BA50E107 Operating Instructions ROCO Butterfly Valve with SKG slider-crank mechanism, with electric actuator

BA50E107 Operating Instructions ROCO Butterfly Valve with SKG slider-crank mechanism, with electric actuator 1 General 2 Safety Aspects 3 Product and Performance Description 4 Design Features of ROCO Butterfly Valve 5 Transport 6 Storage 7 Installation into the Pipeline 8 Initial Operation 9 Operation and Application 10 Maintenance 11 SKG Slider-crank Mechanism 12 Electric Multi-turn Actuator 1 General The technical data of the order are binding for the type of design. Modifications can only be considered if they are specified to us in time before starting production. Every ERHARD valve is checked for completeness, performance, and tightness before leaving the factory. In case of non-compliance with these Operating Instructions, we cannot be made liable for any damages or troubles resulting thereof. We reserve the right to technical modifications as against the data and representations contained in these Operating Instructions in case this should be necessary for improving the valves. 2 Safety Aspects ERHARD valves are reliable and designed to the state of the art. However, these valves can be a danger when handled by untrained staff in an inexpert manner or when they are not used in accordance with their duty and purpose. Whoever in the user s works is engaged in mounting, dismantling or remounting, operation and service (inspection, maintenance, repair) of the valves, is supposed to have read the complete Operating Instructions and to have understood them. The user is recommended to have the person involved confirm this fact in writing in each particular case. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 1/13

Before removing safety devices and/or carrying out work on the valve, the pipe section must be made pressureless leaving no risk, e.g. by lowering the weightloaded lever if any. Unauthorized, erroneous and unexpected operation as well as dangerous movements caused by stored energy (compressed air, compressed water, hydraulic) must be avoided. When using the valves, observe the approved technical rules, e.g. DIN standards, DVGW prints, VDI rules, VDMA standards, etc. For valves which must be supervised, observe the relevant laws and regulations, e.g. trading regulations, regulations for prevention of accidents, steam boiler regulations, regulations for gas mains under high pressure, regulations for combustible liquids as well as technical regulation works TRD, SR, TRG, TRbF, TRGL, TRAC, UVV, AD instructions etc. The local safety regulations and rules for prevention of accidents are applicable. If work is carried out in the vicinity of the valve, which leads to soiling (concrete work, masonry, painting, sandblasting), the valve must be covered effectively. 3 Product and Performance Description 3.1 Product Description ROCO Butterfly Valve to DIN 3354, part 2 with flanges, double-offset shaft bearing, resilient-seated, tightly closing, of ductile cast iron. Operation by SKG slider-crank mechanism by means of handwheel, extension stem, underground installation set, chain wheel, electric multi-turn actuator. Nominal sizes: DN 80, 100, 125 Pressure ratings: PN 16, 25 Prod. No.: 5065... PN 16 5066... PN 25 3.2 Performance Description (see fig. 1) A valve disc (3) hinged in the body (1) is moved through an actuating shaft (7) which protrudes into a laterally mounted part-turn gearbox. The pipeline is isolated, when the valve disc is vertical to the flow direction. Tight closure on the seat in the body is achieved by a sealing element vulcanized on the valve disc. The travel between OPEN and CLOSED position (90 swinging movement) is limited by means of stop nuts on the actuating stem of the attached part-turn actuator. Normally, the valve closes in clockwise direction (turning the handwheel to the right). 4 Design Features BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 2/13

Figure 1: Sectional drawing of ROCO Butterfly Valve DN 80-125 Part Description Spare part 1 Body 2 Bearing bush 3 Valve disc 4 Trunnion 5 Actuating shaft 6 Taper pin 7 Threaded pin 8 Clamping ring 9 Back-up ring X 10 O-ring X 11 O-ring X 12 Cylindrical screw 13 Parallel key Main sealing: internally and externally rubber-coated valve disc with vulcanized sealing element, optimum corrosion protection, maintenance-free. Body seat: rolled-in solid seat ring of stainless steel. Connection key/valve disc by taper pins. Gearbox connection: to pren 12116 (DIN ISO 5211), round spigot with parallel key. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 3/13

Shaft sealing by means of back-up rings and enclosed O-rings (10). When the gearbox is disassembled, the shafts (4, 5) and shaft sealing are protected against blowing-off. Shaft bearing: maintenance-free and self-lubricating plain bearings (2). 5 Transport Transport has to be carried out carefully. Inexpert handling may cause damages to the valve. Prior to mounting, such damages are to be repaired in an appropriate manner. Valves too heavy to be handled manually have to be transported by means of lifting gears suitable for the weight involved, e.g. broad belts. They have to be placed around the body, e.g. between the two connecting flanges. Valves with eyebolts or lugs have to be suspended at these devices in an appropriate manner. It is not allowed to attach the lifting gears to the handwheel, the stem, the gearbox case or to the flange holes which would be contrary to the relevant safety regulations. 6 Storage Do not store the valves outdoors. During the storage period, the valves have to be protected against outside influences and impurities, e.g. by covering them with a tarpaulin. Store valves standing on their feet. Store valves without feet flat on their connecting flange by means of intermediate boards. If long-time storage is required, the place of storage should be selected in such a way that the following conditions are met: frost-protected - cool - dry - dust-free - dark (for elastomer UV-light is inadmissible). If it is impossible to comply with these conditions, the valves must be packed to meet these requirements, e.g. they have to be welded in dark foil. 7 Installation into the Pipeline Remove all packing material from the valve. Prior to installation, check the pipeline for impurities and foreign bodies and clean it if necessary. Attention! It is important that all around the valve there is free access for operation and maintenance. For outdoor installation, the customer has to protect the valve against direct effects of the weather. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 4/13

During installation of the valve, the distance between the pipe flanges should exceed the valve face-to-face dimension by at least 20 mm. Thus, the raised faces will not be damaged and the gaskets can be inserted. Steel-reinforced rubber seals are recommended to be used as flange gaskets (consider resistance to flow medium and temperature), for slip-on flanges they are absolutely necessary. The mating pipe flanges must be plain-parallel and concentric. Tighten the connecting bolts evenly (without distortion) and crosswise. The pipeline mustn t by any means be pulled up to the valve. ROCO Butterfly Valves can be installed in any position. In open position the valve disc exceeds the valve face-to-face dimension. Keep corresponding distance to any fitting or valve, e.g. check valve. 8 Initial Operation After installation, check valve for smooth operation: move the valve over the total travel (Open Closed) by means of operating element. 9 Operation and Application 9.1 Admissible Operation The valve is designed for flow from the direct side (A preferred flow direction) as well as from the indirect side (B). The valve is operated by means of the handwheel, chain wheel or operating key to DIN 3223. It is not permissible to apply excessive forces. Max. admissible flow velocities: PN 16: 5 m/s PN 25: 6 m/s 9.2 Inadmissible Operation Installation behind elbows or similar disturbing installation parts is to be prevented. Long-time operation in throttled position leads to higher wear. When the valve is used as throttling valve, it has to be checked whether the valve is suitable for the operating conditions. Do not exceed limiting values of the flow medium temperature. Do not exceed limiting values of the working pressure. Closed valve may only be charged up to the nominal pressure. For EPDM profile sealing rings and sealings: rubber parts must not get in contact with oil or grease (EPDM swells!). BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 5/13

10 Maintenance 10.1 Maintenance and Inspection ROCO Butterfly Valves are equipped with maintenance-free plain bearings. Gearbox stem and gearbox bearing are of the long-time lubricating type. Control of the performance and tightness is to be done regularly in intervals of <= 4 years according to DVGW print W390. Before carrying out work on the valve, the repair valve must be closed and the pipe section must be made pressureless. Check external condition of the valve including operating gear. If necessary clean the valve and patch the coating. Check tightness at flanges. Check well-running of valve and operating gear. Move valve manually over total travel. Check seat tightness: close the valve. Check pressure drop upstream and downstream of the valve. 10.2 Readjustment and Repair 10.2.1 Readjustment and Replacement of the Sealing Element The sealing element is securely vulcanized on the internally and externally rubber-coated valve disc and dimensioned in such a way that the Butterfly Valve is leaktight under all operating conditions. Therefore, readjustment of the sealing is not required and also not possible. In case of leakage, the complete valve disc has to be replaced at our works. 10.2.2 Replacement of the Shaft Sealing (Drive Side Only) Required spare parts: shaft sealing set consisting of O-rings (10), 2 Nos., and back-up rings (9), 2 Nos. Remove gearbox/part-turn actuator from the valve (see chapter 11). Remove parallel key (13). Loosen cylindrical screws (12) and remove clamping ring (8). Remove O-rings (10) and back-up rings (9). Clean installation area. Install shaft sealing in the following order one after another: back-up ring/o-ring/back-up ring/o-ring (9, 10). Please take care that no damage occurs to the O-rings at the groove of the parallel key. Install clamping ring (8) with cylindrical screw (12). Install gearbox/part-turn actuator (see chapter 11). BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 6/13

11 SKG Slider-crank Mechanism 11.1 Design Features Design (Figure 4): Attachable quarter-turn gearbox according to the slidercrank principle. The rotation of the stem (2) is changed into a swinging movement of the gearbox crank by means of the stem nut (5) and the gearbox bracket (8) (articulated lever). The gearbox crank is rigidly connected to the valve shaft by means of the output shaft. The slider-crank mechanism is irreversible. Cast iron encapsulated gearbox case totally enclosed (enclosure rating IP68). Interfaces: Output: to pren 12116 (DIN ISO 5211), round spigot with parallel key. Output: Flanged bearing with round trunnion for receiving the handwheel, chain wheel, extension stem or underground installation set or flange to DIN 5210, shape B1 (plug socket) for connecting an electric multi-turn actuator. Limit Stops: Solid stop nut (6) on the stem (2). CLOSED position is adjustable. Exceeding load will be absorbed by the stem and does not affect the case components of the gearbox. Maximum input torque : 450 Nm (in the limit positions). Position Indicator: The indicator which is directly connected to the valve shaft is visible through a sight glass on the gearbox case. The sight glass is made of impact resistant polycarbonate (PC) and thus suitable for plant, pit and underground installation. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 7/13

Mechanism design for mounting multi-turn electric actuator Mechanism design for handwheel, buried installation, stem extension Figure 4: Sectional drawing of slider-crank mechanism SKG Part Description Spare part Part Description Spare part 1 Gearbox casing 16 Indicator 2 Stem 17 Cover 3 Bearing ring 18 Gasket 4 Axial bearing 19 Cylindrical screw 5 Stem nut 20 Sight glass 6 Stop nut 21 Flanged bearing 1) 7 Retention pin 22 Neck bearing 2) 8 Bracket 23 Bush 9 Gearbox crank 24 O-ring 1) 10 Bush 25 Hexagon screw 11 Riveting bolt 26 Washer 12 Output shaft 27 Parallel key 13 Threaded pin 28 Follower bush 2) 14 Bush 29 Close-tolerance grooved pin 2) 15 Bush 30 Parallel key 2) 1) Parts only applicable for design with handwheel, for underground installation and extension stem 2) Parts only applicable for design for/with electric multi-turn actuator BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 8/13

11.2 Operation and Application SKG slider-crank gearboxes are used for operating valves with an operating travel (part-turn movement) of up to 90. Manual operation by means of handwheel, chainwheel, underground installation set, operating key. Motor operation by means of electric part-turn and modulating actuators. SKG gearboxes are suitable for plants and pit installation as well as buried and under-water installation up to a max. flooding height of 6 m water column. 11.3 Mounting Attention: Prior to mounting the SKG gearbox to the valve, ensure that both parts are in the same limit position OPEN or CLOSED. Plug output shaft (12) onto the valve shaft up to the flange (see fig. 5) and lock by threaded pin (13). Screw indicator (16) into the centering of the valve shaft and align it parallelly to the valve disc. Grease the toothing of the output shaft (12). Plug the gearbox and draw the fastening screws crosswise with torque according to table 2. Mt [Nm] M10 48 M12 85 M16 210 M20 410 screws of gearbox. Table 2: Tightening torques for fastening Fig. 5: Mounting of output shaft BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 9/13

11.4 Setting the Limit Stop ( CLOSED Position) (Fig. 4) Remove cover (17) and gasket (18) by loosening the cylindrical screws (19). Raise the retention pin (7) of the stem nut (6) by means of a slotted screwdriver pressing the screwdriver into the groove provided for this purpose between stop nut and annular spring. The stop nut can be positioned by turning the screwdriver. Having reached the position of the stop nut, draw off the screwdriver. Then slightly carry on turning the stop nut until the retention pin is perceptibly caught. Check swinging angle by opening and closing of the valve. Mount cover (17) 11.5 Maintenance Stem (2) and axial bearing (4) have a long-time lubrication. The performance of the valve should be checked regularly at least every four years according to DVGW print W 392. Regreasing the Trim of the Stem Gearbox Move valve into OPEN position. Unscrew hexagon screws (25) for fixing the neck bearing/flanged bearing (21/22) and remove them. Screw-out stem (2) by turning to the right until reaching stop nut. Lift off bearing ring (3) so that the whole stem will be accessible. Unscrew cover (17) by turning off the cylindrical screws (19). Grease stem, axial bearing and sliding ways of stem nut. Mount gearbox vice versa and operate it several times. Lubricating agent Manufacturer Standard ALVINA Fett R3 SHELL DIN 51502 K-L3n TEXANDO FO20 TEXACO DIN 51825 K-2n Table: Recommended lubricating agents BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 10/13

12 Electric Multi-turn Actuator The electric actuator is mounted on the neck bearing of the stem gearbox. The standard type is equipped with: Torque and travel limit switches with 1 make and 1 break contact each Blinker transmitter for indication of running operation Thermal switch in the motor winding The valve is switched off in the following manner: in closing direction travel dependent in opening direction travel dependent. The switching points of the travel and torque switch are set at the factory. Moreover, the torque switches serve as safety switches, e.g. in intermediate positions. When the valve is supplied without mounted electric actuator, the travel switches have to be adjusted after mounting the electric actuator. See paragraph "Initial Operation: Resetting the limit switches" (12.2). Observe the relevant safety measures (VDE/TAB, etc.) and the instructions of the manufacturer of the electric actuator concerning transport, storage, initial operation and maintenance. For the electrical connection, observe the suggested wiring and terminal diagram supplied by the manufacturer of the electric actuator (travel, torque and thermal switches, motor, and heating device in case). Measure the insulating resistance of the motor prior to connection. (If it is less than 500 K-ohms, this shows that there is moisture in the winding. Remove the motor for dryingup and heat it by means of a hot-air fan or in a heating chamber: max. admissible temperature 100 C). Compare the existing voltages with the data on the name plate. After connection, the covers and the cable glands on the electric actuator have to be closed and sealed carefully. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 11/13

12.1 Jogging Operation and Manual Emergency Operation A t t e n t i o n : If a foreign body is jammed in when closing the valve, the corresponding torque switch responds and switches off the motor. The time lag between response of the torque switch and disconnection of the motor from the network depends on the signal delay. If a new closing order is given before the valve has been opened sufficiently, the torque will increase. If this procedure is repeated several times, the torque will accumulate. The valve and its operating elements are not designed for such an emergency. We explicitly draw your attention to the fact that such jogging operation is inadmissible. Jogging is only admissible under the following conditions: If the torque switch responds in intermediate position, the valve must first be moved in the opposite direction until the torque switch completely returns to its original position. Only now the valve may be moved again in the direction in which the disturbance occurred. Proceeding this way, you will obtain torques corresponding to the torques set at the torque switch. Moreover, the foreign matter can come off and be flushed out of the seating zone. Operation by Emergency Handwheel: If the valve is operated by means of the handwheel of the electric actuator, the torque switches do not provide any safety function. If a foreign body is jammed with the valve being in intermediate position, excessive operating force particularly in case of high gear reduction might be damaging to the actuating components. If any resistance is detected during emergency handwheel operation, some turns must be made in the opposite direction before the valve is moved in the direction in which the disturbance occurred (flush out the foreign body). Continue operation with utmost care, in no case using excessive force. If need be, repeat flushing operation. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 12/13

12.2 Initial Operation: 1. Turn the valve manually to central position. 2. Check movement of the indicator at the stem gearbox and thus the direction of rotation of the actuator by brief electrical starting. 3. In case of faulty direction of rotation, change the poles of the motor connection. 4. Check once again the direction of rotation shown by the indicator by means of brief electrical starting. 5. Check disconnection of the torque and travel switches in OPEN and CLOSED directions by operating the switches manually in central position. 6. Change poles if necessary. 7. Carry out complete travel only when the correct direction of rotation and disconnecting performance are ensured. In case of faulty direction of rotation, the travel and torque switches do not work. Resetting the limit switches: 1. Move the valve manually against the limit stop in position C of the indicator. 2. Return by one turn of the stem. 3. Adjust OPEN travel switch according to the operating instructions for the electric actuator. 4. Move the valve manually against the limit stop in position B of the indicator. 5. Return by one turn of the stem. 6. Adjust the CLOSED" travel switch according to the operating instructions for the electric actuator. If the proposed measures are not respected, we are not prepared to be made liable for probably occurring damages. BA50E107 Erhard GmbH & Co D-89502 Heidenheim Postfach 1280 Page 13/13