UNI Geräte 40-EVS Series, 6-EVS Series, 25-EVS Series, 135- EVS Series, 120-EVS Series Operating And Mounting Manual

Operating and mounting manual (translation) EVS
Operating and mounting manual
Safety shut off valve gas – solenoid valve
EVS
Contents
1.0 General Remarks
1.1 Valve data
1.2 Application
2.0 Danger Notices
2.1 Safety terms
2.2 Safety notice
2.3 Qualified staff
2.4 Unauthorized modification and spare part production
2.5 Unauthorized operation
2.6 Safety information for the use in explosion-prone areas guideline 94/9/EC
3.0 Handling
3.1 Transport
3.2 Storage
3.3 Handling before mounting
4.0 Product Description
4.1 Function
4.2 Technical data
4.3 Marking
5.0 Installation
5.1 Warning of dangers during installation, operation and maintenance
5.2 Installation
6.0 Operation
6.1 Commissioning
6.2 Shutting down
6.3 Maintenance
6.4 Putting back into operating
7.0 Troubleshooting
7.1 Detection of defects
7.2 Troubleshooting plan
8.0 Dismantling of the Valve
8.1 Replacement of wear parts
9.0 Warranty
10.0 Explanations on Codes and Directives
11.0 Sectional Drawing
11.1 Assembly drawing
11.2 List of parts
12.0 Declaration of Confirmity
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1.0 General Remarks
This operating manual includes instructions to assemble and operate the valve in the prescribed and safe way. Additionally, the adeqaute operating instructions (BTA) of each special solenoid drive must be considered.
Series MG... 220.100.038 Series MG...X 220.000.040 Series MG…Xme 220.000.039
If any difficulties appear that can not be solved by means of the operating manual, further information may be demanded from the manufacturer. This operating manual is in accordance with the relevant valid EN safety standards and the valid prescriptions and rules of the Federal Republic of Germany. If the solenoids are used abroad of the FRG, the operator and/or the person who is responsible for the plant concept must take care that the valid national rules are met. The manufacturer reserves the right of any technical change and improvement. The use of these operating instructions suppose the qualification of the user according to paragraph
2.3 “qualified staff”. The operating staff must be trained in accordance with the operating instructions. The operating manual must always be available at the location where used.
1.1 Valve data Manufacturer:
UNI Geräte E. Mangelmann Elektrotechnische Fabrik GmbH Holtumsweg 13 D-47652 Weeze Phone: +49 (0) 2837/9134-0 Fax: +49 (0) 2837/1444 E-Mail: info@uni-geraete.de Homepage: www.uni-geraete.de
Designation
Directly functioning, currentless closed, spring safety shut off valve with magnet drive.
Test basis: DIN EN 264 E-DIN 3394-1
DIN 3230 T5/T6 following
Type: Working
pressure
16- EVS… 16 bar -10°C to +60°C Propan, Butan -30°C to +120°C PT 16 25- EVS... 25 bar -20°C to +60°C Propan, Butan -30°C to +120°C PT 25 40- EVS... 40 bar -20°C to +50°C Propan, Butan -30°C to +140°C PT 40 120- EVS… 120 bar -20°C to +60°C Natural gas -20°C to + 60°C PT 180 135- EVS… 10 bar -40°C to +80°C Fuil oil Water max. 100°C PT 203
(*) Test pressure to perform leakage test "No FUNCTION TEST"
Fitting position: vertical or horizontal drive.
Switching cycles: see operating instructions (BTA) solenoid drive
Flange connection measures acc. to DIN EN 1092-1 / ANSI 300 lbs Flange DN PN 15 20 25 32 40 50 65 80 100 125 150
16-EVS 16/25 - - - O - - - - - - ­25-EVS ANSI
300lbs
40-EVS 40 - - O - - - - - - - -
O Acceptance test certificate 3.2 possible, - not available,
Ambient
temperature
Medium Medium
Test pressure
temperature
(*) PT
- - - O O O - - - - -
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Threaded connection dimension at DIN ISO 228-1 Connection G 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2
120-EVS - - O - - - - ­135-EVS - - - - - O - -
O Acceptance test certificate 3.2 possible, - not available,
Voltage: 24V– 420V (–15% to +10%) Protection type: IP54 or IP65 Frequency 40 – 60 Hz Power 10 – 4000W
Details to the electrical data can be found on the type signand the adeqaute operating instructions of the solenoid valves.
1.2 Application The UNI Geräte Electro – Solenoid valves EVS are used as automatic safety shut-off valves for protection, limitation, shut-off and release of gas and air supply at main stopps of in front of gas burners.
If used in other cases, the operator must carefully check if construction/design of valve, accessories and materials are suitable for the new application. The range of application is subject to the responsibilty of the plant planner. The service life of the valve is 20 years.
2.0 Danger Notices
2.1 Safety terms
The signal terms DANGER, CAUTION und NOTICE are used in this operating manual in case of notices concerning special dangers, or for unusal information requiring a special marking.
DANGER! means that in case of non-observance there is danger to life and/or considerable damage.
CAUTION! means that in case of non-observance there is danger of injury and/or damage.
NOTICE! means that attention is drawn to technical correlations/connections.
Observance of other, not especially marked notices concerning transport, assembly, operation and maintenance and other data (in the operating manual, product documentation and at the unit itself) is also essential, in order to avoid disturbances that might affect direct or indirect damage to property or injury to persons.
2.2 Safety notice Non observance of safety instructions can lead to loss of any claim for damages.
Non observance can lead to the following mentioned dangers:
Failure of important functions of the valve/plant  Endangering of persons by electrical or mechanical influences.  Protection against accidental contact for moving parts may not be removed as long as the
valve is in operation.
Leakage of dangerous media (e.g. explosive, toxic, hot) must be removed in the way that
there is no danger for persons or environment. Laws and regulations must be observed.
2.3 Qualified staff
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These are persons who are familiar with erection, assembly, starting, operation and maintenance of the product and who have special qualifications acc. to their activities and functions, e.g.:
Instruction and obligation to carry out and meet all regional and in-house orders and
requirements.
Education or instruction according to the safety engineering standards in use and
maintenance of adequate safety and working protection equipment.
Training in first aid.
2.4 Unauthorized modification and spare part production
Modification or changes of the valve are only allowed after agreement of the manufacturer. Original drawings and accessories authorized by the manufacturer are for safety purposes. The use of other parts or unauthorized constructive changes at the valve by third persons may cancel and abolish the manufacturere’s liability for resulting consequences.
2.5 Unauthorized operation Operational reliability of the delivered valve is only guaranteed in case of determined use in accordance to paragraph 1 of the operating manual. The application limits mentioned on the type
sign may on no account be exceeded.
2.6 Safety information for the use in explosion-prone areas guideline 94/9/EC
The temperature of the medium must not exceed the respective temperature class, and
respectively, the respective maximum permitted medium temperature as per operation guideline.
If the valve is heated (e.g. heating jacket), care must be taken, that the specified temperature
class is kept in the time.
The valve must be connected to the ground.
In the case most simple this can be realized via pipe screws by means of tooth disc. Otherwise the connection to the ground must be implemented by other measures e.g. cable links.
Control valves, electrical and electrical/mechanical drives as well as sensors must undergo a
separate conformity check as per ATEX. In doing so the respective safety and explosion protection information in the operation instructions are to taken into special consideration.
Any modifications whatsoever to the valve are not allowed. The ATEX approval is void with
immediate effect if the valve is modified without prior authorisation (even including painting).
UNI-Geräte GmbH must be consulted before any modifications are made.
Furthermore we point out the guideline 95/C332/06(ATEX 118a), which include the minimum regulations for the improvement of the health-related situation and the safety of the employees, who might be jeopardized by an explosive atmosphere.
3.0 Handling
3.1 Transport
For any transport works, the generally recognised technical rules and standards as well as rules for prevention of accidents must be observed.
In case of transport, storage and stopping, the flange protection caps must be mounted at both valve flanges.
The goods to be transported must be carefully treated. During transport, the valve must be protected against strokes, impacts or vibration. The coat of lacquer may not be damaged. Transport temperature is –20°C up to + 60°C.
Never transport the valve at screwed cable glands, appliance plugs or add-on units. The valve can be transported at ring nuts, flange borings or by means of a belt under the solenoid drive.
Transport the valve in a case or on a pallet with smooth base and put it softly on plain floor. Never put
the valve on limit switch box.
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1)
1)
EVS
The goods must be checked on completeness and transport damage. See also section 9.0
3.2 Storage If the valve is not installed immediately after delivery, it must be stored properly.
Storage temperature -20°C up to + 60°C, dry and clean.  The lacquering protects against corrosion in neutral dry atmosphere. Do not damage colour.  In humid rooms, a drying agent or a heating resp. is necessary because of condensation of
water.
Requirements according to DIN 7716 (products made of caoutchouc and rubber) must be met.
3.3 Handling before mounting
In case of valve with protection caps, they must be removed before being mounted!  Protect against atmospheric influences such as humidity (otherwise use drying agent).  Appropriate treatment protects against damage.
4.0 Product Description
The UNI-Geräte Electro – solenoid valve EVS is a directly controlled, currentless closed safety shut-off valve acc. to DIN EN 13611, DIN 3394-1 and DIN EN 161 (DIN EN 264) with solenoid drive.
Sectional drawing 11.1 Fig. 1 - 4 shows the valve construction.
4.1 Function
By switching on the solenoid drive, the solenoid core (207) is drawn against the upper part (106). The pressure spring (503) is pressed and the balance piston (220) releases the valve cross section. The valve is open. The valve closes by switching off, interruption or failure of power energy to solenoid drive. Due to press of the pressure spring (503) the balance piston closes (220). The valve is closed at 15% of nominal voltage.
4.2 Technical data Opening times: 0,3 – 0,7s Closing times: < 1s
Solenoid –drive types MG... Flange DN 15 20 25 32 40 50 65 80 100 125 150
16-EVS 25-EVS 40-EVS
Anschluss G 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2
120-EVS 135-EVS
Drive types with “A” consist of pickup and holding winding
Max. valve loading by pipe power The indicated moments may not work longer than 10s.
DN 8 10 15 20 25 32 40 50 65 80 100 125 150
Torsion Nm
Bending Nm
1)
Not valid in case of valves with flanges
Starting torque, pipe screws greased
DN 8 10 15 20 25 32 40 50 65 80 100 125 150
Torque Nm
- - - 018 - - - - - - -
- - - 019A5 019A5 019A5 - - - - -
- - 018 - - - - - - - -
- - 019A5 - - - - -
- - - - - 019A5 - -
80 35 50 86 125 160 200 250
3251)400
- - -
35 70 105 225 340 475 610 1100 1600 2400 5000 6000 7600
20 30 30 30 30 50 50 50 50 50 80 160 160
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Starting torque, product screws and nuts greased
Screw M6 M8 M10 M12 M16 M20 M24
Torque Nm
5 11 22 39 70 110 150
4.3 Marking
The type sign on the solenoid drive has the following information:
Fabricator Valve type, nominal width, pressure and temperature indication, fitting position Year of construction/ production no. Product ID No. Valve class and valve group acc. to DIN 3394-1 CE-sign and no. of relevant location Fluid group and test pressure PT Solenoid drive type Electr. performance Voltage Frequency Protection type
When using solenoid drives for x-protection zone 1 refer to information in the valid operating instructions.
Refer also to section 10.0.
5.0 Installation
5.1 Warning of dangers during installation, operation and maintenance
DANGER!
Safe operation of the valve can only be guaranteed if it is installed, commissioned and maintained by qualified personnel (see point 2.3 “Qualified staff“) correctly and in observance of the warnings in this operating manual. Apart from that, the operation safety order and the qualified use of tools and protection equipment must be guaranteed. The operating instructions for the valve must be observed during all work on or with the valve. Failure to observe these instructions may result in injury or in damage to the valve or other installations.
When the valve is used as a final sealing element, a safety precaution e.g. blanking disc, blind flange, etc., in accordance with the code of practice of the German Technical and Scientific Association for Gas and Water (DVGW) is recommended during all repair work.
5.2 Installation
Apart from the general installation guidelines, the following points should be observed:
NOTICE!
Remove the flange covers.  The inside of the valve and the pipeline must be free from foreign particles.  Observe the installation position in relation to the flow direction, see markings
on the valve.
Centre gaskets between the flanges.  The connecting flanges must be aligned.  Ensure that none of the components is strained during installation.  The valve must not be used as a fixed point; it is supported by the pipework
system.
Protect valves from soiling, particularly during construction work.  Thermal expansion of the pipework must be equalized using compensators.
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NOTICE!
Please observe the solenoid drive operating instructions (BTA).
6.0 Operation
DANGER!
Before commissioning a new installation or before starting up an installation again after repairs or modifications, ensure:
The proper completion of all installation and assembly work!  Commissioning only by “qualified staff” (see point 2.3).
Installation or repair of existing guards and protection equipment.
6.1 Commissioning
Before commissioning, check the data on material, pressure, temperature and flow direction
with the layout plan of the pipework system.
Depending on the field of application, the local regulations have to be observed, e.g. the
operation safety order.
Residues in the pipework and the valve (dirt, weld beads, etc.) will inevitably result in leaks.  Leakage inspection of the installed valve.
6.2 Shutting down
Depending on the field of application, the local regulations have to be observed, e.g. the
operation safety order.
6.3 Maintenance
Solenoid valves have to be checked at regular intervals for proper function and internal leak tightness. The intervals for regular inspections have to be defined by the operator according to the operating conditions. UNI-Geräte recommends an internal visual inspection once a year and an overhaul of the valve after 2 years or after the following number of switching cycles at the latest:
Application
temperature
25°C > 25°C
6.4 Putting back into operation
When putting a valve back into operation, ensure that all the necessary steps described in section 5.2 (Installation) and section 6.1 (Commissioning) are repeated.
DN 25 DN 80 ≤ DN 150 > DN 150
150 000 75 000 25 000 20 000
50 000 25 000 25 000 5 000
7.0 Troubleshooting
7.1 Detection of defects
DANGER! Be sure to observe the safety instructions during troubleshooting.
If the malfunctions cannot be remedied using the following “Troubleshooting plan (7.2)” please
contact the manufacturer.
In the event of faults in the function or operating behaviour of the valve, check whether the installation work was carried out and completed as described in this operating manual. Depending on the field of application, the operation safety order must be observed.
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Check the data on material, pressure, temperature, voltage and flow direction with the layout plan of the pipework system. In addition, check whether the operating conditions correspond to the technical data in the data sheet or on the rating plate.
7.2 Troubleshooting plan
Malfunction Possible causes Remedy
No flow Valve does not open Switch on solenoid drive (800)
Check operating voltage
Working pressure too high Compare working pressure with the data
on the rating plate
Flange covers were not removed Remove flange covers Low flow rate Clogging in the pipework system Check pipework system Valve leaking at seat,
no internal tightness
Valve seat gasket (400) or valve seat
(100) damaged by external particles
See section 8 or replace valve
No external tightness Gaskets damaged See section 8 or replace valve Valve does not close Connected voltage too high Check whether there is residual voltage,
see section 4.1
Flange fracture (valve/ pipework)
Screws not tightened uniformly, mating
flanges not aligned
Align pipework. Install new valve
NOTICE!
Observe section 10.0 before all installation and repair work!
Observe section 6.4 when putting the valve back into operation!
8.0 Dismantling of the Valve
In addition to the general installation guidelines and the operation safety order, the following points must also be observed:
DANGER!
Depressurised pipework system  Cooled medium  Emptied installation  Vent pipework systems containing corrosive, inflammable, aggressive or toxic
media
Have dismantling work carried out only by qualified staff (see point 2.3)
8.1 Replacement of Wear Parts
Shut down the valve as described in section 6.2.
Switch off and dismantle the solenoid drive as described in the operating manual of the solenoid drive.
DANGER! After continuous operation, the solenoid drive may be hot! Danger of burns!
During the visual inspection, pay attention to the following points:
1. Damage to the valve seat (100).
2. Damage to the valve disc sealing (400)
3. Wear of the guide rings (206)
In case of damage to the valve seat, replace the whole magnetic valve.
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If the sealing element becomes damaged (only applies to flange version Fig.1), the spare parts kit should be used.
Flanged version
Fig.1 16/25-EVS
Loosen set screw (941) and unscrew upper part (106). Remove stud (902) together with safety ring (944) and place solenoid core (207) together with spring pin (210), valve pin (214), pressure spring (503), hex. nut (901/2) and safety plate (908) aside on a clean surface. Loosen hex. nut (901/1) together with lock washer (905). Remove spacer (110) form piston guide (221). Then pull balance piston (220) together with piston guide (221) out of valve chamber (100).
Fig.2 40-EVS Fig.3 40-EVS optional with limit switch mounting
Replace the complete solenoid valve
Threaded version
Fig.4 120-EVS, 135-EVS
Replace the complete solenoid valve
NOTICE!
Before assembly, replace O-rings (403), lip-ring (404) and wiper seal (405). Lubricate the piston guide with Staburags N32 lubricant.
Assemble the valve in the reverse order to the dismantling.
CAUTION! Install wear parts carefully and properly and do not damage them during assembly.
Examine the valve for internal and external leaks in accordance with DIN 3394-1 and finally carry out a function test.
9.0 Warranty
Scope and period of the warranty is specified in the edition of the “General Terms of Business of the UNI-Geräte E. Mangelmann Elektrotechnische Fabrik GmbH” valid at the time of delivery or else in the purchase agreement.
We warranty that the valve is free from faults in line with the state of the art and for the confirmed field of application.
No warranty claims will be accepted for damage resulting from improper use or failure to observe these operating and installation instructions, the statutory accident prevention regulations, the EN, DIN and VDE standards and other codes and regulations.
Warranty claims will also not be accepted for damage occurring during operation due to operating conditions deviating from those specified in the data sheet or in other agreements.
Justified complaints will be remedied by reworking by us or specialist companies authorised by us.
Claims going beyond the scope of the warranty will not be accepted. The customer shall have no right to the supply of a replacement valve.
Maintenance work, installation of parts from other manufacturers, any modifications to the design and natural wear are not covered by the warranty.
Transport damage must be reported not to us but without delay to your responsible goods handling
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company, the railway company or the shipping agent as otherwise all claims for damages against these companies will be voided.
10.0 Explanations on Codes and Directives
The Council of the European Community has passed common guidelines for the free exchange of goods within the Community; these guidelines determines a minimum of requirements for safety and protection of health. The type test confirms that products correspond to the EC guidelines, i.e. are in conformity with the relevant, especially harmonized standards. The directives DIN EN 264 refer to oil solenoid valve (mechanical part). Notes concerning directives DIN EN 264: The valves must be developed, manufactured and checked under observation of standard DIN EN
264. This is proven by the type test. Notes concerning directives 2006/42/EG (machine directives): The valves were developed, manufactured and checked under observation of directive 2006/42/EG. Notes concerning directives 97/23/EG (directive for pressure appliances, DGRL): It was confirmed that the manufacturer UNI-Geräte E. Mangelmann Elektrotechnische Fabrik GmbH fulfils quality assurance with regard to design control, manufacturing and final inspection as per the requirements of 98/23/EG annex III module H. The oil solenoid valves correspond to the basic requirements of guidelines 97/23/EG. Valves with permitted operating pressures of ≤ 0,5bar and DN ≤ 25 do not all under 97/23/EG. The marks as per 97/23/EG must only be implied in case of products, which fall under DGRL and are in Kat I or higher. Fluid group 1 includes explosion-prone, inflammable and poisonous matters. Die Fluid group 2 includes media, which are no included in fluid group 1. Note concerning ex-guideline 94/9/EC (explosion guideline ATEX): The product is not subject to guideline 94/9/EC, since due to the loads occurring during practical operation, there is no effective source of ignition even in case of an error case to be assumed. This also applies for spring-loaded components, in gas-filled rooms. In case of electric drives, sensors or other electric components the application as per 94/9/EC is to be checked separately.
National Codes and Directives
For the use of safety shut-off devices in accordance with DIN EN 12952-8 or DIN EN 746, the requirements of DIN EN 264 have to be satisfied. This is confirmed by a type test or by an acceptance test certificate to EN 10204-3.2.
Thread connection may be used as follows:
DIN EN 746-2 DIN EN 12952-8 TRD 411
pressure
bar
≤ 10 ≤ G 1 Sealing material
≤ 40 ≤ G 1 1/4 Cutting ring connection ≤ G 2 Metal seal, non
Nominal
width
Comment Nominal
width
G 1 Cutting ring connection G 1 /
EN 751-1,-2
max. 150°C
Comment Nominal
width
DN 25
G 1 1/4 /
hardening sealing
DN 32
material
Comment
Metal seal
Cutting ring
connection
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11.0 Sectional drawing
11.1 Fig.1 16/25-EVS
......
1 = Spare part kit X = Option limit switch mounting
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Fig.2 40-EVS
X = Option limit switch mounting
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Fig.3 40-EVS optional with limit switch mounting
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Fig.4 120-EVS….; 135-EVS…
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11.2 List of parts
Pos./ Item Stück/ Qty. Benennung Description
100 1 Ventilgehäuse Valve chamber 106 1 Oberteil Upper part 108 1 Gehäuseflansch Housing flange 110 1 Distanzstück Distance piece 120 1 Endschaltergehäuse Limit switch housing 206 2 Führungsring Guide ring 207 1 Magnetkern Magnet core 210 3 Federbolzen Spring bolt 213 1 Gewindering Threaded ring 214 1 Ventilstift Valve pin 215 1 Tellerschraube Plate screw 220 1 Ausgleichskolben Balance piston 221 1 Kolbenführung Piston guide 243 1 Endschalterspindel Limit switch spindle 246 1 Verbindungsstück Connecting piece
400 1 Ventiltellerdichtung Valve disc seal 403/1 1/2 O-Ring O-ring 403/2 1 O-Ring O-ring 403/3 1 O-Ring O-ring 403/4 1 O-Ring O-ring 404/1 1/2 Lippenring Lip-ring 404/2 1 Lippenring Lip-ring
405 1 Abstreifring Wiper seal
503 3 Druckfeder Compresssion spring
513 1 Endschalterbetätigung Adjusting ring
800 1 Magnet-Antrieb Solenoid drive
803 2 Endschalter Limit switch
900 8 Sechskantschraube Hex. head screw
901 2 Sechskantmutter Hex. nut 901/1 4 Sechskantmutter Hex. nut 901/2 1 Sechskantmutter Hex. nut
902 2 Bolzen Bolt
903 1 Kerbstift Cotter pin
905 4 Federring Lock washer
906 1 Scheibe Washer
908 1 Sicherungsblech Safety plate
911 4 Stiftschraube Headless srew
912 1 Splint Split pin
941 1/2 Gewindestift Threaded pin
944 1 Wellensicherungsring Safety ring
945 1 Sicherungsring Safety ring
948 8 Nordlockscheibe Safety disc
949 1 SL-Sicherung SL-fuse
966 1/2 DU-Buchse DU-bush
Spare parts Version Fig. Type Spare parts Flange version
Fig.1 16- EVS 12N(H)
Spare part kit (1), Solenoid drive (800)
25- EVS 12N(H) – 20N(H)
Fig.2 40- EVS 10NH Solenoid drive (800)
Thread version
Fig.4 120-EVS 5 ; 135-EVS Solenoid drive (800)
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A
1)
A
2)
A
3)
EVS
Dimension with standard solenoid drive
Flange DN Dimension 15 20 25 32 40 50 65 80 100 125 150 Installation
length Flange ASME Dimension 1/2" 3/4" 1” 11/4” 11/2” 2” 21/2” 3” 4” - 6” Installation
length Installation
length 16-EVSA B
B`
ØC
D
25-EVSA B
B`
ØC
D
A1) = Dimension at DIN (resp. flanges ASME and dimension DIN or flanges and dimension at DIN)
2)
A
= Dimension at ASME Class150 (resp. flanges and dimension at ASME)
3)
A
= Dimension at ASME Class300 (resp. flanges and dimension at ASME)
130 150 160 180 200 230 290 310 350 400 480
108 118 127 140 165 203 216 241 292 - 406
152 178 203 - 229 267 292 317 356 - 445
- - - 450 - - - - - - -
- - - 610 - - - - - - -
- - - 191 - - - - - - -
- - - 68 - - - - - - -
- - - 450 450 460 - - - - -
- - - 610 610 620 - - - - -
- - - 191 191 191 - - - - -
- - - 68 68 75 - - - - -
B` = Dimension for removing the solenoid drive
Dimension B and diameter C change for solenoid drives for explosion-proof zone 1. Please observe the dimensions of the attached relay combination for drives with “A1, A2, A3” in the type designation.
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12.0 Declaration of Conformity
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