Danfoss Pilot-controlled PCVQ Bedienungsanleitung

Instructions

Pilot-controlled PCVQ

DN 100 - DN 250

PN 16 / PN 25

73696700 DH-SMT/SI VI.JA.G2.02 © Danfoss 11/2006 1

Table of Contents

1 Safety Notes ...................................................... 2

2 Deﬁnition of Application ............................ 2

3 Description .......................................................... 2

3.1 Construction ......................................................... 2

3.2 Mode of Operation ........................................... 2

4 Technical Data .................................................. 3

5 Scope of Delivery ............................................. 3

6 Assembly ............................................................. 4

6.1 Prior to Assembly ............................................... 4

6.2 Installation Position,

Installation Place ................................................ 4

6.3 When Installaling observe ............................. 4

6.4 Impulse Tube Installation ................................ 4

6.5 Insulation .............................................................. 4

6.6 Installation Scheme ........................................... 5

6.7 Assembly Drawings, Dimensions ................ 6

7 Start-up ..................................................................8

7.1 Required static Pressure .................................. 8

7.2 Leak and Pressure Test ...................................... 8

7.3 Filling the System ............................................... 8

7.4 Start-up .................................................................. 8

7.5 Putting out of Operation ................................. 8

7.6 Flow Rate Adjustment ...................................... 9

7.7 Flow Adjusting Curves ................................... 10

7.8 Sealing ................................................................. 12

7.9 Adjustement of the Throttle Valves .......... 12

7.10 Function Test ..................................................... 12

8 Trouble Shooting ......................................... 13

9 Replacement of Valve,

Actuator, Trims .............................................. 14

9.1 Dismounting and

Mounting Actuator Valve ............................. 14

9.2 Replacement of Trim Valve VFQ 21 ........... 16

9.3 Dismounting,

Mounting Actuator AVP-F ............................ 17

9.4 Replacement of Trim Valve AVP-F .............. 17

Pilot controller AVP-F

(Flow Rate)

Adjusting throttle

Throttling element DE

Valve unit PCV-VFQ 21

Throttling valve

hrottling valve

only by DN150-250

2 VI.JA.G2.02 © Danfoss 11/2006 DH-SMT/SI

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

1 Safety Notes To avoid injury of persons

and damages to the device,

it is absolutely necessary to

carefully read and observe

these Instructions.

Necessary assembly, start-up, and maintenance

work may be performed only by qualiﬁed and

authorized personnel.

Please comply with the instructions of the

system manufacturer or system operator.

2 Deﬁnition of

Application

The controller is used for ﬂow rate limitation of

water for heating, district heating and cooling

systems.

The admissible medium temperatures depend

on the design and comprise 5 to 140 °C,

5 to 150 °C, 5 to 200 °C.

The technical data on the rating plates

determine the use.

3 Description

3.2 Mode of Operation

The control unit consists of the PCV-VFQ21

valve unit, installed in the main pipe and AVP-F

installed as pilot controllers in the bypass. In the

bypass line, a throttle element is installed in front

of the pilot controller.

The controller keeps the diﬀerential pressure

across the main valve ﬂow restrictor on a

constant level and restricts the ﬂow rate to the

adjusted setpoints.

The valve and the pilot valves are pressure-

balanced.

The setpoint for the ﬂow rate limitation is

adjusted at the adjusting throttle of the valve

unit.

The valve unit in the main pipe is opening on

rising pressure. The pilot controller in the bypass

line is closing on rising pressure.

3.1 Construction

Flow Rate Limitation

If the ﬂow rate reaches the adjusted setpoint, the

diﬀerential pressure increases at the adjusting

throttle. This diﬀerential pressure acts on the

actuator AVP-F via the impulse tubes and the

valve AVP-F closes. Consequently, the valve of

the valve unit is throttled, too, and the ﬂow rate

is restricted.

DH-SMT/SI VI.JA.G2.02 © Danfoss 11/2006 3

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

4 Technical Data Technical data, see rating plates and the PCV

data sheet.

5 Scope of Delivery

DN 100, DN 125

Assembly kit valve unit PCV-VFQ 21 Pilot controller DN 25

AVP-F

Throttling element

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

DN 150, DN 250

Assembly kit valve unit PCV-VFQ 21 Pilot controller DN 40

AVP-F

Throttling element

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

pin only

weld

do NOT

weld

4 VI.JA.G2.02 © Danfoss 11/2006 DH-SMT/SI

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

6 Assembly 6.1 Prior to Assembly:

Depressurized system before any

assembly work !

CAUTION!

• Clean pipeline system.

• Install strainer in front of the controller.

• Install shut-oﬀ units in front of and behind

the controller.

6.2 Installation Position, Installation Place

• Installation is only permitted in horizontal

pipelines with the actuators hanging in a

downward position.

• The controller may be installed in the

supply as well as in the return line.

6.3 When installing:

• Observe direction of ﬂow.

• Design with welded ends:

• Loads on the valve body and the throttle

element by the pipes are not permitted.

6.4 Impulse Tube Installation

See installation scheme, section 6.6.

For CU pipes Ø 10 × 1, insert sockets 1 on both

sides.

Care for correct position of the cutting rings 2.

6.5 Insulation

The diaphragm actuators must not be insulated

when insulating system parts.

Bypass controller

PCVQ

Throttling

element

Throttling valve

(only by DN 150 - 250)

Valve unit PCV - VFQ 21

Pilotregler AVP-F

lay impulse tube during mounting

Bypass controller

PCVQ

Throttling

element

Throttling valve

(only by DN 150 - 250)

Valve unit PCV - VFQ 21

Pilot controller AVP-F

DH-SMT/SI VI.JA.G2.02 © Danfoss 11/2006 5

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

6.6 Installation Scheme

Installation in the Return Line

Installation in the Supply Line

6 Assembly

H1 H2

Cu pipe

Ø 10 × 1

Lay when assembling.

CU pipe Ø 6 ×1

Lay when assembling.

244

160

ca. 1000

159

DN 25: pipe Ø33.7 × 3.2

Material: ST 35.8

(not part of the delivery)

DN 25 SW 50

Pilot controller AVP-F

Throttling element

6 VI.JA.G2.02 © Danfoss 11/2006 DH-SMT/SI

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

6 Assembly 6.7 Assembly Drawings, Dimensions

DN 100 - DN 125

D 2

H1 H2

Cu pipe

Ø 10 × 1

Lay when assembling.

CU pipe Ø 6 × 1

Lay when assembling.

ca. 1200

290

200

DN 40: pipe Ø 48.3 × 3.2

Material: ST 35.8

(not part of the delivery)

DH-SMT/SI VI.JA.G2.02 © Danfoss 11/2006 7

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

6 Assembly (continuous) DN 150 - DN 250

Nominal

diameter DN 100 125 150 200 250

350 400 480 600 730

H1 530 530 619 647 697

H2 - 245 300 325

D2 263 380

D1 250 320 385 500

B 200 210 310 336 412

A ≥ 290 320 350 410

7 6

8 VI.JA.G2.02 © Danfoss 11/2006 DH-SMT/SI

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

7 Start-up 7.1 Required Static Pressure

The static pressure p1 in front of the controller

must not fall below 1.5 bar (excess pressure).

Non-observance may lead to cavitation and

damages in the throttling element 1.

7.3 Filling the System

Note:

The controller 4 is closed when no pressure is

applied and only opens with a deﬁned ﬂow in the

bypass.

The pilot controller 5 is closing on rising pressure.

7.2 Leak and Pressure Tests

To avoid too high pressures at

the diaphragm actuators, the

following should be observed

prior to any pressure tests:

Actuator of valve unit:

The admissible operating excess pressure in the

actuator 2 is 25 bar 1). For higher pressures, you

must:

• Remove the impulse tubes 3 at the actuator

and close the connections with a stopper.

• Prior to any leak or pressure test, the

instructions in section 7.3 must be complied

with.

1) Pre-condition: Same pressure on both sides of the diaphragm.

If the pressure load is one-sided, the (+)diaphragm chamber

may have an excess pressure of 1 bar in comparison to the

(-)diaphragm chamber.

To avoid too high pressure

diﬀerences on the controller,

observe the following sequence

when starting-up !

This procedure guarantees that there is no

overturn of the diaphragm in the valve and the

actuators.

1. Open units 6 of the system.

2. Slowly open shut-oﬀ units in the supply

ﬂow 7 and the return ﬂow 8.

7.4 Start-up

During starting-up the ﬁlled system, open the

units in the same sequence as described in

section 7.3.

7.5 Putting out of operation

When putting the system out of operation, ﬁrst

close the shut-oﬀ units in the supply ﬂow and

then those of the return ﬂow.

Required

ﬂow rate

Read rotations

for the adjusting throttle

DH-SMT/SI VI.JA.G2.02 © Danfoss 11/2006 9

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

7.6 Flow Rate Adjustment

The setting of the setpoint for the ﬂow rate

limitation is made by means of ﬂow adjusting

curves (see section 7.7) or a heat meter (see

page 33).

Adjustment by means of ﬂow adjusting

curves

Adjustment is to be made at a shut-down

system.

Procedure

4. Turn the adjusting throttle by this number of

rotations to the left.

1. Unscrew cover 1.

2. Loosen the counter nut 2.

3. Choose diagram,

(see section 7.7, Flow Adjusting Curves)

Observe eﬀecitve pressure Δpb: 0.2 or 0.5 bar

see rating plate on the actuator AVP-F

5. The adjusted ﬂow rate can be veriﬁed by

means of a ﬂow rate measuring device.

Perhaps you need to re-adjust the ﬂow rate.

Care for an adequate diﬀerential pressure in

the system.

6. Tighten the counter nut without changing the

position of the adjusting throttle.

7. Re-screw the cap nut 1.

8. The cap nut can be sealed.

The ﬂow rate adjustment is completed.

Now, adjust the diﬀerential pressure,

see section 7.8.

2. Screw.in the adjusting throttle 3 to its stop.

7 Start-up

DN 100 kvs 125 / DN 125 kvs 160 / DN 150 kvs 320

100

120

140

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

∆pb=0,2

DN100 / 125

DN150

Rotations for the adjusting throttle

Flow rate (m3/h)

DN 100 kvs 125 / DN 125 kvs 160 / DN 150 kvs 320

100

120

140

160

180

200

220

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

DN100 / 125

DN150

∆pb=0,5

Rotations for the adjusting throttle

Flow rate (m3/h)

DN 200 kvs 450 / DN 250 kvs 630

100

120

140

160

180

200

0 1 2 3 4 5 6 7 8 9 10

DN 200

DN 250

∆pb=0,2

necessary

rotations of the

adjusting throttle: 4

Example

Ventil DN 200

required ﬂow rate

limitation: 100 m³/h

Rotations for the adjusting throttle

Flow rate(m3/h)

DN 200 kvs 450 / DN 250 kvs 630

100

120

140

160

180

200

220

240

260

0 1 2 3 4 5 6 7 8 9

DN 200

DN 250

∆pb=0,5

Rotations for the adjusting throttle

Flow rate(m3/h)

Instructions Pilot-controlled PCVQ DN 100 - DN 250 (PN 16, PN 25)

7 Start-up

7.7 Flow Adjusting Curves

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