Operating Instructions ROCO Butterfly Valve with SKG Slider-crank Mechanism, with Electric Multi-turn Actuator 1 Product and Performance Description 2 Design Features of ROCO Butterfly Valve 3 Installation in the Pipeline 4 Initial Operation 5 Operation and Application 6 Maintenance 7 SKG Slider-crank Mechanism 8 Electric Multi-turn Actuator These operating instructions must always be used in combination with operating instructions BA01E001! 1 Product and Performance Description 1.1 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 150, 200, 250, 300, 350, 400, 450, 500, 600 Pressure ratings: PN 10, 16 Prod. No.: 5064... PN 10 5065... PN 16 5061... PN 16/GN 10 1.2 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 (profile sealing ring). 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 gearbox. Normally, the valve closes in clockwise direction (turning the handwheel to the right). Issue 02-06 REV2 Page 1/13
2 Design Features Figure 1: Sectional Drawing of ROCO Butterfly Valve Part Description Spare part Part Description Spare part 1 Body 12 O-ring 2 Bearing bush 13 Hexagon screw 3 Valve disc 14 Washer 4 Profile sealing ring X 15 Key 5 Countersunk screw 16 Tab washer 6 Threaded pin 17 Hexagon screw 7 Actuating shaft 18 Shaft sealing set, X consisting of: spacer, 8 Trunnion O-rings, back-up rings 9 Bearing ring, divided 19 Retaining ring 10 Threaded pin 20 Cylindrical screw 11 Bearing cover 21 Parallel key Main sealing ring: steel-reinforced profile sealing ring (4) internally and externally rubbercoated, optimum corrosion protection, easily replaceable and adjustable. Body seat: enamel coated seat (product No. 50.. 72..) or rolled-in solid seat ring of stainless steel (product No. 50.. 95..). Connection key/valve disc: well-approved and robust key connection (15) for force transmission without clearance, tab washer (16). Gearbox connection: to pren 12116 (DIN ISO 5211), round spigot with parallel key. Page 2/13
Shaft sealing: on the drive side by means of fully enclosed 0-rings (18) of stainless material, on the bearing side by O-ring (12) enclosed in the bearing cover (11). When the gearbox is disassembled, the shafts (7) and shaft sealing (18) are protected against blowing-off. Shaft bearing: maintenance-free and self-lubricating plain bearings (2). 3 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. 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. 4 Initial Operation After installation, check valve for smooth operation: move the valve over the total travel (Open Closed) by means of operating element. 5 Operation and Application 5.1 Admissible Operation The valve disc 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 10: 4 m/sec. PN 16: 5 m/sec. Page 3/13
5.2 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!). 6 Maintenance 6.1 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 repair the coating. Check tightness at the 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. 6.2 Readjustment and Repair 6.2.1 Readjustment of the Profile Ring, fig. 2. ROCO Butterfly Valves are equipped with a readjustable sealing system. The profile ring (4) can be readjusted in closed position of the valve disc. For this purpose, loosen the threaded pins (6) and tighten evenly the countersunk screws (5) in a crosswise manner. As the profile sealing ring acts very fast when tightening, we recommend to proceed by taking small steps (half turn of the screws). Afterwards tighten threaded pins (6) by turning them in clockwise direction and thus locking the profile sealing ring. Page 4/13
Fig. 2: Sealing Zone of ROCO Butterfly Valve 6.2.2 Replacement of the Profile Sealing Ring, fig. 2. Turn valve disc off the CLOSED position of the body seat by approx. 20 to 30. Loosen and screw off countersunk screws (5). Remove profile sealing ring (4) by means of lever force. Clean profile groove in valve disc and repair corrosion protection if necessary. Introduce new profile ring by turning it. It must be fully inserted into the disc. When the profile ring is correctly mounted, it can be moved easily in the disc. Note: The profile sealing ring can be inserted more easily, when it is slightly wetted or greased prior to mounting (please use a grease suitable for potable water). Profile sealing rings of EPDM must not get in contact with grease! Screw-in countersunk screws (5) and tighten crosswise by means of tightening torque according to table 1. Afterwards screw-in threaded pins (6) and tighten them. Note: When mounting the countersunk screws and threaded pins, we recommend to use commercial screw locking and sealing materials thus achieving an improved corrosion protection and increased safety against slackening. Page 5/13
M A [Nm] 10 bars 16 bars DN 150 5 6 DN 200 5 6 DN 250 10 12 DN 300 12 13 DN 350 13 14 DN 400 13 14 DN 450 14 17 DN 500 14 17 DN 600 17 23 Table 1: Tightening Torques M A for Clamping Ring Screws 6.2.3 Replacement of Shaft Sealing, fig. 3. Required spare parts: shaft sealing set consisting of: Spacer (22); 1 piece External O-rings (23); 2 pieces Internal O-ring (24); 2 pieces Back-up rings (25); 3 pieces O-ring for bearing cover (12); 1 piece Fig. 3: Shaft Sealing Zone of ROCO Butterfly Valve Drive Side: Dismount gearbox/part-turn actuator from Butterfly Valve (see chapter 7). Remove parallel key (21). Unscrew cylindrical screws (20) and remove retaining ring (19). Remove external O-ring (23) and back-up ring (25) as far as possible. Place two medium-sized slotted screw drivers one opposite the other at the spacer (22) and remove spacer by lever force (spacer will be damaged during this procedure). Page 6/13
Remove remaining sealing parts. Clean space of installation. Slightly grease 0-ring (23), insert into groove on the backside of the new 0-ring (22) and press spacer with 0-ring into the installation space until reaching the stop. Insert the second O-ring into the groove between body and spacer. Assemble shaft sealing system one after the other as follows: Back-up ring/o-ring/back-up ring/o-ring/back-up ring (24, 25) taking care that the O-rings at the parallel key groove of the shaft will not be damaged. Mount retaining ring (19) with cylindrical screw (20). Mount gearbox/part-turn actuator (see chapter 7). Bearing Side: Dismount bearing cover (11) by unscrewing the hexagon screws (13). Remove old O-ring (12) from the groove of the bearing cover. Clean O-ring groove. Insert new O-ring (12) and remount bearing cover (11). During mounting see to it that the O-ring is retained in the groove and is not jammed between body and bearing cover. 7 SKG Slider-crank Mechanism 7.1 Design Features Design (Figure 4): Attachable quarter-turn gearbox according to the slider-crank 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 IP 68). Interfaces: Output: to pren 12116 (DIN ISO 5211), round spigot with parallel key. Input: 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. 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 Rivet pin 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 Page 8/13
7.2 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, chain wheel, 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. 7.3 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 Tightening Torques for Fastening Screws of Gearbox Table 2: Fig. 5: Mounting of Output Shaft Page 9/13
7.4 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 the valve. Mount cover (17) 7.5 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 390. 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 (grease) SHELL DIN 51502 K-L3n TEXANDO FO20 TEXACO DIN 51825 K-2n Table 3: Recommended Lubricating Agents Page 10/13
8 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 switches with 1 make and 1 break contact each Blinker transmitter for indication of motor 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 switches 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" (8.2). 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 drying-up 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 nameplate. After connection, the covers and the cable glands on the electric actuator have to be closed and sealed carefully. Page 11/13
8.1 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. Therefore: 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. 8.2 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. Page 12/13
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 indicator position C. 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 indicator position B. 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. Page 13/13