Technical Specifications; Troubleshooting - Cepex PVC-U Guia De Inicio Rapido

ENGLISH
INDUSTRIAL BUTTERFLY VALVE
INDUSTRIAL BUTTERFLY VALVE
PVC-U (EPDM/FPM)
CPVC (EPDM/FPM)
PPH (EPDM/FPM)
1. DEFINITION
Butterfly valve for isolating or regulating the flow in liquid handling systems. The liquid can flow in both directions.
Design based on the EN ISO 16136 Standard in accordance with the 97/23/EC Directive.
The valve is available with PVC-U, CPVC and PP discs and EPDM and FPM sealing gaskets. The choice of material for the disc and gasket
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 (G4.1).
2. WARNINGS
• Carefully read these instructions before handling the valve and observe their recommendations. Any damage caused by failure to
observe these instructions is not covered by the warranty.
• All connection and handling tasks must be performed by qualified personnel.
• The maximum service life of the valve is specified in EN ISO 16136. It is verified on the production plant by aging tests specified in the
standard.
• Correct installation and handling of the valve, as well as adherence to the maximum pressure and temperature conditions specified 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. This process must be done manually.
• Before carrying out any maintenance operations on the pipe or valve, ensure that the system is depressurised by releasing the pressu-
re and emptying the pipes, following the specific safety regulations of each product.
• Turning the handle when the safety lock is in place could damage the valve.
• Avoid shocks during transport, since they may damage the body and mechanism of the valve. Store the valve in the original packa-
ging, protected against humidity and direct sunlight.
• Before installation, check that the valve is undamaged and that it contains all the parts required for installation.
• After long periods of inactivity, check the grease on the gasket and follow the maintenance instructions set out in this manual. The
grease must be compatible with the valve materials.
• 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 final element of a installation, take into account the risks of the liquid and control the pressure and tem-
perature, according to the standards of safety of each product.
3. COMPONENTS Fig. 1 (T3.1)
19
13
22
16
14
15
20
18
5
8
17
11
9
4
21
3
6
1
2
10
12
7
4.

TECHNICAL SPECIFICATIONS

DN65-DN200 (2½"-8"): PN10 (150 psi) at 20 °C liquid tempera-
ture.
DN250-DN300 (10"-12"): PN6 (90 psi) at 20 °C liquid tempera-
ture.
The working pressure of the valve reduces with increasing li-
quid temperature, as shown in the accompanying chart.
Maximum torque at the output of the gearbox = 500 Nm
(Ratio = 37:1).
Pressure / Temperature Chart. (G 4.1)
PVC-U
PVC-C
PP-H
DN63-DN200
DN250-DN315
0 10 20 30 40 50 60 70 80 90 100
32 50 68 86 104 122 140 158 176 194 212
Temperature
Pressure loss table (T4.1)
D DN Kv (l/min) Cv (GPM)
63-75 (2 1/2") DN65 1800 126
90 (3") DN80 4020 282
110 (4") DN100 8280 580
125-140 (5") DN125 11760 826
160 (6") DN150
16200 1134
200-225 (8")
DN200
33000
2311
250 (10") DN250
5200 3655
315 (12") DN300 78571 5502
Operating torque table (N·m)
Valve operating torque
Operating torque values at rated pressure (PN)
and 20 °C in as new direct from the factory condi-
tion. Installation (flange tightening) and operating
N·m
(pressure and temperature) conditions will affect
lbf·inch
these values. If automation of operation is required,
please contact the manufacturer.
Manual VP IND 2014 05 05.indd 2
Declaración de conformidad CE / EC Declaration of Conformity
El fabricante / the manufacturer: CEPEX S.A.U.
Avinguda Ramon Ciurans 40 ( Parcel.la 6) - P. I. Congost
08530 LA GARRIGA
Declara que nuevas vávulas / declares that our valves:
Tipo / Type: Válvulas de Mariposa / Butterfly valves
Modelos / Models:
UP.84.SS.FGEP, UP.84.SS.VI, UP.84.SS.FGEP.RM, UP.84.SS.VI.RM, CP.84.SS.FGEP, CP.84.
SS.VI, CP.84.SS.FGEP.RM, CP.84.SS.VI.RM, PPH.84.SS.FGEP, PPH.84.SS.VI, PPH.84.
SS.FGEP.RM, PPH.84.SS.VI.RM.
Cumplen con los requisitos establecidos por la Unión Europea para EQUIPOS A
PRESIÓN según Directiva 97/23/CE (PED), categoria II modulo A1, de acuerdo con
las normas harmonizadas:
- EN ISO 16136 VÁLVULAS INDUSTRIALES: Válvulas de mariposa de materiales
termoplásticos.
Meets the requirements established by the European Union for PRESSURE EQUIP-
MENT according to Directive 97/23/EC (PED), category II module A1, in accordance
with the harmonized standards:
- EN ISO 16135 INDUSTRIAL VALVES: Butterfly valves of thermoplastic materials.
La marca CE sobre la válvula hace referencia a esta conformidad. Según la direc-
tiva 97/23/CE solamente las válvulas mayores a DN25 pueden ir marcadas con CE.
The CE marking on the valve refers to this conformity. According to Directive 97/23/EC
only valves larger than DN25 can be marked with CE.
Director Calidad / Quality Director:
La Garriga, March 2014
Supervisión de la avaluación final: TÜV Nord (CE 0045).
Monitoring of final assessment: TÜV Nord (CE 0045).
N DESCRIPTION MATERIAL DN65-
DN200
1 Body PP-GR 1
2 Sealing gasket EPDM / FPM 1
3 Disc PVC-U / PP / CPVC 1
4 Bearing PP-GR 2
5 Auxiliary bearing PP-GR 1
6 AISI-630 1
Shaft
7 Cap PP 1
8 Ring DIN-471 AISI-304 1
9 O-ring EPDM / FPM 4
10 Lower washer AISI-304 1
11 O-ring EPDM / FPM 2
12 Screw DIN-912 AISI-304 1
13 Handle PP-GR 1
14 Washer DIN-6798 AISI-304 1
15 POM 1
Lever
16 Pin AISI-304 1
17 PP-GR 1
Throttle plate
18 Safety lock POM 1
19 Handle cap PP 1
20 Screw DIN-912 AISI-304 2
21 Nut DIN-934 AISI-304 2
22 Screw DIN-912 AISI-304 1
23 Gear box Aluminium (housing) -
24 Screw DIN-912 AISI-304 -
Kv / % opening (G 4.2)
K v %
100
90
80
70
60
50
40
30
20
10
0
10 20 30 40 50 60 70 80 90 100
% opening / % d'ouverture / % de apertura /
% di apertura / % Öffnung / % de abertura
Pressure loss chart (G 4.3)
psi bar
15 1
1,5 0,1
0,15 0,01
V=2m/s
0,015 0,001
0,001 0,01 0,1 1
2,12 21,19 211,90 2.119
Flow / Débit / Caudal
(T4.3)
DN65 DN80 DN100 DN125 DN150 DN200 DN250
25 28 35 85 110 110 180
221 248 310 752 974 974 1593
ENGLISH
5. DIMENSIONS.
Fig. 2 DN65-200
L
DN
A F
K
B
DN A B C
T 5.1
(mm) 65 201 156 120
80 232 190 136
100 255 212 148
125 284 238 164
Yasmin Fernández
150 314 265 180
200 378 320 217
250 450 453 310
300 545 477 310
Valve design Flanged dimensions
ISO 16136: 2005 EN 558-1,ANSI B16.5 Class 150,JIS B2220, BS/E
6. INSTALLATION AND COMMISSIONING
Before starting the installation process, check that you have all the parts needed for the valve assembly, and that the materials, connection
type and nominal pressure are suitable for the installation.
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.
To install the valve, follow best installation practice recommendations provided on the Cepex website, paying particular attention to thermal
expansion and pipe alignment.
When filling the pipes with liquid, check that all the air is purged from the system and that the initial pressure does not exceed the nominal
pressure of the valve, or of the system element with the lowest nominal pressure rating.
Valve assembly using standard ISO-DIN, ANSI, JIS and BS/E flanges. Flat gaskets are not needed in the socket couplings, as they are
incorporated in the valve itself. Observe the tightening sequence of the screws on the flanges (Fig. 5) and the maximum tightening torque.
It is essential that all the screws are installed in order to ensure proper operation of the valve.
The PP/PE sockets for butt welding must be chamfered as indicated in the diagram (Fig. 6) and table (T6.2), to ensure correct opening and
closing of the disc.
Install the valve once the sockets are solvent-bonded and dry, to avoid problems with the adhesive (entry of the latter into the valve).
Flanges must be well centred on the valve (pay special attention to measurements DN100-DN125 and DN200). Assembly misalignment
could cause problems with the valve operation.
Fig. 5
Fig. 4
Fig. 6
PP/PE sockets
DN250-
Pipe and chamfer
DN300
measurements
1 T 6.2
x
1
1
2
1
1
1
7. OPERATION AND MAINTENANCE INSTRUCTIONS
1
8
It is recommended that the condition of the sealing gasket is checked regularly, since it may display signs of mechanical wear due to
pressure, handling and contact with the liquid. The sealing gasket should be greased in the disc contact area (the grease must be compatible
1
with the materials of the gasket and the disc). It is also advisable to check regularly that the flange fixing nuts are tightened correctly, as per
4 the recommended torque values specified above (T6.1).
In long periods of inactivity, and in case that the installation allows it, maintain the valve slightly open.
1
The manual gearbox is maintenance-free and greased for life.
- To operate the valve, unlock the handle (13) removing the pin (16) and pulling the lever (15) upwards, releasing its teeth from the throttle
plate (15) then turning the handle in the appropriate direction.
-
To lock the valve, re-insert the pin (16) and, optionally, secure with a padlock.
-
7.1 Replacing the Sealing Gasket
- Should it be necessary to replace the sealing gasket, proceed as follows:
· Ensure that the system is depressurised by releasing the pressure and emptying the pipes, following the
-
specific safety regulations of each product. Also check the temperature of the liquid and follow safety stan-
dards of temperature.
-
· Remove the valve from the installation.
-
· Remove the handle as per 7.2, screws (20), nuts (21) and throttle plate (17).
· Remove the ring (8). Take off the cap (7) and remove the screw (12).
2
· Tap on the shaft (6) with a rubber mallet until the bearing (4) is exposed from the bottom (Fig. 7).
2 · Once the bearing is out, remove the shaft (6), turn it and re-insert it (Fig. 8) from the bottom.
· Tap again until the bearings (4 and 5) emerge from the top. Remove the shaft again.
-
· Remove the disc by pressing in the direction of the liquid.
· Remove the sealing gasket. Fit the new sealing gasket; it needs to be warped and placed so that it lines up
1
with the shaft, according to the indication tab of the gasket (Fig. 9).
4
WARNING: Before installing the new gasket, check the condition of the O-rings (9 and 11).
7.2 Assembling and Removing the Handle
To assemble the handle:
· Fit the handle on the shaft while holding the lever. Place it so that, with the valve closed, the handle indicator
shows 90º on the throttle plate (17).
· Fit the washer (14), screw (22) and cap (19).
To remove the handle:
· Remove the round cap (19) from the handle, the screw (22) and the washer (14).
· Press the lever (15) fully upwards so that its teeth are fully disengaged from the teeth on the throttle plate (17).
· Remove the handle from the shaft (6).
9.

TROUBLESHOOTING

FAULT
The disc does not fully open or close. The sockets were not correctly bevelled.
Foreign materials in the compartment (adhesive, etc.).
Excessive opening or closing torque. The valve has been inactive for a long time.
Overtemperature or chemical attack cause damage to
the gasket.
Excessive flange torque.
Misalignment between sockets and valve.
The valve is not fully watertight at Misalignment between sockets and valve.
the sockets.
Flange screws not tight enough.
m 3 /s
The valve is not completely Inadequate chemicals.
ft 3 /min
watertight at the sealing gasket . Temperature out of range.
Excess pressure.
Conduction of abrasive elements.
DN300 Damaged sealing gasket.
250
2213
INDUSTRIAL BUTTERFLY VALVE
M
DN250-300
Fig. 3
N
G
S
E
E DN
F
C
K
B
H
E F G H K L M
40 18 112 48 125-145 220 70
40 19 112 52 150-170 245 70
40 19 112 59 180-192 245 70
40 22 112 66 190-215 320 70
40 24 112 72 240 320 70
50 23 136 73 270-298 391 102
525 29 488 114 329-355 - -
616 29 578 114 384-427 - -
Valve connections Other connections
EN 1090-1 ISO15494, ISO15493, ISO10931
Screws and screw tightening torque
D DN inch
63 65
75 65 2 1/2"
90 80
DN D min. x
110 100
65 50.5 30º
125 125
80 70 30º
140 125
100 91.5 30º
160 150
125 113 30º
200 200
150 141 30º
225 200
200 191.5 20º
250 250
250 226 20º
280 250
300 296.5 20º
315 300
T 9.1
POSSIBLE CAUSE
Disassemble the valve and bevel the sockets as indicated
in table T6.2.
Disassemble the valve and check for obstructions in the
disc and gasket contact area.
Operate with an auxiliary release key (not plastic handle).
Disassemble the valve and lubricate the sealing gasket.
Check the chemical compatibility of the liquid with the
disc and the working temperature. Replace the gasket.
Tighten flanges as indicated in section 6.
Disassemble the valve and reassemble with concentric
alignment (observe the correct tightening sequence and
torque).
Disassemble the valve and reassemble with concentric
alignment (observe the correct tightening sequence and
torque).
Tighten flanges as indicated in section 6.
Check compliance with the specifications in this
document.
Replace the gasket.
V1.0 (05/2014)
E
E
H
N E' S HOLES
9 35 10 4
9 35 12 8
9 35 16 8
9 35 20 8
9 35 20 8
11 47 26 8
- 57 18 12
- 57 18 12
Actuator coupling (optional)
EN/ISO 5211
T 6.1
Screws (A2) Torque Torque
(N·m) (inch·lbs)
- 4xM16x120 25 221
4xM16x140 25 221
3" 8xM16x150 25 221
4" 8xM16x160 30 265
- 8xM16x170 35 310
5" 8xM16x170 35 310
6" 8xM20x200 40 354
- 8xM20x210 50 442
8" 8xM20x230 50 442
- 12xM20x270 80 708
10" 12xM20x270 80 708
12" 12xM20x310 80 708
Fig. 7 Fig. 8
Fig. 9
FAULT CLEARANCE
15/10/2014 10:09:58