Danfoss PCVSAA Operating guide [de]
Instructions
Pressure relief controller PCVA,
Safety pressure relief controller PCVSAA
English |
Page 2 |
Einbau-, Bedienungsanleitung
Hilfsgesteuerters Überströmregler PCVA, Hilfsgesteuertes Sicherheitsüberströmventil PCVSAA
Deutsch |
Seite 15 |
DN 100DN 250
PN 16/PN 25
© Danfoss | 2016.06 |
VI.JA.D2.5B | 1 |
Instructions |
PCVA, PCVSAA |
Table of Contents |
1 |
Safety Notes............................................. |
3 |
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2 |
Definition of Application........................ |
3 |
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3 |
Description............................................... |
4 |
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3.1 |
Construction.......................................................... |
4 |
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3.2 |
Mode of Operation.............................................. |
4 |
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4 |
Technical Data.......................................... |
4 |
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5 |
Scope of Delivery..................................... |
5 |
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6 |
Assembly.................................................. |
6 |
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6.1 |
Prior to Assembly................................................. |
6 |
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6.2 |
Installation Position............................................. |
6 |
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6.3 |
When Installing observe.................................... |
6 |
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6.4 |
Impulse Tube Installation.................................. |
6 |
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6.5 |
Insulation................................................................. |
6 |
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6.6 |
Installation Scheme............................................. |
7 |
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6.7 |
Assembly Drawings, Dimensions................... |
8 |
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7 |
Start-up................................................... |
10 |
7.1Required Static Pressure, Pressure
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Difference............................................................. |
10 |
7.2 |
Leak and Pressure Tests................................... |
10 |
7.3 |
Filling the System............................................... |
10 |
7.4 |
Start-up.................................................................. |
10 |
7.5 |
Putting out of Operation................................. |
10 |
7.6 |
Adjustment of the Setpoint............................ |
11 |
7.7 |
Sealing.................................................................... |
11 |
7.8 |
Function Test........................................................ |
11 |
8 |
Trouble Shooting................................... |
12 |
8.1 |
Fault, Possible Cause, Remedy...................... |
12 |
8.2Diaphragm Break of the Controller SAVA. 12
9 Replacement of Valve, Actuator, Trim. 13
9.1Dismounting and Mounting Actuator and
Valve of the Valve Unit...................................... |
13 |
9.2 Replacement of Trim Valve VFG 21.............. |
14 |
9.3Dismounting, Mounting Actuator AVA,
SAVA........................................................................ |
14 |
9.4 Replacement of Trim Valve AVA, SAVA ..... |
14 |
2 | © Danfoss | 2016.06 |
VI.JA.D2.5B |
Instructions |
PCVA, PCVSAA |
1 |
Safety Notes |
MAINTENANCE
FREE
To avoid injury of persons and damages to the device, 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 pressure control of |
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Application |
waterfor 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.D2.5B |
© Danfoss | 2016.06 | 3 |
Instructions |
PCVA, PCVSAA |
3 |
Description |
3.1 Construction |
Pilot controller SAVA |
Throttling element |
|
Valve Unit PCV-VFG21 |
Throttling valve |
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only DN150-250 |
Throttling valve |
3.2 Mode of Operation
The control unit consists of the PCV-VFG21 valve unit, installed in the main pipe, and the pressure relief controller AVA or safety pressure relief controller SAVA installed as pilot controller in the bypass. In the bypass line, a throttle element is installed in front of the pilot controllers.
As a pressure relief controller, the controller keeps the pressure before the controller unit in accordance with the preset setpoint on a constant level.
As a safety pressure relief controller, the controller guarantees that the pressure is not exceeded before the control unit. If the controller diaphragm is
damaged, the valve is closed via the second diaphragm.The setpoint for the pressure is adjusted by pre-stressing the setpoint spring of the pilot controller.
The valve and the pilot valves are pressurebalanced. The setpoint for the pressure is adjusted by prestressing the setpoint spring of the pilot controller. 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 shockfree 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 | 2016.06 |
VI.JA.D2.5B |
Instructions |
PCVA, PCVSAA |
5 Scope of Delivery |
DN 100-125 |
Assembly kit valve unit PCV-VFG 21 |
Pilot controller DN 25 |
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AVA |
SAVA |
DN 25 |
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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 DN 40 |
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AVA |
SAVA |
DN 40 |
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Throttling element
Cu pipe Ø 6 × 1 × 1500 mm
Cu pipe Ø 10 × 1 × 3000 mm
VI.JA.D2.5B |
© Danfoss | 2016.06 | 5 |
Instructions |
PCVA, PCVSAA |
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.
6.2Installation Position
•Installation is only permitted in horizontal pipelines with the actuators hanging in a downward position.
6.3When installing:
•Observe direction of flow.
•Design with welded ends:
pin only
weld
do NOT weld
•Loads on the valve body and the throttle element by the pipes are not permitted.
6.4 Impulse Tube Installation
1.See installation scheme, section 6.6.
2.For CU pipes Ø 10 × 1, insert sockets 1 on both sides.
1
3. Care for correct position of the cutting rings 2.
2
4.Press impulse tube into the threaded fitting up to its stop.
5.Tighten union nut, torque 40 Nm
6.Dismount again and check the position of the cutting rings.
6.5 Insulation
The diaphragm actuators must not be insulated when insulating system parts.
6 | © Danfoss | 2016.06 |
VI.JA.D2.5B |
Instructions |
PCVA, PCVSAA |
6 Assembly |
6.6 Installation Scheme |
Valve unit
PCV - VFG 21
Throttling valve |
Throttling element |
CU pipe Ø 10 × 1 |
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Shut-o valve |
Throttling valve |
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Pilot controller AVA |
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(only by DN 150 - 250) |
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CU pipe Ø 6 × 1 |
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lay impulse tube during mounting |
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Installation PCVA
Valve unit
PCV - VFG 21
Throttling valve |
Throttling element |
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CU pipe Ø 10 × 1 |
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Pilot controller SAVA |
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Do not install a |
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shut-o valve her. |
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But if you do so, |
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Throttling valve |
it is absolutely necessary |
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to secure against |
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(only by DN 150 - 250) |
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unauthorized closing. |
CU pipe Ø 10 × 1 lay impulse tube during mounting
Installation PCVSAA
VI.JA.D2.5B |
© Danfoss | 2016.06 | 7 |
Instructions |
PCVA, PCVSAA |
6 |
Assembly |
6.7 Assembly Drawings, Dimensions |
Install impulse tubes laterally because of dirt
<![if ! IE]><![endif]>H2
- |
Dismount impulse |
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tube |
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- |
Unscrew threaded |
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fittings at the valve and |
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at the actuator |
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- Close opening at the |
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valve with a stopper |
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(see assembly kit order |
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No. 003G1599) |
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D2 |
Cu pipe Ø 10 × 1 |
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Lay when assembling. |
<![endif]>H1
Cu pipe Ø 6 × 1, when laying,
use the assembly kit order No. 003G1599
L1
Valve unit PCV - VFG 21
<![endif]>A
DN 25: pipe Ø 33.7 × 3,2 Material: ST 35.8
(not part of the delivery)
Pilot controller |
DN 25 |
Throttling |
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AVA |
SW 50 |
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element |
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75 |
160 |
159 |
244 |
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ca. 1000 |
these parts are not in the scope of delivery
DN 100-125
8 | © Danfoss | 2016.06 |
VI.JA.D2.5B |
Instructions |
PCVA, PCVSAA |
6 |
Assembly |
Dismount impulse tube |
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- |
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- |
Unscrew threaded |
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fittings at the valve and |
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at the actuator |
L1 |
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- |
Close opening at the |
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valve with a stopper |
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(see assembly kit order |
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No. 003G1599) |
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<![if ! IE]> <![endif]>H2 |
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Install impulse tubes laterally because of dirt
<![endif]>H1
Cu pipe Ø 6 × 1, when laying,
use the assembly kit order No. 003G1599
Cu pipe Ø 10 × 1
Lay when assembling.
D2
<![endif]>A
DN 40: pipe Ø 48,3 × 3,2 Material: ST 35.8
(not part of the delivery)
DN 150-250
these parts are not in the scope of delivery
<![if ! IE]><![endif]>B
D1
200 290
cca. 1200
these parts are not in the scope of delivery
Dimensions
Nominal diameter DN |
100 |
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125 |
150 |
200 |
250 |
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L1 |
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350 |
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400 |
480 |
600 |
730 |
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H1 |
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530 |
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530 |
619 |
647 |
697 |
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H2 |
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- |
245 |
300 |
325 |
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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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150 |
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250 |
320 |
385 |
500 |
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B |
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200 |
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210 |
310 |
336 |
412 |
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A ≥ |
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290 |
320 |
350 |
410 |
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VI.JA.D2.5B |
© Danfoss | 2016.06 | 9 |
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