Cepex EXTREME PVC-U Serie Instrucciones De Instalación Y Manual De Mantenimiento

ENGLISH EXTREME BALL VALVE
EXTREME BALL VALVE
INSTALLATION AND
MAINTENANCE MANUAL
PVC-U (PTFE - EPDM/FPM)
CPVC (PTFE - EPDM/FPM)
PPH (PTFE - EPDM/FPM)
PVDF (PTFE - EPDM/FPM)
ABS (PTFE - EPDM/FPM)
DN15-DN50
DN65-DN100
1. DEFINITION
Ball valve for isolating the fl ow in liquid handling systems.
Design based on the EN ISO 16135:2007 Standard in accordance with the 2014/68/EU (PED) Directive.
The valve is available with PVC-U, CPVC, PPH, PVDF and ABS bodies and EPDM and FPM (FKM) sealing gaskets. The choice of material
for the body and gaskets depends on the type of liquid to be carried and on the working temperature of the liquid, in accordance with
the chemical resistance tables available on our website and the pressure/temperature chart in this Manual.
2. GENERAL ADVICES
• The valves described in this manual are especially designed to ensure a correct fl ow circulation in all working phases.
• Apparatus should be installed in accordance with the specifi c instructions for each installation. All existing safety legislation
should be respected at all times in order to avoid accidents.
• Any modifi cation to the ball valve requires the prior authorisation of the manufacturer. Spare parts and accessories authorised by
the manufacturer are a guarantee of greater safety. The manufacturer of this valve is exempt from all responsibility for damage
arising from unauthorised spare parts and accessories.
• The user should ensure that all assembly and maintenance work is carried out by suitably authorised, qualifi ed personnel, and that
these have previously read the installation and service instructions set out in this manual.
• Avoid shocks during transport, since they may damage the body of the valve.
• Store the valve in the original packaging, protected against humidity and direct sunlight.
• The maximum service life of the valve is specifi ed in EN ISO 16135:2007. It is verifi ed on the production plant by aging tests
specifi ed in the standard.
• Correct installation and handling of the valve, as well as adherence to the maximum pressure and temperature conditions speci-
fi ed in this manual are essential for preserving the service life of the valve.
• The driven liquid must be compatible with the valve materials. Consult chemical resistance charts published by Cepex or consult
the technical department.
• Using tools for opening or closing the manual valve control is not recommended.
• Before carrying out any maintenance operations on the pipe or valve, ensure that the system is depressurised by releasing the
pressure and emptying the pipes, following the specifi c safety regulations of each product.
• Before installation, check that the valve is undamaged and that it contains all the parts required for installation.
• It is important to avoid rapid closure of valves to eliminate the possibility of water hammer causing damage to the pipeline.
• When using the valve as the fi nal element of a installation, take into account the risks of the liquid and control the pressure and
temperature, according to the standards of safety of each product.
• It is not recommended to use this valve for transport of solids or liquids with impurities that may damage the seat or the ball of
the valve.
3. COMPONENTS DN15-DN50
15
14
13
5
16
10
2
11
7
8
4
3
12
DN65-DN80
15 14
23
13
16
18 22
24
Fig. 1
25 20
26
17
2
8
10
5
9
1
11
12
4 3 7
DN100
28
29
27
16
4. BALL VALVE TECHNICAL SPECIFICATIONS
DN10-DN50 (PVC-U, CPVC, PVDF): PN16 at 20ºC liquid temperature.
DN65-DN100 (PVC-U, CPVC, PVDF): PN10 at 20ºC liquid temperature.
DN10-DN50 (PPH, ABS): PN10 at 20ºC liquid temperature.
DN65-DN100 (PPH, ABS): PN6 at 20ºC liquid temperature.
The working pressure of the valve reduces with increasing liquid temperature, as shown in the accompanying chart.
Pressure / Temperature Chart.
DN15 - DN50 (PVC-U, CPVC, PVDF) (G 4.1)
psi bar
psi bar
(G 4.1)
DN65 - DN100 (PVC-U, CPVC, PVDF)
psi bar
psi bar
Valve operating torque
Operating torque values at rated pressure (PN) and 20 °C in as new direct from the factory condition. Installation and operating
conditions (pressure and temperature) will affect these values.
The actuator that is required for an automatic operation must be calculated according to some safety factors that were determined
in life tests carried out in the factory.
Operating torque table (N·m)
(T4.1)
DN15 DN20 DN25 DN32 DN40
N·m 1 2 3,5 3,5
lbf·inch 8,9 17,7 31 31
Declaración de conformidad CE / EC Declaration of Confor-
mity
El fabricante / the manufacturer : CEPEX S.A.U.
Avinguda Ramon Ciurans 40 ( Parcel.la 6)
Polígon Industrial Congost
08530 LA GARRIGA
Declara que nuevas vávulas / declares that our valves :
Tipo/type: Válvula de Bola manuales / Manual Ball valves
Modelos / Models: [IND] and EXTREME SERIES
Material / Material: PVC-U / PVC-C / PPH / PVDF / ABS
Cumple con los requisitos establecidos por la UNIÓN EUROPEA para
EQUIPOS A PRESIÓN según Directiva 2014/68/UE (PED), categoría II
módulo A2, de acuerdo con las normas harmonizadas :
- EN ISO 16135 VALVULAS INDUSTRIALES - Válvulas de bola de
materiales termoplásticos
Meets the requirements established by the European Union for PRESSURE
EQUIPMENT according to Directive 2014/68/EU (PED), category II module
A2, in accordance with the harmonized standards:
- EN ISO 16135 INDUSTRIAL VALVES - Ball valves of thermoplastics
material.
La marca CE sobre la válvula hace referencia a esta conformidad.
Según la directiva 2014/68/UE solamente las válvulas mayores a DN25
pueden ir marcadas con CE.
The CE marking on the valve refers to this conformity. According to
Directive 2014/68/EU only valves larger than DN25 can be marked with
CE.
N DESCRIPTION MATERIAL
T 3.1
1 Body PVC-U, PPH, CPVC, PVDF, ABS
Fig. 1 Fig. 1
2 Shaft PVC-U, PPH, CPVC, PVDF, ABS
3 Ball PVC-U, PPH, CPVC, PVDF, ABS
4 Seal carrier PVC-U, PPH, CPVC, PVDF, ABS
5 Nut PVC-U, PP, CPVC, PVDF, ABS
6 End connector PVC-U, PPH, CPVC, PVDF, ABS, PE-100
Threaded versions with AISI-304 ring
6
7 Ball Seat PTFE
9
1
8 O-ring EPDM / FPM
9 O-ring EPDM / FPM
10 O-ring EPDM / FPM
11 Dampener seal EPDM / FPM
12 Stainless steel AISI-303
Insert
13 Handle PP-GR
14 Screw A2-70
19
15 Cap PP
21 16 Adjusting tool ABS (DN15-80), POM (DN100)
6
17 PP-GR
Mounting clamp
18 Throttle plate PP-GR
19 Lever-lock PP-GR
20 Pin AISI-304
21 Locking pin POM
22 AISI-302
Spring
23 Screw A2-70
24 Screw A2-70
25 Coupling bush PA-GR
26 Nut A2-70
27 Mounting clamp PVC-U (PVC-U Valve),CPVC (CPVC
Valve),PP-GR (PPH,PVDF, ABS valve)
28 Screw A2-70
29 Nut A2-70
DN15 - DN50 (PP-H, ABS)
psi bar
psi bar
PVC-U
PVC-C
PVC-U PVDF
PVC-C
PVDF
ºC
ºF
ºC
ºF DN65 - DN100 (PPH, ABS)
psi bar
psi bar
PVC-U
PVC-C
PVDF
PVC-U
PVC-C
PVDF
ºC
ºF
ºC
ºF
DN50 DN65 DN80 DN100
5 15 25 45 60
44,3 132,8 221,3 398,3 531
ENGLISH
Pressure loss table (T4.2)
DN D Kv (l/min)
10 16
75
15 20
190
20 25
380
25 32 690
32 40
980
40 50
1600
50 63
3000
65 75
5500
80 90 6800
100 110
8900
Valve connections
Threads: ISO 7-1, ISO 228-1
Flanges: EN 558-1, EN 1092-1
PVC-U, CPVC, ABS: ISO 15493
PPH, PE-100: ISO 15494
PVDF: ISO 10931
5. DIMENSIONS
DN
T 5.1(mm)
10
DN15-DN50
Yasmin Fernádez
Fig. 4 15
Quality Manager
La Garriga, April 2017
20
25
K
32
40
50
DN65-DN100
DN D / G A ± 2
PVC-U, CPVC,ABS
65 75 - 2 1/2" 238
80 90 - 3" 278
100 110 - 4" 359
Fig. 4
Q
1
1
1
1
2
2
6. INSTALLATION AND COMMISSIONING
2
Before commencing the installation process, check that you have all the parts needed for the valve assembly, and that the materials,
2
connection type and nominal pressure are suitable for the installation.
2
For solvent or welded connections, ensure also that the parts to be connected are of the same material and that you are using the correct
solvent or welding tools.
1
To install the valve, follow best installation practice recommendations provided on the Cepex website, paying particular attention to
thermal expansion and pipe alignment.
2
When fi lling the pipes with liquid, check that all the air is purged from the system and that the initial pressure does not exceed the nominal
4
pressure of the valve, or of the system element with the lowest nominal pressure rating.
Install the valve pointing in the direction of fl ow marked on the body of the valve (downstream).
1
Install the valve once the sockets are solvent-bonded and dry, to avoid problems with the adhesive (entry of the latter into the valve).
1
The valve is supplied assembled from the factory and the following steps should be followed for its installation:
1. Check that the diameter of the tube corresponds to the inside of the end connector (if it is a solvent socket).
1
2. Adjust the valve to the installation leaving the union nut (3) Fig. 6 on the tube before gluing the end connector (5) Fig. 7.
1
3. Leave an exact distance between end connectors (see Fig. 8), so that the body of the valve can be easily introduced, preventing it from
being strained by both ends of the tubing.
1
4. Solvent sockets (PVC-U / PVC-C / ABS) are made by cleaning the areas to be joined with a suitable solvent and then adding adhesive. It
1 not recommended that pressure is applied until 24 hours after gluing.
In the solvent operation you have to separate the body of the end connectors, just to avoid the adhesive damages the valve internal parts.
1
5. PTFE tape is placed in the male threads of the threaded unions: "it is very important that an excessive amount is not used as when it is
put together it could cause breakage of the female housing".
1
6. The soldered unions (PE / PP-H / PVDF) are made taking into account the instructions of the soldering tool used.
1
This range of valves allows the valve to be fi xed to a base using threaded inserts at the bottom.
When using the inserts, take note of the dimensions of the screws.
2
3 Fig. 6
2
2
1
2
2
7. OPERATION AND MAINTENANCE INSTRUCTIONS
4
4 If the valve is installed correctly pointing in the direction of fl ow marked on the body, it is possible to carry out the maintenance downs-
tream without problems. By simply closing the valve this acts as a plug. If on the contrary it is upstream where maintenance is required, it
is essential that there is no pressure in the circuit when dismantling the union nut and end connector.
The operations described next are always carried out without fl uid in the line.
The valve is adjusted in the factory for correct and prolonged functioning. Nevertheless, it is possible to readjust the tightening of the
sealing gasket on the ball when the conditions of use so require it.
This operation is carried out with the help of the handle or the supplied tool (Fig. 18).
Dismantle the valve's union nuts (3) and remove them from their housing. Put the outil into the slot that is found in the seal carriers for
this purpose (12) and turn the key anti-clockwise to tighten the o-ring and clockwise to loosen it. If any of the components of the valve
wear out, you can replace them by dismantling the body of the valve. To do so, proceed in the same way with the adjustment but turn it
clockwise until the seal carriers (12) are free. When you have done this you may substitute any of the body's O-rings. Turn the shaft until the
ball is in a closed position; remove the ball (2) and remove the ball seat (9).
To replace the shaft, it has to be forced as shown in Fig.16. Once the shaft has been removed (1) the o-rings can be replaced (7). Remember
that excessive force on the seal carriers can aff ect the action which can damage the actual functioning of the valve.
Assembly can be done by reversing the process but always taking the precaution of lubricating the o-rings with PTFE oil. Do not use grea-
se or mineral oils that attack the material of the o-rings.
(G 4.2)
12
Fig. 12
PP-H
ABS
PP-H
ABS
ºC
ºF
ºC
(G 4.2) ºF
PP-H
ABS
PP-H
ABS
8. TROUBLESHOOTING
ºC
ºF
ºC FAULT
ºF
Leackage on the body of the valve
Leackage on the shaft of the valve
The torque is too strong or the valve
is blocked
* For other languages, please visit our website: www.cepexindustrial.com
EXTREME BALL VALVE
Pressure loss chart (G 4.4)
Cv (GPM)
5,3
13,3
26,6
48,3
68,6
112
210,1
385,2
476,2
623,2
Actuator coupling
(Optional)
Flow / Débit / Caudal / Portata / Durchfluss / Caudal
EN/ISO 5211
D / G A ± 2 (PVC-U, A' ± 2 B B
CPVC, ABS) PPH, PVDF cemented welded threaded
16 - 3/8" 102 101 15,5 14,5 8,5
20 - 1/2" 102 101 17 15,5 13,5
25 - 3/4" 120 118 20 17 15,5
32 - 1" 139 136 23 19 18,5
40 - 1 1/4" 156 151 27,5 21,5 20
50 - 1 1/2" 170 165 32 24,5 20
63 - 2" 197 190 39,5 28,5 24
A' ± 2 B B B C E
PPH, PVDF cemented welded threaded
235 45 31 27 75 137
272 53 35 30 88,5 153
350 63 42 63 140 215
K
Fig. 7
8
6 9
2
10
Fig. 13
Fig. 16
Fig. 18
T 8.1
POSSIBLE CAUSE
Wear of the body o'ring
Looseness of the seal carrier
Presence of solids or strange elements
Wear of the shaft o'rings
The seal carrier is over-tight
CODE: C560073XT - Version 5: 2019/04
COPYRIGHT © CEPEX, S.A.U. - ALL RIGHTS RESERVED
B C E J K L R ± 2 F H
± 2
26 53 16 M4 48 - - -
26 53 16 M4 48 170,5 65 130
31,5 65 20 M5 56 75 150 105
36 73 24 M5 66 204,5 85 160 140
45 88 28 M5 74 226 100 180 150
51 102 30 M8 77 250 110 195 165
61 114 37,5 M8 90 296 125 223 185
J K F Holes F' Holes H ± 2 M
DIN DIN ANSI ANSI
38 M8 145 4x18 139,7 4x19 290 185
53 M8 160 8x18 152,4 4x19 310 200
- - 180 8x18 190,5 8x19 418 220
Fig. 8
5
Fig. 14 Fig. 15
9
7
1
Fig. 17
FAULT CLEARANCE
Change the o'ring
Ajust the seal carrier
Remove the valve and replace damaged parts
Change the o'rings
Ajust the seal carrier
M
-
95