Pressure Controller PCVP
.
CU pipe Ø 6 × 1
to the return flow
these parts are not in the scope of delivery
6.7 Assembly Drawings, Dimensions
Lay when assembling.
pp
ly
to the su
Install impulse tubes
laterally because of dirt
flow
Cu pipe Ø 10 × 1
Lay when assembling
DN 100-125
DN 25: pipe Ø 33.7 × 3.2
Material: ST 35.8
(not part of the delivery)
Pilot controller AVP
DN 25 SW 50
Throttling
element
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Instructions Pilot-controlled Differential Pressure Controller PCVP
CU pipe Ø 6 × 1
Lay when assembling.
to the supply flow
to the return flow
Cu pipe Ø 10 × 1
Lay when assembling.
Install impulse tubes
laterally because of dirt
DN 40: pipe Ø 48.3 × 3.2
Material: ST 35.8
(not part of the delivery)
DN 150-250
Dimensions
Nominal diameter DN 100 125 150 200 250
L1
H1 530 530 619 647 697
H2 - 174 229 254
D2 263 380
D1 250 350 385 500
B 200 210 310 336 412
A ≥ 290 320 350 410
350 400 480 600 730
mm
these parts are
not in the scope of delivery
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Instructions Pilot-controlled Differential Pressure Controller PCVP
5
4
3
67
p2 p1
7 Start-up 7.1 Required Static Pressure
The static pressure p1 in front of the controller
must not fall below 1,5 bar (excess pressure).
Non-observance may lead to cavitation and
damages in the throttling element 1.
7.2 Leak and Pressure Tests
To avoid too high pressures at
the diaphragm actuators, the
following should be observed
prior to any pressure tests:
7.3 Filling the System
Note:
The controller 4 is closed when no pressure is
applied and only opens with a defined flow in the
bypass.
The pilot controller 5 is closing on rising pressure.
1. Open shut-off valves 6 that possibly exist in
the impulse tubes.
2. Open units 7 of the system.
3. Slowly open shut-off units in the supply
flow 8 and the return flow 9.
1
8
9
Actuator of valve unit:
The admissible operating excess pressure in the
actuator 2 is 25 bar 1). For higher pressures, you
must:
• Remove the impulse tubes 3 at the actuator
and close the connections with a stopper.
• Prior to any leak or pressure test, the
instructions in section 7.3 must be complied
with.
7.4 Start-up
During starting-up the filled system, open the
units in the same sequence as described in
section 7.3.
7.5 Putting out of operation
When putting the system out of operation, first
close the shut-off units in the supply flow and
then those of the return flow.
2
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1)
Pre-condi tion: Same pressure on both side s of the diaphragm.
If the pressure lo ad is one-sided, the (+)diaphragm cham ber
may have an excess p ressure of 1 bar in comparison to th e (-)
diaphragm chamber.
VI.JA.B3.5B
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