Angle seat valve with piston actuator VZXA-...-K

Transcription

1 Angle seat valve with piston actuator VZXA-...-K Instructions Operating (Translation of the original instructions) Festo AG & Co. KG Ruiter Straße Esslingen Germany a [ ] 2.3 Training of specialized personnel Work on the product should only be conducted by qualified personnel. The qualified personnel must be familiar with installation of process automation systems. 3 Further information Accessories Spare parts 4 Service Contact the regional Festo contact if you have technical questions 5 Information on functional safety 5.1 Attainable safety rating The product is suitable for use as an element in a safety-related system in accordance with IEC In low-demand mode up to SIL 2 In high-demand mode up to SIL 2. Taking into account the necessary minimum hardware fault tolerance from HFT = 1, the product can also be used up to SIL 3 with a redundant design of the entire system. Note The suitability for certain applications can only be determined in connection with the evaluation of further components of the subsystem. Angle seat valve with piston actuator VZXA-...-K... English 1 About this document This document describes the use of the above-mentioned product. It contains additional information for the implementation of the product in safety-oriented systems (safety handbook in accordance with IEC 61508). For all available product documentation Specified standards Version status IEC :2010 part 1, 2, 4 7 IEC 61511:2016 Fig. 1 2 Safety 2.1 General safety information The product may only be used in its original status without unauthorized modifications. Use the valve only in the flow direction indicated. Only use the product if it is in perfect technical condition. Take into consideration the ambient conditions at the location of use. Media Only use media in accordance with specifications Technical data. Use only media that will not cause dangerous reactions if mixed. Do not operate the product with chemically unstable gases, abrasive media or solid materials. If water is used: up to approx ppm of chloride content is permitted. Avoid tensile stresses. If aggressive media are used: limit temperature of medium to 65 C. Actuator Do not open the actuator (pressure in the actuator or loaded spring). Avoid mechanical loads on the valve. Do not use the actuator as a lever. Returning to Festo Hazardous substances can endanger the health and safety of personnel and cause damage to the environment. To prevent hazards, the product should only be returned upon explicit request by Festo. Consult your regional Festo contact. Complete the declaration of contamination and attach it to the outside of the packaging. Comply with all legal requirements for handling hazardous substances and transporting dangerous goods. 2.2 Intended use The angle seat valve VZXA-...-K is intended to shut-off gaseous or liquid media in piping systems. To control liquid media, use only the product variant VZXA-B... (medium flow under the valve seat). 5.2 Safety function Single-acting valves The safety function consists of taking the initial position on request. The request is made by removing the operating pressure. Valves with control function NO: The valve opens completely and remains open until operating pressure is applied. Valves with control function NC: The valve closes completely and remains closed until operating pressure is applied. Double-acting valves The safety function consists of taking the desired position on request. Supply of external energy is required for this. 5.3 Operating conditions General notes on safe operation Chapter 2. Periodic tests (performance test) Chapter 12. Ambient conditions and additional technical specifications Chapter Limitations of application The service life is not limited if the operating conditions are complied with. Maximum admissible interval for a complete performance test: seven years. 5.5 Characteristic values Safety standards (in accordance with IEC 61508) Value Route of assessment 2 H / 1 S Type of Sub System Type A Mode of Operation Low Demand and High Demand Assumed Test Interval T i 1 a Confidence Level 1-á 95 % Hardware Fault Tolerance HFT 0 Lambda ous ë D 1, / h Lambda ous Undetected ë DU 1, /h Mean Time To ous Failure MTTF D 7, h Proof Test Coverage PTC 95 % Low Demand Mode Assumed Demands per Year n op 1 / a Average Probability of Failure on Demand PFD avg 5, High Demand Mode Assumed Demands per Year n op 1 / h (8760 / a) Probability of dangerous Failure per Hour PFH 1, / h Fig. 2

2 6 Product overview 6.1 Design Function The angle seat valve VZXA-...-K is an externally controlled 2/2-directional control valve with piston actuator. The valve seat is slanted around 40 toward the medium flow. To close the valve, the valve actuator using the actuator rod presses the valve disc into the valve seat in a force fit. The supply of the operating medium is controlled by an external valve (usually electrically controlled) that must be additionally integrated into the supply line for the actuator. The actuator can be rotated 360 on the valve housing. Flow over valve seat The valve is closed by spring force with the medium flow. Medium pressure supports the valve closing. Opening the valve with operating pressure. Only suitable for gaseous media, because when incompressible media are used, pressure surges are caused in the piping. Flow under valve seat The valve is closed by spring force or with operating pressure against the medium flow. Medium pressure supports the valve opening. In certain constructions, medium pressure that is too high or operating pressure that is too low can lead to the valve not completely closing. Control function Single-acting Double-acting 1 Position indicator ( Fig. 6) 2 Pneumatic connection (2) 3 Actuator housing 4 Pipe connection; Feed or forwarding (depending on flow direction) Fig. 3 5 Leakage hole 6 Arrow for direction of flow 7 Valve housing 8 Actuator interface / angle seat valve with spanner flat 9 Pneumatic connection (4) Closed via spring force or through reduced spring force (normally closed - NC) Opened via spring force (normally open - NO) Opening and closing by twoway pressurising with operating medium (compressed air) 6.2 Product variants and type code Fig. 4 explains selected product characteristics that are necessary to understand the instructions. Description of the complete type code: Fig. 5 Position indicator The pneumatic position indication shows the position of the actuator rod. Indicator cylinder above Indicator cylinder below Characteristic Value Description Type VZXA Angle seat valve Medium flow A Over valve seat - closing in the direction of medium flow (for gaseous media) B Under valve seat - closing against the direction of medium flow (for gaseous and fluid media) Connection type TS6, TS7, TS13 Line connection and connection standard Fig. 10 Temperature M C of medium M C Valve housing material V13 Stainless steel V14 Stainless steel ASTM A351-CF3M Seat seal material TP PTFE modified T PTFE Medium pressure 4 to bar to 0 30 bar Actuator K Piston actuator Actuator size 46, mm, 75 mm Control function Closed via spring force, NC D Double-acting S Opened via spring force, NO PR Closed via reduced spring force, NC Actuator rod retracted, valve opened Fig. 6 Actuator rod extended, valve closed 7 Transport and storage When shipping used products: comply with all legal requirements for handling hazardous substances and transporting dangerous goods. For return to Festo Chap. 2. Store the product in a cool, dry, UV- and corrosion-protected environment. Ensure that storage times are kept to a minimum. Fig. 4

3 8 Mounting and installation For angle seat valves VZXA-...-K46-..., use only fittings Gx with max. SW Installing the angle seat valve Requirements The piping system is unpressurised and no medium flows in it. Lines are clean. The line ends are mounted. Clean valve Remove all transport packaging. The material used in the packaging has been specifically chosen for its recyclability (exception: oil-impregnated paper = residual waste). Traces of residual grease may be evident on the product due to the production process used. Clean the valve immediately before installation. Warning Risk of injury due to slipping or falling objects! The angle seat valve can weigh up to 5.75 kg, depending on the product version. Body parts can be crushed. In overhead installations, the result can be serious head injuries. Secure angle seat valve against falling or slipping using appropriate means of securing. 1. Bring the angle seat valve into the mounting position. Observe the flow direction. The permitted direction of flow is marked by an arrow on the valve housing. 2. Connect the piping on the valve housing. Max. tightening torque Fig Connect the line of the operating medium. Pneumatic connection (2): operating medium. Pneumatic connection (4): exhaust port for single-acting actuators or operating medium for double-acting actuators. 4. For single-acting actuators: mount the silencer in the exhaust port or use a tubing connection for guided exhaust air. Connection size [ ] ½ ¾ 1 1¼ 1½ 2 Max. tightening torque pipe [Nm] connection Fig. 7 9 Commissioning Warning Risk of injury from manipulation in the area of the angle seat valve! Limbs can be cut or severed. Place only the fully assembled angle seat valve in operation. Requirements The valve is fully mounted and connected. Checking operating conditions Comply with the operating conditions and limit values Technical data and product labelling. Check connection points for tightness. Check compatibility of the devices in the system for maximum pressure (consider pressure peaks). If necessary, adjust the application parameters. Place the valve with single-acting actuators into operation 1. Supply medium. 2. Slowly apply operating pressure to the valve. The operating pressure required for reliable switching of the valve depends on the medium pressure Fig. 12 to Fig Function and direction control of the individual pneumatic actuators. Placing the valve with a double-acting actuator into operation 1. Slowly apply operating pressure to the valve. The operating pressure required for reliable switching of the valve depends on the medium pressure Fig. 12 to Fig Add medium. 3. Function and direction control of the individual pneumatic actuators. 10 Operation Risk of injury from touching hot surfaces! Valve and actuator can become hot at high temperature of medium. Severe burns are possible. Do not touch the angle seat valve during operation or immediately afterward. Comply with operating conditions. Comply with maintenance conditions Chap. 12. After longer standstills: Actuate the valve several times and check for correct function. 11 Malfunctions Malfunction Possible cause Remedy Valve does not close or closes too slowly Valve does not open or opens too slowly Medium leaks from a leakage hole Medium will not let itself be shut off Fig Maintenance VZXA-B: medium pressure is too high or operating pressure too low Too many contaminants, or contaminants that are too large, in the medium VZXA-A: operating pressure is too low or medium pressure too high VZXA-B: operating pressure is too low Seal cartridge defective Seat seal defective Create necessary differential pressure Technical data. Adjust operating pressure. Comply with operating conditions. Adjust operating pressure or medium pressure. Adjust operating pressure. Replace seal cartridge Spare parts documentation. Replace seat seal Spare parts documentation. Risk of injury from touching hot surfaces! Valve and actuator can become hot at high temperature of medium. Severe burns are possible. Allow the angle seat valve to cool off before working on it. Check product regularly from the outside for leakage. Check function of the product regularly. Clean product regularly with commercial cleaners Proof Test The proof test consists of turning the operating pressure off and back on. Perform the proof test annually. During the proof test, the safety of the application must be ensured. 1. Switch off the operating pressure. 2. Check valve position. The test is successful if the safe status is reached within the specified time. For evaluation of the safe status Chapter Slowly apply operating pressure to the valve. The test is successful if the valve takes its original position again. 4. Check the valve externally (visual inspection). The test is successful if no defect or leakage is detected. 5. Document test results.

4 13 Conversion 14 Removal Risk of injury from items flying around! If they are not secured well enough, parts under pressure can fly around and injure people. Before exchanging wearing parts, depressurise the valve and piping. Risk of injury from touching hot surfaces! Valve and actuator can become hot at high temperature of medium. Severe burns are possible. Allow the angle seat valve to cool off before working on it. 1 Risk of injury due to movement of pressurised parts! The angle seat valve can switch if there is a drop in pressure. Limbs can be cut or severed. Before removal, move the valve to the closed position. Before removal, depressurise the valve and the piping. 2 1 Wrench flat for counter holding 2 SW46 Interface screw Fig Remove the actuator from the valve housing in built-in state The actuator can be disassembled from the valve housing without having to remove the valve from the piping. 1. Depressurise pipelines and let the valve cool off. 2. Secure the actuator from falling or slipping with appropriate means of securing. 3. Extend the actuator rod. With double-acting valves: pressurise connection (4) (3 bar). With valves with NO control function: pressurise connection (2) (3 bar). With valves with NC control function: exhaust the actuator. 4. Loosen interface screw ( Fig. 9, 2 ). 5. Remove actuator from the valve housing. 6. Switch off the operating pressure Remove actuator from the valve housing in removed state 1. Extend the actuator rod. With double-acting valves: pressurise connection (4) (3 bar). With valves with NO control function: pressurise connection (2) (3 bar). With valves with NC control funct2ion: exhaust the actuator. 2. Loosen interface screw ( Fig. 9, ). 3. Remove actuator from the valve housing. 4. Switch off the operating pressure. Warning Risk of injury due to slipping or falling objects! The angle seat valve can weigh up to 5.75 kg, depending on the product version. Body parts can be crushed. Secure angle seat valve against falling or slipping using appropriate means of securing. 1. Depressurise the piping and the operating medium connection line. Allow the valve and piping to cool. 2. Empty the piping and valve completely. Make sure no one is located in front of the outlet opening. Catch discharging media in a suitable container. 3. Disconnect the operating medium connection line from the valve. 4. Loosen piping connectors. 5. Remove angle seat valve. 15 Disposal Observe the local regulations for environmentally friendly disposal. Dispose of the product in an environmentally friendly manner. When doing this, also take residual media into account (potential recycling of hazardous waste) Mount the valve housing onto the actuator 1. Extend the actuator rod. With double-acting valves: Pressurise connection (4) slowly (3 bar). For valves with NO control function: Pressurise connection (2) slowly (3 bar). With valves with NC control function: exhaust the actuator. 2. Slide spindle of the process valve completely into the process valve. 3. Place actuator onto valve housing. 4. Tighten interface screw ( Fig. 9, 2 ). Tightening torque: 50 Nm 5. Switch off the operating pressure Turning the actuator 1. Loosen interface screw (max. ½ turn) ( Fig. 9, 2) 2. Turn the actuator into the desired position. 3. Tighten interface screw ( Fig. 9, 2 ). Tightening torque: 50 Nm

5 16 Technical data General VZXA-A-...-K-... VZXA-B-...-K-... Design Piston actuator with poppet valve Mounting position Any Type of mounting In-line installation Valve function 2/2 Flow direction Non-reversible Medium 1) Compressed air grade of filtration 200 μm, inert gases, vapour Compressed air grade of filtration 200 μm, inert gases, water, petroleum, neutral liquid media, petroleum based hydraulic oil, vapour 0 30, in accordance with the specification on the rating plate Viscosity [mm 2 /s] š 600 Temperature of medium [ C] Seat seal material: PTFE modified Seat seal material: PTFE Perm. min./max. temp (TS) [ C] Seat seal material: PTFE modified Seat seal material: PTFE Ambient temperature [ C] Operating medium Compressed air in accordance with ISO :2010 [7:4:4] Max. 10 ( Fig. 12 to Fig. 27) Degree of protection for the actuator IP65, IP67, IP67K (with guided exhaust air) Valve housing connection VZXA-...-TS6 Threaded collar in accordance with DIN ISO 228 VZXA-...-TS7 Threaded collar in accordance with ANSI/ASME B VZXA-...-TS13 Threaded collar in accordance with DIN Operating medium port Note on materials GÁ Valve housing VZXA-...-V13 Stainless steel casting (1.4409) Valve housing VZXA-...-V14 Seat seal VZXA-...-TP Seat seal VZXA-...-T Stainless steel casting (ASTM A351-CF3M) PTFE modified PTFE Actuator housing Stainless steel casting (1.4408) Piston actuator seals Actuator rod Actuator cover Product weight CE marking (see declaration of conformity 1) Other media on request Fig. 10 FPM High-alloy stainless steel Stainless steel casting According to EU Machinery Directive Nominal pressure, burst pressure and flow rate of process valve VZXA-...-TS Connection size [ ] ½ ¾ 1 1¼ 1½ 2 Nominal width DN Nominal pressure process [bar] valve PN (up to 200 C temperature of medium) Burst pressure (up to 200 C [bar] temperature of medium) Flow rate K 1) v VZXA-B [m 3 / h] VZXA-A [m 3 / h] VZXA-B [m 3 / h] VZXA-A [m 3 / h] ) Water, at +20 C, medium pressure 1 bar at the valve input, free outlet Fig. 11 Medium pressure and operating pressure for valves with medium flow under valve seat VZXA-B-...-K S (Medium flow under valve seat, NO) Nominal width DN Max. medium pressure [bar] Min. operating pressure [bar] Fig. 12 Fig. 13 DN13 VZXA-B-...-K S (Medium flow under valve seat, NO) Max. medium pressure [bar] Min. operating pressure [bar] Fig. 14 Fig. 15 DN40 VZXA-B-...-K D (Medium flow under valve seat, double-acting) Nominal width DN Max. medium pressure [bar] 16 6 Min. operating pressure [bar] Fig. 16 DN13 DN50 Fig. 17

6 VZXA-B D (Medium flow under valve seat, double-acting) Max. medium pressure [bar] Min. operating pressure [bar] Fig. 18 Medium pressure and operating pressure for valves with medium flow over valve seat VZXA-A-...-K PR (Medium flow over valve seat, NC with reduced spring force) Nominal width DN Max. medium pressure [bar] Min. operating pressure [bar] DN40 DN50 Fig. 24 DN13 Fig. 19 VZXA-B-...-K-46 (Medium flow under valve seat, NC) Nominal width DN Fig. 25 Max. medium pressure [bar] Min. operating pressure [bar] 4.8 Fig. 20 VZXA-B-...-K-75 (Medium flow under valve seat, NC) Max. medium pressure [bar] Min. operating pressure [bar] 4.6 VZXA-A-...-K PR (Medium flow over valve seat, NC with reduced spring force) Max. medium pressure [bar] Min. operating pressure [bar] Fig. 26 Fig. 21 DN40 VZXA-B-...-K PR (Medium flow under valve seat, NC with reduced spring force) Nominal width DN Max. medium pressure [bar] Min. operating pressure [bar] 2.6 Fig. 22 DN50 VZXA-B-...-K PR (Medium flow under valve seat, NC with reduced spring force) Nominal width DN Max. medium pressure [bar] Min. operating pressure [bar] 2.2 Fig. 23 Fig. 27