CONFLOW AMS Series Installation And Maintenance Manual Download Page 1

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M/UNIWORLD-M/E

2020

Installation and Maintenance Manual

Electric Valves

“PSL – PSL/AMS”

2 Way

– 3 Way

WWW.CONFLOW.IT

Servizio Assistenza

E-mail: [email protected]

Summary of Contents for AMS Series

Page 1: ...M UNIWORLD M E 05 2020 Installation and Maintenance Manual Electric Valves PSL PSL AMS 2 Way 3 Way WWW CONFLOW IT Servizio Assistenza E mail servicing conflow it ...

Page 2: ... 4 COVER REMOVAL 10 3 5 BASIC VERSION INTERNAL SWITCHES 11 3 5 1 BASIC VERSION INTERNAL SWITCHES PSL201 214 11 3 5 1 1 BASIC VERSION INTERNAL SWITCHES FORCE STROKE 11 3 6 ELECTRICAL POWER SUPPLY 12 3 6 1 AMS VERSION WIRING DIAGRAMS 12 3 6 2 PSL BASIC VERSION WIRING DIAGRAMS 13 3 6 3 PSL AMS AC DC MONOPHASE MAIN POWER SUPPLY 14 3 6 4 PSL AMS AC THREE PHASE MAIN POWER SUPPLY on request 14 3 6 5 PSL ...

Page 3: ...T REPLACEMENT 22 3 14 2 PACKING REPLACEMENT 24 3 14 2 1 VALVES 2000 EP 5000 EP 2100 EP 5100 EP 5800 EP 24 3 14 2 2 VALVES 2600 EP 5600 EP 2700 EP 5700 EP 26 3 14 3 REPLACEMENT OF THE PLUG PROFILE SOFT SEAL and COMPARTMENT 26 3 12 5 ACTUATOR MAINTENANCE 27 4 OPERATING ANOMALIES 27 4 1 VALVE OPERATING ANOMALIES IN GENERAL 27 4 2 AMS TYPE OPERATING ANOMALIES ACTUATOR LIST OF ERRORS 28 5 RISK ANALYSIS...

Page 4: ...ON Before removing the cover of the actuator ensure the main power supply is disabled preventing any possible involuntary removal The live areas must be isolated before starting to work ATTENTION Ensure the actuator always works in optimal conditions any damage or error and change of operating characteristics which may regard safety must be notified Non compliance with the main safety information ...

Page 5: ...r high humidity you are advised to use an anti condensate resistor as well as a higher degree of protection optional accessories 3 ELECTRIC VALVES TYPE 2000 EP 2100 EP 2600 EP 2700 EP 5000 EP 5100 EP 5600 EP 5700 EP 5800 EP PSL202 204 AMS PSL210 214 AMS Stroke 50 PSL320 325AMS ON REQUEST Figure 2 Dimensions mm AMS Version 90 90 Figure 1 Installation position ...

Page 6: ...n A possible wrong manoeuvre could cause torsion and breakage of the bellows 3 2 ELECTRIC VALVES COMMISSIONING The PSL AMS actuators were designed as valve electrical actuators The actuator is assembled on the value using small columns The mechanical power is generated by a 24 volt DC motor which is controlled electronically using pulse width modulation PWM The motor torque is transmitted from a s...

Page 7: ...valve or setting of the limit positions ATTENTION The handwheel is permanently engaged and rotates during operation of the motor in the series devices of the PSL202 214 and BASIC version ATTENTION Do not exceed the electrical limit switch setting using the handwheel The mechanical limits must be correctly set If these instructions are not observed damage or malfunctions of the actuator can occur D...

Page 8: ... working hours or when the stem moves in a linear manner You are advised to use anti seize molybdenum disulphide grease for temperatures 200 C 3 3 ACTUATOR ASSEMBLY ON VALVE The valves are supplied calibrated and tested ready to work with the actuator assembled in the conditions requested by the client during the order phase 3 3 1 ACTUATOR REPLACEMENT ASSEMBLY PSL202 214 AMS and PSL 201 214 BASIC ...

Page 9: ...per end Place the actuator on the valve The small columns are screwed in with hexagon socket head cap screws inserted under the flange 4 With the stem downwards move the coupling until the stem touches the valve Screw in the joint for 12 mm on stems M10 and 16 mm for stems M14 5 6 Fasten the coupling joint Tighten the locking screws crossways with 8 Nm force ...

Page 10: ... valve stem Secure the coupling joint using a counter a counter nut item 2 Move the valve stem with the coupling joint and the Belleville washers item 9 in the screw drive screwing the rotary nut on the bottom using the cross key supplied Move the small columns item 10 into the holes of the assembly flange and screw in with the locking screws ATTENTION Before the locking screws are screwed in ensu...

Page 11: ...g it pull the cover upwards PSL214 AMS and PSL202 210 AMS IP67 PSL214 and PSL202 210 IP67 Remove the handwheel by loosening the locking grub screw remove the locking screws of the actuator cover pull the cover upwards For electrical connection there is no need to remove the cover PSL320 AMS PSL 325 AMS IP65 PSL320 325 IP65 Unscrew the locking screws of the actuator Pull the cover upwards ...

Page 12: ...4 3 5 1 1 BASIC VERSION INTERNAL SWITCHES FORCE STROKE To disconnect the limit switch depending on the force the limit switches can be set using the spring joint compression s To carry out this operation use the manual command handwheel Turn the handwheel until the plug closes then Open the closure screw and adjust the gear screw until it clicks at end of stroke then tighten the closure screw 1 op...

Page 13: ...the switch or sectioning circuit as the insulation circuit of the actuator valve ATTENTION The electrical installation as well as the overcurrent and overvoltage protection systems must comply with the standards DIN IEC 60364 4 41 responsible protection class I protection class III 24V AC 24V DC and also the standard DIN IEC 60364 4 44 in compliance with the overvoltage categories of the actuator ...

Page 14: ...actuator well and tighten the cable glands to ensure protection as outlined in the specifications The wiring diagram can differ based on the actuators in the special version X1 Not used X2 Internal cable X3 Not used X4 Potentiometer 1 0 1000 Ohm optional X5 1 Neutral X5 2 Phase to Open X5 4 Phase to Close X7 Internal cable X9 Potentiometer 2 0 1000 Ohm optional X0 Potentiometer 1 with PSAP X11 Pot...

Page 15: ...s can vary from 0 14 mm to 2 5 mm as well as a PE screw on the structure Comply with the power supply and the maximum power of the actuator as indicated on the actuator label Connect the power supply and command lines to the terminals as outlined in the wiring diagram 3 6 4 PSL AMS AC THREE PHASE MAIN POWER SUPPLY on request ATTENTION Disconnect electricity and protect yourself from any possible u...

Page 16: ... as well as a PE screw on the structure Comply with the power supply and the maximum power of the actuator as indicated on the actuator label Connect the power supply and command lines to the terminals as outlined in the wiring diagram 3 6 6 PSL BASIC AC THREE PHASE MAIN POWER SUPPLY on request ATTENTION Disconnect electricity and protect yourself from any possible unauthorised and or involuntary ...

Page 17: ...for a control within a range of 0 20 Ma or 0 10 V split range is also possible 3 7 2 2 Feedback signal for process control Optional on request The terminals from 15 to 17 are used to receive process sensor feedback an optional on request process controller in a range of 0 20 Ma or 0 10 V ATTENTION The following binary inputs 3 5 2 3 and 3 5 2 4 have priority over the control signal if the actuator...

Page 18: ...on points of the optional additional signalling limit switch can be freely calibrated via cams Terminals 18 19 and 20 21 are clean opening or closure contacts The standard signals are calibrated to 230 VAC 5 The special limit switches with gold plated contacts are available for low power up to 100 Ma and 30V 3 7 3 3 Power supply for process sensor The terminals 14 and 17 offer the advantage of non...

Page 19: ... powered separately To replace the resistor connect two cables to the terminal of the motherboard as represented in the image on the left The anti condensate resistor is available in two different versions for 24 VAC DC or 115 230 VAC Choose the voltage of the actuator based on the voltage Assembly of the resistor must be carried out in the position indicated on the base using the screws supplied ...

Page 20: ...the communication port 3 10 COVER CLOSURE PSL 202 PSL 210 AMS and BASIC VERSION IP65 See the label on the cover of the actuator ATTENTION Ensure the cover is not assembled correctly and does not interfere with movement of the handwheel stem Insert the cover in the two reference internal notches PSL 214 and PSL 202 110 AMS and BASIC VERSION IP67 Place the cover on the actuator and ensure the two lo...

Page 21: ... frees the planned maximum force torque each time it reaches the final position If the closure point inside the valve is modified for example when the seal gasket is worn the actuator will move forward based on its actuation range trying to reach the planned force torque 3 11 1 2 Automatic positioning limitation In normal operation the actuator stops in the position it was in as the mechanical sto...

Page 22: ... the valve is moving in both the limit positions 2 3 Fixed green light The valve has successfully started and is ready to enter in operation 3 12 2 MANUAL COMMISSIONING 1 2 Connect the PSCS USB cable to the PC and start the software Select the type of actuator and the program interface 3 4 Select Operate Commissioning and confirm with OK During manual commissioning ensure the correct value for the...

Page 23: ...ACTIVATE THE ACTUATOR ELECTRICALLY FROM NOW ON YOU CAN EXTRACT THE YOKE ACTUATOR AND ANY COMPONENT CONNECTED 3 14 1 BODY GASKET REPLACEMENT ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL CONSIDERING THE COMPLEXITY OF THE OPERATIONS FOR BODY GASKET S REPLACEMENT YOU ARE ADVISED TO CONTACT OUR SUPPORT SERVICE For EP valves Fig 2000 EP 5000 EP 2100 EP 5100 EP 5800 EP proceed as follows unscrew the...

Page 24: ...nt washer ref 4 if the valve is model 2600 5600 EP the plug remains inside the compartments same applies for 5700 EP DN15 20 then unscrew the locking nuts ref 17 and remove the servomotor bonnet trim assembly remove the old gasket clear the compartment carefully and proceed to replace the gasket ref 9 Then proceed to assemble in the reverse order If the valve is model 2700 5700 EP DN25 200 the low...

Page 25: ...EP 5000 EP Fig 5000 EP 2100 EP 5100 EP 5800 EP proceed as follows unscrew the locking nuts ref 12 that tighten the bonnet ref 9 at the same time remove the overall actuator with the bonnet and trim connected and then proceed as follows unscrew the nuts ref 17 unscrew and remove the entire stem ref 7 unscrew the packing bush ref 16 with a hooked iron tool gently extract the packing rings ref 15 the...

Page 26: ...UNIWORLD Series M UNIWORLD M E ed 01 2020 WWW CONFLOW IT Page 25 2000 EP 5000 EP Fig PACKING ...

Page 27: ... must also be changed see 3 14 1 Then proceed to assemble the new packing following the previous operations in the reverse order see Fig PACKING Then proceed to assemble in the reverse order 3 14 3 REPLACEMENT OF THE PLUG PROFILE SOFT SEAL and COMPARTMENT ATTENTION IF THE VALVE IS FITTED WITH A SOFT SEAL CONSIDERING THE COMPLEXITY OF THE OPERATIONS FOR TRIM REPLACEMENT YOU ARE ADVISED TO CONTACT O...

Page 28: ...ment compared to index 3 Reposition the stroke reference based on index 4 The instrumentation does not supply the correct signal and is necessary to execute stroke 4 Search the causes on the instrumentation The stem moves in jolts 1 Stem seized and or damaged 1 If possible polish the stem otherwise replace the trim 2 Sediment in packing chamber 2 Replace the bonnet with packing Heavy seal compartm...

Page 29: ...tuator does not close the valve correctly 1 The actuator was not correctly commissioned 2 The actuator force torque too low 1 Repeat commissioning 2 Check actuator selection X X The actuator is working but does not respond to the control signal variation 1 The fixed digital signal is on 2 The actuator is configured to work with a process controller 1 Check setting of the control signal see AMS PSC...

Page 30: ...polarity 2 Ensure correct feedback range of the process 3 Check the process sensor and its power supply Errors inside actuator environment Possible causes Possible solutions X X The actuator goes to the preselected position 1 The safety binary signal is applied 2 Power supply errors in actuators with PSCP option 1 Disconnect the signal 2 Check power supply X X Control signal disconnected or outsid...

Page 31: ...e team X X Electronic errors or invalid parameters 1 Power supply cut during commissioning 2 Electrical component defects 1 Relaunch the parameters see AMS PSCS manual then repeat commissioning 2 Contact PS service team X X Critical or maximum temperatures reached 1 Number starts too high 2 Ambient temperature too high 1 Check application settings 2 Check ambient temperature and try to reduce it s...

Page 32: ...nd or chooses the valve CAUSE REACTION FORCE TO EXTERNAL STRESS EFFECT Deformation structural failure DANGER Breakage or deformation of the body leaking fluid SOLUTION 1 Check there are not external loads it is compulsory for the installation technician to protect the valve from external stress 2 This manual in section 2 point 2 1 describes the indications in point 1 and 2 3 The installation techn...

Page 33: ...uids SOLUTION 1 Maintenance activities must be carried out with the valve shut off 2 The valve must be free of hydrostatic pressure 3 The valve must be shut off as described in this manual in point 1 General safety information CAUSE EXTERNAL ENVIRONMENT ADDITIONAL LOADS Wind and Earthquake not applicable EFFECT Deformation structural failure DANGER Breakage and or deformation of the body leaking f...

Page 34: ...ne di conformità utilizzata Conformity Assessment procedures followed Buona Prassi di Ingegneria SEP CERTIFICATO DI CONFORMITA I prodotti sono stati verificati e ispezionati rispetto al nostro Sistema Controllo Qualita UNI EN ISO 9001 Noi certifichiamo che questo prodotto corrisponde alla Vostra richiesta e che le sue caratteristiche sono in conformita con le nostre specifiche tecniche CERTIFICATE...

Page 35: ... primo trattino GRUPPO 1 Table 8 Piping reffered to in Article 4 1 c ii first indent GROUP OF FLUID 1 Max pressione ammissibile Max allowable pressure DN PN 15 125 16 15 100 ANSI 150 20 bar 15 50 40 15 40 ANSI 300 50 bar C Conformity Assessment procedures followed Procedure di valutazione di conformità utilizzata Modulo A CAT I MODULE A CAT I Tutti i fluidi di gruppi e tabelle classificati in Art ...

Page 36: ...ble 8 Piping reffered to in Article 4 1 c ii first indent GROUP OF FLUID 1 Max pressione ammissibile Max allowable pressure DN PN 150 250 16 125 200 ANSI 150 20 bar 65 200 40 50 200 ANSI 300 50 bar C Conformity Assessment procedures followed Procedure di valutazione di conformità utilizzata Modulo A2 CAT II MODULE A2 CAT II Monitoraggio eseguito da TECNO Srl Via A Colla 7 2 17014 CAIRO MONTENOTTE ...

Page 37: ... Allegato IIB Direttiva Macchine 2006 42 CE è disponibile su richiesta presso l uffico vendite Mail vendite conflow it va compilata con i dati di commessa ordine cliente Tipo Valvola Tipo Attuatore Serial N The Declaration of Incorporation Annex IIB to Machine Directive 2006 42 EC is available on request from the sales office Mail sales conflow it must be completed with the order acknoledgemnt cus...

Page 38: ... 2019 Gli Attuatori Elettrici a bordo valvola sono conformi alle seguenti Direttive Electric Actuators on valve board are conformed to following Directives Costruttore Manufacturer PS Automation GmbH Phlllp Kramer Ring 13 D 67098 Bad Dürkhelm Date of Issue Data di rilascio 22 11 2019 Via Lecco 69 71 20864 AGRATE BRIANZA MB ITALY ...

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Page 40: ...Servizio Assistenza Servicing Department Via Lecco 69 71 20864 AGRATE BRIANZA MB ITALY Tel 39 0 39 651705 650397 Fax 39 0 39 654018 E mail servicing conflow it Web www conflow it ...

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