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 |
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© Danfoss | 2016.05 |
VI.JA.B3.5B | 1 |
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 |
7.1Required 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 |
7.6Adjustment of the Differential
|
Pressure ................................................................ |
11 |
7.7 |
Sealing .................................................................. |
11 |
7.8 |
Function Test ..................................................... |
12 |
8 |
Trouble Shooting ................................. |
12 |
9 |
Replacement of Valve, Actuator, |
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Trims ...................................................... |
13 |
9.1Dismounting and Mounting
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Actuator Valve ................................................... |
13 |
9.2 |
Replacement of Trim Valve VFG 2 .............. |
14 |
9.3 |
Dismounting, Mounting |
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Actuator AVP ...................................................... |
14 |
9.4 |
Replacement of Trim Valve AVP................... |
15 |
2 | © Danfoss | 2016.05 |
VI.JA.B3.5B |
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 |
The controller is used for flow rate limitation of |
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Application |
water for heating, district heating and cooling |
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systems. |
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The admissible medium temperatures depend |
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on the design and comprise 5-150 °C, |
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5-200 °C. |
The technical data on the rating plates determine the use.
VI.JA.B3.5B |
© Danfoss | 2016.05 | 3 |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
3 |
Description |
3.1 |
Construction |
Pilot controller AVP
Throttling element
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Valve unit PCV-VFG 2 |
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Throttling valve |
Throttling valve |
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only by DN150-250 |
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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.
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 |
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data sheet. |
4 | © Danfoss | 2016.05 |
VI.JA.B3.5B |
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 |
AVP
Throttling element
Cu pipe Ø 6 × 1 × 1500 mm
Cu pipe Ø 10 × 1 × 3000 mm
VI.JA.B3.5B |
© Danfoss | 2016.05 | 5 |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
6 |
Assembly |
6.1 Prior to Assembly: |
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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.
pin only
weld
do NOT weld
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
6.5 Insulation
The diaphragm actuators must not be insulated when insulating system parts.
6 | © Danfoss | 2016.05 |
VI.JA.B3.5B |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
6.6 Installation Scheme
Throttling valve
Valve unit PCV - VFG2 |
Throttling element |
|
Throttling valve
(only by DN 150 - 250)
Pilot controller AVP 
lay impulse tube during mounting
Installation in the Return Line
Throttling valve
Valve unit PCV - VFG2 |
Throttling element |
|
Throttling valve
(only by DN 150 - 250)
Pilot controller AVP
lay impulse tube during mounting
Installation in the Supply Line
VI.JA.B3.5B |
© Danfoss | 2016.05 | 7 |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
6.7 |
Assembly Drawings, Dimensions |
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CU pipe Ø 6 × 1 |
to the return flow |
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Lay when assembling. |
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to the supply flow |
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Install impulse tubes |
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laterally because of dirt |
Cu pipe Ø 10 × 1 |
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Lay when assembling. |
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Pilot controller AVP |
Throttling |
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DN 25 SW 50 element |
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DN 25: pipe Ø 33.7 × 3.2 |
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Material: ST 35.8 |
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(not part of the delivery) |
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these parts are not in the scope of delivery |
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DN 100-125 |
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8 | © Danfoss | 2016.05 |
|
VI.JA.B3.5B |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
CU pipe Ø 6 × 1
Lay when assembling.
to the supply flow
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
to the return flow
Cu pipe Ø 10 × 1
Lay when assembling.
these parts are
not in the scope of delivery
Dimensions
Nominal diameter |
DN |
100 |
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125 |
150 |
200 |
250 |
L1 |
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350 |
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400 |
480 |
600 |
730 |
H1 |
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530 |
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530 |
619 |
647 |
697 |
H2 |
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- |
174 |
229 |
254 |
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D2 |
mm |
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263 |
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380 |
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D1 |
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250 |
350 |
385 |
500 |
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B |
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200 |
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210 |
310 |
336 |
412 |
A ≥ |
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290 |
320 |
350 |
410 |
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VI.JA.B3.5B |
© Danfoss | 2016.05 | 9 |
Instructions |
Pilot-controlled Differential Pressure Controller PCVP |
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.
p2 |
p1 |
|
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:
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.
5 |
4 |
2 |
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3 |
1)Pre-condition: Same pressure on both sides of the diaphragm. If the pressure load is one-sided, the (+)diaphragm chamber may have an excess pressure of 1 bar in comparison to the (-) diaphragm chamber.
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.
6 |
7 |
8 |
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9 |
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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.
10 | © Danfoss | 2016.05 |
VI.JA.B3.5B |
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