CONTROL VALVES FOR GRINDER Instlltion, Mintennce nd Operting Instructions 5 GA 71 en Issue 5/02
2 Tble of Contents 1 OPERATION......................... 3 1.1 Generl......................... 3 1.2 Min components................. 3 1.3 Automtic opertion............... 3 1.4 Mnul opertion................. 3 1.5 "Relese of pressure shoe" opertion.. 3 1.6 Opertion of solenoid vlves........ 3 2 MAINTENANCE...................... 5 2.1 Vlve GV652..................... 5 2.1.1 Replcing of set........ 5 2.1.2 Replcing of cover O-rings... 5 2.2 Cylinder ctutor GAL121 nd GAA121. 5 2.2.1 Chnging of piston sel..... 5 2.2.2 Chnging of piston rod sels.. 6 2.3 Chnge of ctutor mounting position. 6 2.4 Shft protection.................. 6 2.5 Updting series GV651 vlves....... 6 2.5.1 Shft end protection....... 6 2.6 Pointer mounting.................. 6 3 RECYCLING AND DISPOSAL OF A REJECTED VALVE.................. 6 4 DRAWINGS AND PART LISTS.......... 7 4.1 Grinder control vlve, GV652........ 7 4.2 Grinder control vlve, GV652........ 9 4.3 Grinder controls vlve, GV652Y.... 11 4.4 Actutor GAL121................ 13 4.5 Actutor GAA121................ 15 4.6 Dimensionl drwings............ 17 4.6.1 GV652LK-GAL121 Position "A" (DIN flnges)... 17 4.6.2 GV652LC-GAL121 Position "A" (ANSI/ASME flnges)17 4.6.3 GV652AK-GAA121 Position "A" (DIN flnges)... 18 4.6.4 GV652AC-GAA121 Position "A" (ANSI/ASME flnges)18 4.6.5 GV652AK-GAA121 Position "B" (DIN flnges)... 19 4.6.6 GV652AC-GAA121 Position "B" (ANSI/ASME flnges)19 4.6.7 GV652Y-GAL121 Position "A" (Y = weld flnges). 20 4.6.8 GV652Y-GAA121 Position "A" (Y=weld flnges). 21 4.6.9 GV652Y-GAA121 Position "B" (Y=weld flnges). 22 4.7 GV651 vlve updte.............. 23 5 TYPE CODING...................... 24 READ THESE INSTRUCTIONS FIRST! These instructions provide informtion bout sfe hndling nd opertion of the unit. If you require dditionl ssistnce, plese contct Metso Automtion or your uthorized distributor or representtive. SAVE THESE INSTRUCTIONS! Subject to chnge without notice.
3 1 OPERATION 1.1 Generl The system comprises the equipment needed for controlling the hydrulic cylinders of pressure shoe nd feed gte of the ginder. The control cn be either mnul or utomtic. The grinder opertes in 5 phses: Phse 1. "Grinding" pressure shoe moves downwrds influenced by grinding pressure. Phse 2. "Pressure shoe reversing" fst movement Phse 3. "Feed gte opening" Phse 4. "Feed gte closing Phse 5. "Pressure shoe lowering" fst movement 1.2 Min components See Fig. 1. Control vlve of pressure shoe (GVA) with pneumtic ctutor. Control vlve of feed gte cylinder (GVL) with pneumtic ctutor. Shut-off vlve of grinding pressure wter (SV) with pneumtic ctutor. Solenoid vlves operting the bove mentioned pneumtic ctutors (SV1, SV2, SV3, SV4), Fig. 2. Mgnetic or inductive limit switches indicting limit positions of pressure shoe nd feed gte. 1.3 Automtic opertion Strting position pressumed to be phse "grinding". When the pressure shoe comes to its lower position, the limit switch in question gives signl - phse "pressure shoe reversing" follows. Pressure shoe comes to its upper position nd the limit switch in question gives signl. The opertion continues on the condition tht simultneous signl comes from the limit switch system in the conveyor system, indicting "logs on gte - gte my open". Phse "gte opening" follows nd the logs fll into the piston pocket. After the feed gte hs reched its open-position, the limit switch concerned gives signl, phse "feed gte closing" follows. If the feed gte is not fully closed (e.g. logs between the gte nd the grinder), the opertion stops. If the gte closes, the limit switch in question gives signl. Phse "pressure shoe lowering" follows (fst movement).at the sme time the conveyor system receives signl llowing new log lod to be trnsported on the gte. When the pressure shoe meets the logs in the piston pocket, the pressure in the cylinder increses until the pressure switch in the control pnel gives signl - phse "grinding". 1.4 Mnul opertion The movement of pressure shoe nd feed gte cn be mnully controlled, with the following exceptions, indipendently of ech other, by mens of the push buttons. For phse "grinding" there is no prticulr push buttons; grinding is switched on utomticlly when "pressure shoe lowering" control is on, by the signl from presure switch. The mnul opertion circuit hs the following lockings: The feed gte will not open if the grinding is switched on. The grinding cnnot be switched on if the gte is open. Vlves GVL nd GVA cn, in emergency cses, be operted by plcing tool in the shft bore nd turning the vlve shft by hnd. The plugs (29, 30) must be removed from the shft bore first. The plugs must be-remounted immeditely fter the emergency opertion, see Section 2.4. WARNING: The bore in the shft is for emergency opertion only. The bore must be fitted with plugs to meet the occuptionl sfety requirements. There must not be n open bore in the shft where finger or tool cn be trpped. 1.5 "Relese of pressure shoe" opertion When the system is in utomtic opertion nd the phse "grinding", it is possible to crete "relese of pressure shoe" circuit by mens of push button. The purpose of this is to eliminte the rching of logs in the piston pocket, which might stop the movement of the pressure shoe during "grinding" phse. This round is following: "pressure shoe reversing - pessure shoe lowering - grinding". 1.6 Opertion of solenoid vlves See Fig. 2. Control of the gtes A. Upper gte closed: - -coil energized, solenoid vlve SV1 in position - GVL1 in position 1, upper gte closed B. Upper gte open: - b-coil energized, solenoid vlve SV1 in position b - GVL1 in position 2, upper gte open A. Lower gte closed: - -coil energized, solenoid vlve SV2 in position - GVL2 in position 1, lower gte closed B. Lower gte open: - b-coil energized, solenoid vlve SV2 in position b - GVL2 in position 2, lower gte open Control of the pressure shoe A. Pressure shoe up: - solenoid vlves SV3 nd SV4 de-energized in position b
4 1. GRINDING 2. PRESSURE SHOE UP 3. GATE OPEN GVL GVA SV 4. GATE CLOSED 5. PRESSURE SHOE DOWN Fig. 1. Hydrulic vlves b SV1 C2 C1 P2 A B 1 2 S E 1 2 P1 GVL 1 EXHAUST LOW PRESSURE WATER GVL 1 EXHAUST LOW PRESSURE WATER b B A b B A b p AIR SUPPLY SV1 p AIR SUPPLY UPPER GATE b SV2 CHAMBER B LOWER GATE POCKET B A B GVA 3 P3 GVA 3 C2 1 3 2 S PRESSURE SHOE C1 P2 E 1 3 2 P1 EXHAUST LOW PRESSURE WATER EXHAUST LOW PRESSURE WATER A B 1 2 1 2 SV GVL 2 EXHAUST LOW PRESSURE WATER GVL 2 EXHAUST LOW PRESSURE WATER GRINDING PRESSURE WATER b A B b b A B b b B A b B A b p AIR SUPPLY SV3 DE-ENERGIZED p AIR SUPPLY p AIR SUPPLY SV2 p AIR SUPPLY b b A p B ENERGIZED b b A p B C GVA 3 1 3 2 EXHAUST LOW PRESSURE WATER SV4 DE-ENERGIZED ENERGIZED Fig. 2. Solenoid vlves
5 - GVA3 in position 2 - pressure shoe up by low pressure wter, SV is closed B. Pressure shoe down: - SV3 energized, solenoid vlve chnges to position - GVA3 chnges to position 1 - pressure shoe down by low pressure wter - SV4 de-energized in position b nd SV is closed C. Grinding: - SV3 remins energized - SV4 energized nd chnges to position. GVA3 chnges to position 3 - SV will open nd grinding pressure is on 2 MAINTENANCE 2.1 Vlve GV652 The vlve needs no regulr mintennce. 2.1.1 Replcing of set Replcement of set cn be done without removing the ctutor nd while the vlve is fstened to the piping system. 1. Open the socket hed screws (21). 2. Lift off divider (2) nd cover (3). Remove sel rings (8) (3 pcs.) nd sel ring (9) with O-rings (14). 3. Remove bering (10) if replcement is required. 4. Mount new bering (10) using press. 5. Mount O-rings (14) over the neck of sel ring (8). Push sel rings with O-rings crefully into the body. Check tht the seling surfce ginst divider is in the proper position. 3. Detch socket hed screws (21) nd lift off cover (3). Leve divider (2) in plce. 4. Chnge both O-rings (15). 5. Mount the cover (3). Don t forget the O-ring (18). 6. Mount the ger wheel (7) nd retiner ring (18) bck. See the ssembly drwing in 3.4 or 3.5. 7. Assemble the ctutor. Check the mounting position. See Section 2.3, phse 6. 2.2 Cylinder ctutor GAL121 nd GAA121 Actutor GAL121 for gte control vlves, see 3.4. Actutor GAA121 for pressure shoe control vlves, see 3.5. Actutors do not require no regulr mintennce in norml circumstnces. However, it would be beneficil to lubricte the support bering (8), ger wheel (7) nd ger rck (6) 3-4 times yer with oil, e.g. Mobil Vctr Oil No 2 or equivlent. The brether (19) must be detched during lubriction. 2.2.1 Chnging of piston sel 1. Detch the ctutor from the vlve, see 2.3. 2. Open the screws (22) or (42) nd detch the cylinder. 3. When chnging the piston rings (11) or (36), renew the O-rings (12) or (37) lso. 4. The sems of the piston rings should be s fr s possible from ech other. Use specil tool, see Fig. 3. Tighten the collr round the piston rings. Push the piston with rings through the collr into the cylinder. NOTE: The mteril of the O-ring (14) is EPDM, which doesn t tolerte minerl oil. 6. Mount O-rings (14) over the neck of sel ring (9). Push sel rings with O-rings crefully into the body 7. Mount divider (2) nd cover (3) crefully into the body. Tighten the socket hed screws (21). Remember O- ring (18). 2.1.2 Replcing of cover O-rings NOTE: In cover (3) there re two O-rings (15) nd between these groove nd drilling. If there is wter coming from the drilling it mens tht the lowest O-ring is dmged. Fig. 3. Using the specil tool 5. Check, tht cylinder opertes properly. 6. Fsten nd tighten the screws (22) or (42). 1. Detch ctutor (Section 2.3) 2. Remove ger wheel (7) nd retining ring (19). See ssembly drwing for ctutor, Section 3.4 or 3.5.
6 2.2.2 Chnging of piston rod sels When chnging the piston rings, renew lso O-ring of the piston rod. Bigger cylinder GAA121 1. Pull out the piston (32) nd piston rod (34) with the cylinder (33). 2. Renew O-ring (39) nd bering (35). 3. Renew O-rings (40) if needed. 4. Mount the cylinder with piston bck. Fsten nd tighten the screws (42). Smller cylinder GAA121 nd cylinder GAL121 1. Detch the piston (3) from the piston rod (5) by removing the screw (13). 2. Detch the cylinder bse (2) by removing the screws (31). 3. Renew the O-ring (14) nd bering (10). 4. Renew the O-rings (16) if needed. 5. Mount the cylinder bse (2). Remember to use set rings (30) with the screws (31). 6. Fsten the piston (3) to the piston rod (5) with screw (13). Apply thredlock, e.g. Loctite 225 or equivlent. Tighten the screw (13). 2.3 Chnge of ctutor mounting position If the mounting position hs to be chnged, plese note, tht the position indiction should lwys follow the position compred to vlve body. 1. Operte the vlve to the outer most position. 2. Open the fstening screws (20) nd lift off the ctutor without chnging the position of the divider. 3. Apply new selnt, Loctite 573 or equivlent, between the vlve body nd ctutor. 4. Mount the ctutor into the correct position without chnging the position of the ger rck. 5. Fsten screws (20). 6. Check, tht the pointer (52) is in the correct position compred the vlve. If needed, remove screws (53) nd turn the pointer 180 degrees. Fsten the pointer (52) with screws (53). WARNING: The pointer (52) must be in position where the text "S->C2, C1->E" is ligned with the port C2. The pointer should lwys show the phse of grinding. If the pointer is in wrong position, i.e. it hs not been turned during mounting position chnge, there is sfety risk. The drwings show the ctutor rotted 180 degrees (position "A" or "B"). If needed, the ctutor cn be rotted 90 degrees s well using procedures described elier. Also in this cse tke cre of the position indiction. The pointer must be in position where the text "S->C2, C1->E" is ligned with the port C2. 2.4 Shft protection See ssembly drwing, Section 3.1, 3.2 or 3.3. WARNING: The bore in the shft is for emergency opertion only. The bore must be fitted with plugs to meet the occuptionl sfety requirements. There must not be n open bore in the shft where finger or tool cn be trpped. 1. Instll the plug (30) in the shft bore so, tht the groove in the plug is ligned with the rrow in the shft end. This wy the plug serves s position indictor lso. 2. Instll the plug (29) in the shft bore. 3. Fsten the prts with screw (31). 2.5 Updting series GV651 vlves The old series GV651 vlves cn be updted to meet tody s occuptionl sfety requirements. There must not be n open bore in the shft where finger or tool cn be trpped. Also flt end shfts re not llowed to prevent the use of wrench. 2.5.1 Shft end protection See figure in Section 3.7. 1. Instll the plug (30) in the shft bore so, tht the groove in the plug is ligned with the rrow in the shft end. This wy the plug serves s position indictor lso. 2. Instll the plug (29) in the shft bore. 3. Fsten the prts with screw (31). 2.6 Pointer mounting See figure in Section 3.7. 1. Two bores with M5 thred for mounting screws (53) re needed in the ctutor housing (thred depth 7 mm, drilling depth 10 mm). 2. Fix the pointer (52) with screws (53) in the correct position. The pointer must be in position where the text "S->C2, C1->E" is ligned with the port C2. 3 RECYCLING AND DISPOSAL OF A REJECTED VALVE Most vlve prts cn be recycled if sorted ccording to mteril. Most prts hve mteril mrking. A mteril list is supplied with the vlve. In ddition, seprte recycling nd disposl instructions re vilble from the mnufcturer. A vlve cn lso be returned to the mnufcturer for recycling nd disposl ginst fee.
7 4 DRAWINGS AND PART LISTS 4.1 Grinder control vlve, GV652 804260
8 Prt Qty Description 001 1 Body 002 1 Divider 003 1 Bonnet 007 1 Flnge 008 3 Sel ring 009 1 Sel ring 010 1 Bering 013 1 Bll bering 014 8 O-ring 015 2 O-ring 017 1 O-ring 018 1 O-ring 019 1 Snp ring 020 1 Snp ring 021 4 Socket hed screw 022 4 Hexgon screw 022 4 Hexgon screw 025 1 Identifiction plte 029 1 Plug 030 1 Plug 031 1 Socket hed screw
9 4.2 Grinder control vlve, GV652 7188400
10 Prt Qty Description 001 1 Body 002 1 Divider 003 1 Bonnet 007 1 Flnge 008 3 Sel ring 009 1 Sel ring 010 1 Bering 013 1 Bll bering 014 8 O-ring 015 2 O-ring 017 1 O-ring 018 1 O-ring 019 1 Snp ring 020 1 Snp ring 021 4 Socket hed screw 022 4 Hexgon screw 022 4 Hexgon screw 025 1 Identifiction plte 029 1 Plug 030 1 Plug 031 1 Socket hed screw
11 4.3 Grinder controls vlve, GV652Y 789020
12 Prt Qty Description 001 1 Body 002 1 Divider 003 1 Bonnet 007 1 Flnge 008 3 Sel ring 009 1 Sel ring 010 1 Bering 013 1 Bll bering 014 8 O-ring 015 2 O-ring 017 1 O-ring 018 1 O-ring 019 1 Snp ring 020 1 Snp ring 021 4 Socket hed screw 022 4 Hexgon screw 023 12 Hexgon screw 024 4 Hexgon screw 025 1 Identifiction plte 029 1 Plug 030 1 Plug 031 1 Socket hed screw
13 4.4 Actutor GAL121 7238000
14 Prt Qty Description 001 1 Housing 002 1 Cylinder bse 003 1 Piston 004 1 Cylinder pipe 005 1 Piston rod 006 1 Ger rck 007 1 Ger wheel 008 1 Support bering 009 1 Key 010 1 Bering strip 011 2 Piston ring 012 1 O-ring 013 1 Hexgon screw 014 1 O-ring 015 1 O-ring 016 2 O-ring 017 1 Spring pin 018 1 Retiner ring 019 1 Brether 020 3 Socket hed screw 021 3 Hexgon screw 022 8 Hexgon screw 023 1 Limit screw 024 1 Hexgon nut 025 1 Identifiction plte 027 1 Limit screw 028 1 Hexgon nut 029 1 Cylinder end 030 4 Set ring 031 4 Socket hed screw 052 1 Pointer 053 1 Socket hed screw
15 4.5 Actutor GAA121 F05279
16 Prt Qty Description 001 1 Housing 002 1 Cylinder bse 003 1 Piston 004 1 Cylinder pipe 005 1 Piston rod 006 1 Ger rck 007 1 Ger wheel 008 1 Support bering 009 1 Key 010 1 Bering strip 011 1 Piston ring 012 1 O-ring 013 1 Hexgon screw 014 1 O-ring 015 1 O-ring 016 2 O-ring 017 1 Spring pin 018 1 Retiner ring 019 1 Brether 020 3 Socket hed screw 021 3 Hexgon screw 022 8 Hexgon screw 023 1 Limit screw 024 1 Hexgon nut 025 1 Identifiction plte 029 1 Cylinder end 030 4 Set ring 031 4 Socket hed screw 032 1 Piston 033 1 Cylinder pipe 034 1 Piston rod 035 1 Bering 036 2 Piston ring 037 1 O-ring 038 1 Spring pin 039 1 O-ring 040 2 O-ring 041 1 Bushing 042 8 Hexgon screw 043 1 Limit screw 044 1 Hexgon nut 045 1 Hexgon screw 046 1 Cylinder bse 047 1 Filter 050 1 Cylinder end 052 1 Pointer 053 2 Socket hed screw 054 1 Spring pin
17 4.6 Dimensionl drwings 4.6.1 GV652LK-GAL121 Position "A" (DIN flnges) 304651 4.6.2 GV652LC-GAL121 Position "A" (ANSI/ASME flnges) 304652
18 4.6.3 GV652AK-GAA121 Position "A" (DIN flnges) 302804 4.6.4 GV652AC-GAA121 Position "A" (ANSI/ASME flnges) 302805
19 4.6.5 GV652AK-GAA121 Position "B" (DIN flnges) 303353 4.6.6 GV652AC-GAA121 Position "B" (ANSI/ASME flnges) 303352
20 4.6.7 GV652Y-GAL121 Position "A" (Y = weld flnges) 304802
21 4.6.8 GV652Y-GAA121 Position "A" (Y=weld flnges) 304801
22 4.6.9 GV652Y-GAA121 Position "B" (Y=weld flnges) 304540
23 4.7 GV651 vlve updte Prt Qty Description 29 1 Plug 30 1 Plug 31 1 Socket hed screw 32 1 Protective plte
24 5 TYPE CODING VALVE 1. 2. 3. GV 652 AK 1. sign PRODUCT GROUP 2. sign PIPE SIZE AND VALVE TYPE 3. sign APPLICATION AND SUITABLE FLANGE DRILLING AK Pressure shoe ctution, for flnge drilling PN 16/64 AC Pressure shoe ctution, for flnge drilling ANSI 150/600 LK Gte ctution, for flnge drilling PN 16 LC Gte ctution, for flnge drilling ANSI 150 Y Pressure shoe nd gte ctution, weld ends, suitble for ll pressure clsses, dimensions sme s for GV 651 ACTUATOR 1. 2. 3. GA A 121 1. sign PRODUCT GROUP 2. sign APPLICATION A Pressure shoe ctution L Gte ctution 3. sign ACTUATOR SIZE AND TYPE Metso Automtion Inc. Europe, Levytie 6, P.O. Box 310, 00811 Helsinki, Finlnd. Tel. +358 20 483 150. Fx +358 20 483 151 North Americ, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fx +1 508 852 8172 Ltin Americ, Av. Independénci, 2500- Iporng, 18087-101, Sorocb-São Pulo, Brzil. Tel. +55 15 3235 9700. Fx +55 15 3235 9748/49 Asi Pcific, 501 Orchrd Rod, #05-09 Wheelock Plce, 238880 Singpore. Tel. +65 673 552 00. Fx +65 673 545 66 Middle Est, Roundbout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubi, United Arb Emirtes. Tel. +971 4 883 6974. Fx +971 4 883 6836 www.metsoutomtion.com