TLV CV5 Bedienungsanleitung

172-65238M-00 (CV5)25 February 2003

Control Valve

CV5

All rights reserve

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

Introduction

Thank you for purchasing the Control Valve

This product has been thoroughly inspected before being shipped from the

factory. When the product is delivered, before doing anything else, check the

specifications and external appearance to make sure nothing is out of the

ordinary. Also be sure to read this manual carefully before use and follow the

instructions to be sure of using the product properly.

For products with special order specifications or options, if detailed

instructions for the special order specifications or options are not contained in

this manual, please contact for full details.

This instruction manual is intended for use with the model(s) listed on the

front cover. It is necessary not only for installation but for subsequent

maintenance, disassembly/reassembly and troubleshooting. Please keep it in

a safe place for future reference.

Contents

Introduction........................................................................1

Safety Considerations.......................................................2

Specifications....................................................................4

Configuration.....................................................................5

Installation.........................................................................6

Operation...........................................................................9

Maintenance....................................................................12

Troubleshooting...............................................................14

Product Warranty ............................................................15

Safety Considerations

• Read this section carefully before use and be sure to follow the

instructions.

• Installation, inspection, maintenance, repairs, disassembly, adjustment,

and valve opening/closing should be carried out only by trained

maintenance personnel.

• The precautions listed in this manual are designed to ensure safety and

prevent equipment damage and personal injury. For situations that may

occur as a result of erroneous handling, three different types of cautionary

items are used to indicate the degree of urgency and the scale of potential

damage and danger: DANGER, WARNING and CAUTION.

• The three types of cautionary items above are very important for safety:

be sure to observe all of them as they relate to installation, use,

maintenance, and repair. Furthermore, TLV accepts no responsibility for

any accidents or damage occurring as a result of failure to observe these

precautions.

Symbols

Indicates a DANGER, WARNING or CAUTION item.

DANGER

Indicates an urgent situation which poses a threat of death or

serious injury

WARNING

Indicates that there is a potential threat of death or serious injury

CAUTION

Indicates that there is a possibility of injury or equipment / product

damage

CAUTION

DO NOT use this product outside the recommended operating

pressure, temperature and other specification ranges.

Improper use may result in such hazards as damage to the product or

malfunctions that may lead to serious accidents. Local regulations may

restrict the use of this product to below the conditions quoted.

Use hoisting equipment for heavy objects (weighing approximately

20 kg or more).

Failure to do so may result in back strain or other injury if the object

should fall.

Take measures to prevent people from coming into direct contact

with product outlets.

Failure to do so may result in burns or other injury from the discharge of

fluids.

When disassembling or removing the product, wait until the

internal pressure equals atmospheric pressure and the surface of

the product has cooled to room temperature.

Disassembling or removing the product when it is hot or under pressure

may lead to discharge of fluids, causing burns, other injuries or damage.

Safety considerations continued on next page.

CAUTION

Be sure to use only the recommended components when repairing

the product, and NEVER attempt to modify the product in any way.

Failure to observe these precautions may result in damage to the

product and burns or other injury due to malfunction or the discharge of

fluids.

Do not use excessive force when connecting threaded pipes to the

product.

Over-tightening may cause breakage leading to fluid discharge, which

may cause burns or other injury.

Use only under conditions in which no freeze-up will occur.

Freezing may damage the product, leading to fluid discharge, which

may cause burns or other injury.

Use only under conditions in which no water hammer will occur.

The impact of water hammer may damage the product,

leading to fluid

discharge, which may cause burns or other injury.

Specifications

DO NOT use this product outside the recommended operating pressure,

temperature and other specification ranges. Improper use may result in

such hazards as damage to the product or malfunctions which may

lead to serious accidents. Local regulations may restrict the use of this

product to below the conditions quoted.

Use only under conditions in which no freeze-up will occur. Freezing may

damage the product, leading to fluid discharge, which may cause

burns or other injury.

Valve

Model CV5

Body material Cast Iron Cast Steel

Connection Flange

Size 15

PMO (MPaG) 1.3 1.0

2.5 1.7

1.0

TMO (MPaG) 200 220

Seat Plug Sealing Metal Sealing

Characteristic Equal Percentage

Rangeability 50 : 1

Leakage Class (IEC534-4) ClassⅣ

Actuator

Actuator Area (cm2) 120

Fail-safe Position Air to open Air to close

Bench Range (MPa) 0.04 –0.14 0.21 –0.33

Electrical Input Signal (mA) 4 –20

Air Supply Press. (MPaG) MAX. 0.6

Transit Time for Rated Travel

Approx. 3 seconds

Hysteresis (%) <1

Protection Class IP54

Ambient Temp. Range -30 –70

Motive Medium Oil-free air, filtered 5μm

* Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are PRESSURE SHELL

DESIGN CONDITIONS, NOT OPERATING CONDITIONS.

Configuration

Fig. 1

No. Parts Name No. Parts Name

1Valve body 8Body Gasket

2Valve Bonnet 9Actuator Body

3Valve Seat 10 Diaphragm

4Plug and Stem 11 Actuator Stem

5Guide Bushing 12 Positioner Case

6Stuffing Box V-ring 13 Stem Bracket

7Stuffing Box Spring 14 Yoke

Installation DO NOT use this product outside the recommended operating pressure,

temperature and other specification ranges. Improper use may result in

such hazards as damage to the product or malfunctions which may

lead to serious accidents. Local regulations may restrict the use of this

product to below the conditions quoted.

Use hoisting equipment for heavy objects (weighing approximately

20 kg or more). Failure to do so may result in back strain or other injury if

the object should fall.

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from the

discharge of fluids.

Do not use excessive force when connecting threaded pipes to the

product. Over-

tightening may cause breakage leading to fluid discharge,

which may cause burns or other injury.

Installation, inspection, maintenance, repairs, disassembly, and adjustment should

be done only by trained maintenance personnel.

1. Mounting position

The valve can be mounted in any position. However, strictly observe the limitations

resulting from the type of actuator used.

The valve must be installed free of stress. If necessary, support the pipelines near

the connections.

Do not install supports on the valve or on the actuator!

Thoroughly flush the pipeline prior to installation of the valve!

2. Strainer, bypass

We recommend that you install a Strainer upstream of the valve. We also

recommend that you install a shut-off valve both upstream of the strainer and

downstream of the control valve as well as a bypass line so that the plant need not

be shut down for maintenance routines.

3. Mounting preparations

Before attaching the actuator to the valve bonnet, actuators with close fail-safe

action "Air to open" must be pressurized to slightly retract the actuator stem.

Should no electric control signal be available during the mounting procedure, the

hexagon nut (5) must be tightened (use a hexagonal wrench SW 36) to hold the pre-

tensioned springs.

Actuators with open fail-safe action "Air to close" require to be pressurized only

for attaching the stem connector. The top diaphragm chamber must be pressurized

to approach the plug and actuator stem until they contact one another.

For electropneumatic actuators, a signal pressure can be applied to the pressure

gauge connection, however, the plug (2, Fig. 2) must be removed first.

3.1 Mounting the actuator on the valve

1) For the electropneumatic actuator, apply a pressure of approx. 3 bar to the

connection "Supply" and additionally connect a control signal of 10 mA to retract

the actuator stem.

2) Remove the hexagon nut (5) from the valve bonnet and place the actuator with

its stem retracted on the valve bonnet.

3) Make sure that the actuator is in the proper position and secure with the

hexagon nut (SW 36), applying a tightening torque of min.150 Nm.

4) Pull up the plug stem until it contacts the actuator stem.

5) Attach the stem connector pieces to each stem and screw tight with the

fastening screws.

Fig. 2 1

1. Zero adjuster

2. Plug (Press. gauge)

3. Electrical connector

4. Cover plate

(span and tight-

closing

function)

5. Nut

6. Vent plug

Air to close type

Air to open type

In case you need to deactivate the control valve action, deactivation

may only be carried out by switching off the electric control signal, do not

disconnect the supply air!

3.2Pneumatic connections

The electropneumatic actuator has tapped holes with G1/4 thread.

The customary male connections for metal pipes or plastic hoses can be used.

Connect the supply air to the "Supply" connection.

The required supply pressure is on the name plate.

Important: Supply air must always be dry, oil-and dust free. Thoroughly flush the

air pipes prior to installation.

3.3Electrical connection

1) Unthread the fastening screw of the plug connector and remove the plug

connector (3, fig.2) from the female connector on the actuator housing.

Note: Do not remove the female connector from the actuator housing. Correct

ground connection can only be guaranteed when it is in its original position.

2) Unthread the fastening screw of the plug connector and remove the rubber

gasket.

3) Lever the plug insert out of the plug connector case using a screw driver.

4) Connect the wires transmitting the control signal via the PG screw joint of the

plug connector case to the terminals of the insert which are marked 1 + , 2 –and to

its ground terminal. Secure them with screws.

5) Re-install the insert in the plug connector case. Be sure that the Pg screw joint

points to the desired direction (the plug connector case can be turned by 90°

around the insert to point to all four directions).

6) Put on the rubber gasket.

7) Plug the plug connector back in the actuator housing and secure with fastening

screw.

Fig. 3

Operation

DO NOT use this product outside the recommended operating pressure,

temperature and other specification ranges. Improper use may result in

such hazards as damage to the product or malfunctions which may lead

to serious accidents. Local regulations may restrict the use of this product

to below the conditions quoted.

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids.

Installation, inspection, maintenance, repairs, disassembly, and adjustment should

be done only by trained maintenance personnel.

1. Checking and adjusting zero and span in electropneumatic actuators

Adjustment may only be carried out when the actuator is mounted on the valve!

Zero and span are adjusted to determine the starting point and the upper range

value of the actuator.

When the control signal (reference variable) changes from 4 to 20 mA, the valve

must correspondingly pass through its entire travel range from 0 to 100 %.

Zero adjustment is always based on the closed position of the control valve.

Actuator with close fail-safe action "Air to open", zero (starting point) must be

adjusted to 4 mA and the upper range value to 20 mA.

Whereas a globe valve assuming an open fail-safe position (Air to close), requires

adjustment to be the other way round. That is, zero must be adjusted to 20 mA and

the upper range value to 4 mA.

Zero and span of the electropneumatic actuator are adjusted to rated travel by the

manufacturer.

Air to open type

Air to close type

Fig. 4

Potentiometer for span (1)

Protective cap

Zero adjuster (4)

Jumper (2)

Cover plate (3)

Zero adjuster (4)

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