Danfoss PCVA User manual

Pressure relief controller PCVA,

Safety pressure relief controller PCVSAA

English Page 2

Instructions

Hilfsgesteuerters Überströmregler PCVA,

Hilfsgesteuertes Sicherheitsüberströmventil PCVSAA

Deutsch Seite 15

DN 100- DN 250

PN 16/PN 25

Einbau-, Bedienungsanleitung

Instructions PCVA, PCVSAA

2 | © Danfoss | 2016.06 VI.JA.D2.5B

Table of Contents 1 Safety Notes ............................................ 3

2 Definition of Application ....................... 3

3 Description .............................................. 4

3.1 Construction..........................................................4

3.2 Mode of Operation .............................................4

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

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

6 Assembly.................................................. 6

6.1 Prior to Assembly.................................................6

6.2 Installation Position ............................................6

6.3 When Installing observe...................................6

6.4 Impulse Tube Installation .................................6

6.5 Insulation................................................................6

6.6 Installation Scheme ............................................7

6.7 Assembly Drawings, Dimensions ..................8

7 Start-up .................................................. 10

7.1 Required Static Pressure, Pressure

Difference............................................................ 10

7.2 Leak and Pressure Tests...................................10

7.3 Filling the System ..............................................10

7.4 Start-up..................................................................10

7.5 Putting out of Operation ................................10

7.6 Adjustment of the Setpoint...........................11

7.7 Sealing ...................................................................11

7.8 Function Test.......................................................11

8 Trouble Shooting .................................. 12

8.1 Fault, Possible Cause, Remedy......................12

8.2 Diaphragm Break of the Controller SAVA. 12

9 Replacement of Valve, Actuator, Trim 13

9.1 Dismounting and Mounting Actuator and

Valve of the Valve Unit.....................................13

9.2 Replacement of Trim Valve VFG 21..............14

9.3 Dismounting, Mounting Actuator AVA,

SAVA........................................................................14

9.4 Replacement of Trim Valve AVA, SAVA ..... 14

Instructions PCVA, PCVSAA

VI.JA.D2.5B

MAINTENANCE

FREE

1 Safety Notes

2 Definition of

Application

The controller is used for pressure control of

waterfor heating, district heating and cooling

systems.

The admissible medium temperatures depend

on the design and comprise 5 - 150 °C,

5 - 200 °C.

The technical data on the rating plates determine

the use.

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 must be performed only by qualified,

trained and authorized personnel.

Prior to assembly and maintenance work on the

controller, the system must be:

depressurized,

cooled down,

emptied and

cleaned.

Please comply with the instructions of the

system manufacturer or system operator.

Instructions PCVA, PCVSAA

4 | © Danfoss | 2016.06 VI.JA.D2.5B

3.2 Mode of Operation

The control unit consists of the PCV-VFG21 valve

unit, installed in the main pipe, and the pressure

relief controller AVA or safety pressure relief

controller SAVA installed as pilot controller in the

bypass. In the bypass line, a throttle element is

installed in front of the pilot controllers.

As a pressure relief controller, the controller

keeps the pressure before the controller unit

in accordance with the preset setpoint on a

constant level.

As a safety pressure relief controller, the

controller guarantees that the pressure is not

exceeded before the control unit. If the controller

diaphragm is

damaged, the valve is closed via the second

diaphragm.The setpoint for the pressure is

adjusted by pre-stressing the setpoint spring of

the pilot controller.

The valve and the pilot valves are

pressurebalanced. The setpoint for the

pressure is adjusted by prestressing the

setpoint spring of the pilot controller. The

valve unit in the main pipe is opening on

rising pressure. The pilot controllers in the

bypass line are closing on rising pressure.

In case of small flow rates, the valve in the

main pipe remains closed through the

pressure spring in the actuator of the valve

unit. The pressure is exclusively controlled

by the pilot controller. If the flow rate in the

bypass is increased, the

pressure in the throttle element (Venturi

nozzle) decreases.

The reduced pressure acts through an

impulse tube upon the lower chamber

of the actuator of the valve unit. The

main valve is thus opened shockfree and

continuously.

If the flow rate is reduced, the pressure in

the throttle element raises and the main

valve closes. This sequential switching

guarantees an operation free of vibrations

and a small control deviation over a wide

positioning range.

3 Description

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

data sheet.

3.1 Construction

Throttling valve

Valve Unit PCV-

VFG21

Throttling element

Pilot controller SAVA

hrottling valve

only DN150-25

Instructions PCVA, PCVSAA

VI.JA.D2.5B

5 Scope of Delivery

SAVA

DN 100-125

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

AVA

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

Throttling element

DN 150-250

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

Throttling element

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

DN 25

DN 40

Instructions PCVA, PCVSAA

6 | © Danfoss | 2016.06 VI.JA.D2.5B

pin only

weld

do NOT

weld

Depressurized system before

any assembly work !

CAUTION!

6 Assembly 6.1 Prior to Assembly:

• 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 is only permitted in horizontal

pipelines with the actuators hanging in a

downward position.

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

1. See installation scheme, section 6.6.

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

sides.

3. Care for correct position of the cutting rings 2.

6.5 Insulation

The diaphragm actuators must not be insulated

when insulating system parts.

4. Press impulse tube into the threaded fitting

up to its stop.

5. Tighten union nut, torque 40 Nm

6. Dismount again and check the position of the

cutting rings.

Instructions PCVA, PCVSAA

VI.JA.D2.5B

hrottling valve

Throttling valve

(only by DN 150 - 250)

Throttling element

CU pipe Ø 10 × 1

Pilot controller SAVA

Do not install a

shut-o valve her.

But if you do so,

it is absolutely necessary

to secure against

unauthorized closing.

lay impulse tube during mounting

Valve unit

PCV - VFG 21

CU pipe Ø 10 × 1

hrottling valve

Throttling valve

(only by DN 150 - 250)

Throttling element

CU pipe Ø 10 × 1

Shut-o valve

Pilot controller AVA

CU pipe Ø 6 × 1

lay impulse tube during mounting

Valve unit

PCV - VFG 21

6 Assembly 6.6 Installation Scheme

Installation PCVA

Installation PCVSAA

Instructions PCVA, PCVSAA

8 | © Danfoss | 2016.06 VI.JA.D2.5B

Dismount impulse

tube

Unscrew threaded

ﬁttings at the valve and

at the actuator

Close opening at the

valve with a stopper

(see assembly kit order

No. 003G1599)

Install impulse tubes

laterally because of dirt

Cu pipe Ø 6 × 1,

when laying,

use the assembly kit

order No. 003G1599

Cu pipe Ø 10 × 1

Lay when assembling.

H1 H2

Valve unit PCV - VFG 21

DN 25: pipe Ø 33.7 × 3,2

Material: ST 35.8

(not part of the delivery)

Pilot controller

AVA

DN 25

SW 50 Throttling

element

160

ca. 1000

159 244

these parts are not in the scope of delivery

6.7 Assembly Drawings, Dimensions

DN 100-125

6 Assembly

Instructions PCVA, PCVSAA

VI.JA.D2.5B

- Dismount impulse tube

- Unscrew threaded

ﬁttings at the valve and

at the actuator

- Close opening at the

valve with a stopper

(see assembly kit order

No. 003G1599)

Install impulse tubes

laterally because of dirt

Cu pipe Ø 6 × 1,

when laying,

use the assembly kit

order No. 003G1599

Cu pipe Ø 10 × 1

Lay when assembling.

H1 H2

these parts are not in the scope of delivery

DN 40: pipe Ø 48,3 × 3,2

Material: ST 35.8

(not part of the delivery)

290

cca. 1200

200

these parts are not in the scope of delivery

Dimensions

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 150 250 320 385 500

B200 210 310 336 412

A ≥ 290 320 350 410

DN 150-250

6 Assembly

Instructions PCVA, PCVSAA

10 | © Danfoss | 2016.06 VI.JA.D2.5B

8 10

7 Start-up 7.1 Required Static Pressure, Pressure

Difference

For a proper functioning, a minimum pressure

difference of p1 - p2 ≥ 0.5 bar is required.

The static pressure p1 in front of the controller

must not fall below 1.5 bar (excess pressure).

Nonobservance may lead to cavitation and

damages in the throttling element 1.

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

must:

• Remove the impulse tubes 3.

The admissible operating excess pressure in the

actuator 4is 25 bar 1). For higher pressures, you

must:

• Remove the impulse tubes 5 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.

7.3 Filling the System

Note:

The controller 6is closed when no pressure is

applied and only opens with a defined flow in the

bypass.

The pilot controllers 7are closing on rising pressure.

Procedure

1. Open shut-off valves 8that possibly exist in

the impulse tubes.

2. Slowly open shut-off units first in the return

flow 9and then in the supply flow 10.

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.

p2 p1

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