How it Works
IMI BUSCHJOST
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82730G Series
Operation Manual
11 pgs2.52 Mb0
Table of contents
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IMI BUSCHJOST 82400G Series, 82410N Series, 83030F Series, 82740N Series, 82730G Series Operation Manual

Operation manual – pre-controlled diaphragm valves
Document No. 1377005.0000.10011 Revision 8
Keep documentation for future use!
Series
82400
82730
83030
G
G
F
82410
82740
N
N
G
G-Thread
N
NPT-Thread
F
Flange
Contents

1.1 Documentation validity 1

1.7 Obligations of operator 2
1.8 Personnel qualification 2
6.1 NC-valve (normally closed) 4
7.1 Dimensions 5
7.2 Mounting accessories 5
10.1 Checking the switching function 7
12.2 Checking for tightness and strength 8
12.5 Unmounting solenoid 9
12.7 Checking valve parts 9
12.12 Mounting solenoid 10 13 Re-commissioning 10 14 Decommissioning 10 15 Replace complete valve 10 16 Trouble shooting 11 17 Return 11 18 Disposal 11 19 Directives and certificates 11
Translation of the original operating manual Status as of November 2018
1
About this documentation
These mounting instructions guides you to mount, operate and maintain pre-controlled diaphragm valves safely.
This operation manual is intended for: plant operators, installers, maintenance and service technicians.
1.1
Documentation validity
This operation manual applis to pre-controlled diaphragm valves of the following series
•82400, 82730 (G-Thread)
•82410, 82740 (NP T-Thread)
•83030 (Flange)
•for special products that are based on the
series mentioned above
in combination with these c-solenoids:
Series 9101 9151
G
82400
82410
82730
82740
83030
• • • •
N
• • • •
G
• • • •
N
• • • •
F
• • • •
Order No. Connection Connection Nominal
xxxx0xx G 1/4 1/4 NPT -
xxxx1xx G 3/8 3/8 NPT -
xxxx2xx G 1/2 1/2 NPT DN 15
xxxx3xx G 3/4 3/4 NPT DN 20
xxxx4xx G 1 1 NPT DN 25
xxxx5xx G 1 1/4 1 1/4 NPT DN 32
xxxx6xx G 1 1/2 1 1/2 NPT DN 40
xxxx7xx G 2 2 NPT DN 50
Series 82400
82730
913 6 x 6106 x
82410 82 74 0
size
83030
1.2
Structure of safety instructions
Safety instructions warns against dangerous situations and must be observed in particular. Safety instructions are structured as follows:
SIGNAL WORD
Type of hazard
Consequences of non-observance
→ Precautions necessary to avoid the hazard
1.3
Hazard classes (ANSI Z535.6)
! DANGER
Safety information indicates a hazardous situation with high risk which, if not avoided, will certainly result in death or (serious) injury.
! WARNING
Safety information indicates a hazardous situation with moderate risk which, if not avoided, can cause death or severe injury.
! CAUTION
Safety information indicates a hazardous situati­on which, if not avoided, could result in minor or moderate injury.
NOTICE
Information indicates a hazardous situation which, if not avoided, could result damage to property.
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1
1.4

Styles and symbols

This documentation uses the following styles and symbols:
• list
→ instruction
1.
preset order of instructions
2.
701 part number (according to part list)
1 flexible part number (section)
replace spare part
q
! + DANGER / WARNING / CAUTION;
NOTICE: embedded safety message
given limits or fixed value
1.5

Intended use

The valve is solely intended to control or stop a fluid flow within approved operating limits. The fluid must only flow through the valve in the determined flow direction.
You may only operate the valve with fluids that will not cause any chemical reaction with the valve’s materials or lead to abrasive effects.
Under the following conditions, a valve with nominal diameter > DN 25 is not approved as the only shut-off valve at the end of a pressure line:
•The contents of the pressure system must
not be released into the atmosphere.
•The contents of the pressure system must
not be transferred to a downstream system with lower nominal pressure rating (PN).
1.6

Improper use

In the following cases it is prohibited to opera­te the valve:
•The valve is not used for the designated
purpose.
•The permitted temperature and pressure
ranges are exceeded.
•Damages to the valve – e.g. cracks,
deformation – were detected but the valve remains in operation.
•Malfunctions were detected but the valve
remains in operation.
•The valve has been modified without authori-
sation of the manufacturer.
•The safety instructions of this documentation
are not observed.
For damages caused by improper use, the liability of the manufacturer is excluded.
Our guarantee expires in the following cases:
•Undue intervention and altering are done to
the valve.
•This documentation or the operating limits
as shown in the particular data sheet are not observed.
1.7

Obligations of operator

Product
→ Over the entire life cycle of the valve all
applicable regulations must be observed. The instructions of this operation manual must be observed and followed.
→ Initiate a risk assessment of the overall
installation, to detect potential dangers that may occur in combination of the valve with other components.
Persons
→ Initiate the instruction of each person who
is working with the valve. Applicable regulations about occupatio­nal safety ad safety engineering must be known and applied.
Documentation
→ This documentation must be fully read and
understood.
→ The instructions given in this operation
manual must be put into practice.
→ This documentation must be available at
any time.
Markings at the operating site
→ Ensure adequate warning of the risks linked
to the valve. Use in the area of the installed valve the following warning and prohibition sings in compliance with EN ISO 7010 and and BGV A8 ( VBG125):
Warning sign to indicate risk of burns at the solenoid
Warning sign to indicate elec­trical hazards at the solenoid
Prohibition sign to prevent people from entering hazardous areas
1.8

Personnel qualification

→ Ensure as operator that persons who work
on or with the valve are sufficent qualified for this job.
→ Comprehensively train the operating per-
sonnel in terms of safety.
→ Only allow trained specialists to perform
electric connections, commissioning, main­tenance and trouble shooting.
Demands
Operating personnel must be instructed on operational sequences and procedures.
Operating personnel must know its responsi­bilities regarding the work to be performed.
Trained specialists must possess profound knowledge in mechanical engineering, electri­cal engineering, hydraulic und pneumatic.
Trained specialists must be authorized to commission, ground and designate devices, systems and power circuits according to the standards of safety technology.
Trained specialists must possess profound knowledge about design and principle of ope­ration of the valves and the plant.
1.9

Personal protection equipment

→ Wear appropriate protection equipment.
Observe the personal protection equip­ment as requested in “residual risks” (see chapter
2 ).
Protective eye glasses
to protect from escaping fluids or exhausting compressed air
Protective gloves Resistance to cutting to protect
from sharp edges or ridges; Resistance to acids to protect from hazardous fluids
Protective footwear
to protect from parts or tools falling down
2

General safety instructions

These safety instructions are only related to the single valve. In combination with other plant components there may be other potential dangers, which must be taken into account by carrying out a risk analysis for the system.
→ Compare the details on rating plate and
datasheet to the operating data. The limits for the particular application (e.g. pressure, temperature) must not be exceeded.
→ Only perform assembly and maintenance
works when the pipe system is in depres­surized state.
→ Flood the valve slowly during commissio-
ning. Fast pressurizing will cause the valve to open briefly.
→ Strength tests with the valve seat open are
permitted maximum up to 1.5 times of the nominal pressure rating (PN) at room tem­perature. The valve must not be operated during these tests.
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2
! DANGER
7 *
8
1
6
Hazardous electrical voltage (>25V AC; >60V DC)
There are risks from electrical voltage during assembly and maintenance.
→ The electrical connection of the solenoid
must be carried out only by a qualified electrician.
→ You may only plug or remove the device
socket in de-energized state.
→ Disconnect the power supply off the sole-
noid prior to assembly or disassembly.
! WARNING
Danger from pressurized pipelines
Pressurized pipelines may burst resulting in injuries.
→ Depressurize pipe system and block the
fluid flow prior to opening or unmounting the valve.
! CAUTION
Risk of burns at the solenoid
Solenoid is heating up during operation. Touching the solenoid leads to risk of burns.
→ Leave the solenoid to cool down before
working at the valve.
Residual risks
Weight of the valve Phases: transport, storage,
kg
assembly, maintenance, disposal
Risk: falling off, tipping over Personal protection equipment (PPE): Protective footwear
Hazardous fluids Phases: assembly, operation,
maintenance, disposal Risk: skin contact, eye contact, breathing vapors PPE: protective gloves, protective eye glasses, breathing protection
Potentially explosive atmosphere Risk: danger of explosion
! WARNING: Use solenoid an device
socket with Ex-protection.
Sharp-edges and threads Phases: transport, assembly,
maintenance, disposal
Risk: risk of cuts PPE: protective gloves
3

Avoid damage to property

NOTICE
Deposits and dirt lead to malfunctions
If the control bores are clogged or the core is blocked by soil the valve no longer closes or opens.
→ Install a strainer (mesh size ≤0.25mm) in
front of the valve inlet P if necessary.
Damages through accumulation of heat
The solenoid will overheat during conti­nuous duty if the heat can not be radia­ted. This shortens the service life of the solenoid.
→ You must not cover the solenoid with paint. → You must not encase the solenoid in
atight housing or in a thermal insulation.
Residual risks
Pressure against valve outlet
The valve only firmly closes in flow direction.
Fluid freezing
The valve is not designed to with­stand the fluid freezing.
4

Identifying the valve

The rating plate is situated on the solenoid body.
Made in Germany
Buschjost GmbH D-32545 Bad Oeynhausen
1
Part no./Bestell-Nr.
2
3
1 2 3 4 5 6 7
8
8240000.9101.23050
VHz
23050
PA
www.imi-precision.com
Rating plate (example)
Order number Operating voltage Frequency of voltage Power consumption inrush/holding Operating pressure range Date of manufacture (week /year) * if this marking is shown on the rating plate:
use device socket with rectifier Duty cycle
15VA /7W
0–25
100%
XXXX
use -plug only
4
5
bar
6
An additional marking is applied to the spring clip of the
22
23
Marking of the spring clip (example)
1 2 3 4 5 6
c-solenoid.
8240000.9100
0,1 - 16 bar DC only G 1/4
Order number (without voltage/frequency) Operating pressure range Size of connection DC only (only with DC coils) Date of manufacture (week /year) Serial number
xxxx
xxxx
4
5
5

Transport and storage

NOTICE
Damage of the valve
Valve may be damaged if foreign particles get into the valve.
→ Transport and store the valve dry and only
in the delivery packaging.
→ Take valve out of the packaging immedia-
tely prior to assembly.
→ Leave the blanking plugs or protective
collars into valve connections.
Prolonged storage at −10 °C to +20 °C
Avoid during transport:
mechanical loads: falling off, tipping over
Damages to the electrical terminal elements
Avoid during storage:
thermal stress: permanently increased storage
temperatures; distance to heat sources < 1m
chemical load: through solvents, chemicals, acids, fuels and similar at the storing site
weather conditions: at construction sites strong, watertight containers are necessary
Unfavourable storing conditions may reduce the service life of the sealing materials.
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3
P
PA
2
5
PA
2
6
5
9
7

Mounting

NOTICE
Damage of the valve
The valve may be damaged through in­appropriate installation.
→ Only trained and authorized specialists
may install the valve.
→ Only use appropriate tools and suitable
sealing materials.
→ Make sure that the valve is mounted in
flow direction.
→ Make sure not to distort the valve body,
particularly in case of a misaligned pipe­work.
There must be no mechanical loads applied to the solenoid.
→ Do not use solenoid as a lever during
mounting.
Valve only firmly closes in flow direction. Inflow against the valve’s flow direction may lead to the destruction of compo­nents.
→ Implement adequat measures if back flow
is to expect; for example by adding check valves to the pipe system.
The valve may get damaged by external loads at the operating site.
→ Protect valve from objects falling down. → Secure the valve against direct weather
influences and the possible effects.
6

Function

Design
2/2-Way seat valve with diaphragm as sealing device.
Operation
The valve is electromagnetic indirectly-control­led. The switching function needs a pressure difference between valve inlet P and valve outlet A.
6.1

NC-valve (normally closed)

7
6
A
Normal position: closed
Due to the effect of the compression spring 6 inside the core the pilot seat Compression spring
4 presses the diaphragm
sealingly to the main valve seat
5 is closed.
1.
The operating fluid flows through the control bore
2 in the diaphragm to the chamber 3
above the diaphragm and increases the closing force.
Switching position: open
The magnetic force lifts the core towards the magnet face of core tube solenoid is energized. Since the pilot seat
7 when the
5
is open the fluid pressure is reducing from chamber flowing off via the pilot seat ber trol bore
3 towards valve outlet. More fluid is
5 to the cham-
3 than the amount flowing in via the con-
2 in the diaphragm. The differential
pressure lifts up the diaphragm and opens the main valve seat
6.2

NO-valve (normally open)

1.
Main valve seat
1
Control bore in the diaphragm (pressure build-up)
2
Chamber
3
Compression spring above the diaphragm
4
Control bore in the valve (pressure reduction)
5
Pilot seat
6
Pole piece
7
Compression spring inside pole piece
8
Core
9
Normal position: open
When the solenoid is de-energized, the pilot seat compression spring
6 is opened by the effect of the
8 and the control bore 5
inside the valve is opened. The pressure diffe­rence inside chamber
3 keeps the diaphragm
open against the power of the compression spring
4. The main valve seat 1 is open.
Switching position: closed
When the magnet is energized, the core 9 is pulled against the pole piece
7. The core 9
presses the seal plug sealingly against the
4
3
P
8
A
7
force of compression spring seat
6. The outflow of the fluid flow from
the chamber spring
3 is interrupted. Compression
4 presses the diaphragm sealingly
to the main valve seat fluid flows through the control bore diaphragm to the chamber
4
3
Sectional view (NC-valve; closed)
Main valve seat
1
Control bore in the diaphragm (pressure build-up)
2
Chamber
3
Compression spring above the diaphragm
4
Pilot seat
5
Compression spring inside the core
6
Magnet face of the core tube
7
Sectional view (NO-valve; open)
phragm and increases the closing force.
6.3

Solenoid types AC/DC

The valve may be equipped without changing of the mechanical part with an DC voltage solenoid or AC voltage solenoid. In both cases the permissible voltage tolerance amounts to ±10%. Special versions may cause deviations.
8 on the pilot
1. The operating
2 in the
3 above the dia-
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