GESTRA Gestramat CW 41 Original Installation Instructions Download Page 20

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No.

Nominal size

DN25

DN40, DN50

DN80, DN100

Name

Order number

Body gasket

184372

184373

184374

Spring

004950

004981

030001

Adjuster, complete

004953

Thermometer

184596

Pressure gauge

004704

w-thermostat

004941

n-thermostat

030040

k-thermostat

030042

Double cone
s-cone

004940

004980

030000

r-cone, complete
with O-ring

184283

184288

184292

Sealing ring

000992

Adjusting key

004962

Sealing ring

DN25–50 order number 010333

DN 80–100 order number 010510

Circlip

010332

O-ring for r-double
cone

030092

030093

031493

Required no. of parts dependent on type:



DN25: 1x



DN40, DN50: 2x



DN80, DN100: 3x

For thermometers and screw plugs, 4x required
To install the pressure gauge, suitable sealing tape (19) is required in place of the sealing ring. PTFE
sealing tape may be used, for example.

Summary of Contents for Gestramat CW 41

Page 1: ...Gestramat Cooling Water Control Valve CW 41 CW 41 4 MCW 41 MCW 41 4 Original Installation Instructions 819468 01 ...

Page 2: ...equipment 11 Transporting the equipment 11 Mounting and connecting the equipment 12 Preparing installation 12 Attaching parts to the equipment 13 Connecting the equipment 14 Operation 15 Adjusting the cooling water outlet temperature 15 Setting the bleed flow 17 After operation 17 Removing external dirt deposits 18 Maintaining the equipment 18 Servicing the equipment and installing spare parts 19 ...

Page 3: ...re reference Make sure that this installation operating manual is available to the operator The installation operating manual is part of the equipment Please hand over this installation operating manual when selling the equipment or passing it on Formatting features in the document Certain text elements of this installation operating manual feature a specific typographic design You can easily dist...

Page 4: ...nt parts must only be mounted or removed by qualified personnel A qualified person must be acquainted with and experienced in the following Making pipe connections Selecting suitable lifting gear and understanding the rules for its safe use Working with dangerous contaminated hot or pressurized fluids If the admissible temperature and pressure limits are exceeded the equipment may be destroyed and...

Page 5: ...h a particular job to be carried out at the site of installation Protective clothing equipment must provide protection from potential hazards in particular from injuries to Head Eyes Body Hand Feet Hearing Note that this list is not exhaustive The operator must establish personal protective equipment guidelines and specify any additional protective gear that is required if the worker is exposed to...

Page 6: ...tted before assembly Thermometer with sealing ring Pressure gauge Adjusting key The diagrams below show a type CW 41 DN25 device Equipment specification No Designation 1 Lid 2 Body gasket 3 Spring 4 Body 5 Name plate No Designation 6 Adjuster with adjusting key 7 Setting screw for bleed flow 8 Thermometer 9 Pressure gauge 10 Direction of flow arrow ...

Page 7: ...e bleed flow Optional extras The following items are available as optional extra The double cone is available in two versions s cone for high flow rates r cone for reduced flow rates with holes and additional groove with O ring The control unit consists of one DN25 two DN40 DN50 or three DN80 DN100 solids thermostats depending on the size of the equipment ...

Page 8: ...ts suitable for saline media cooling water containing ammonia and chlorinated hydrocarbons Type CW 41 4 units differ only in the type of materials used for the standard equipment For CW 41 4 models adapters for the adjuster thermometer and pressure gauge are available as optional extras These adapters increase the distance from the body making it possible to read and operate the equipment after th...

Page 9: ...reventing possible static charge If it is possible for medium to escape e g through actuating mechanisms or leaks in threaded joints the plant manufacturer or plant operator must take this into consideration when dividing the area into zones MCW 41 and MCW 41 4 The equipment has classification CE Ex II 2G D c X For use in potentially explosive atmospheres in zones surrounding atmosphere to Directi...

Page 10: ... 4 The control unit consists of one DN25 two DN40 DN50 or three DN80 DN100 solids thermostats depending on the size of the equipment When the equipment becomes hot the expansion material in the thermostat 11 expands in volume When the return temperature increases a pin is pushed out of the thermostat This lifts and therefore opens the double cone 12 against the pressure of the spring 3 The flow ra...

Page 11: ...n 12 months Use the supplied sealing plugs or other suitable seal caps in order to seal off all openings of the equipment Protect the sealing surfaces and contact areas against mechanical damage Protect the equipment and all components against hard shocks and impacts Store the equipment only in closed rooms that meet the following environmental conditions Air humidity below 50 not condensing Indoo...

Page 12: ...eparing installation Take the equipment out of the transport packaging Check the equipment for transport damage Contact the manufacturer if you detect any kind of shipping damage When supplied by the factory the connections may be sealed off with sealing plugs Remove sealing plugs before mounting the equipment Keep the sealing plugs and the packing for further use DANGER Personnel working on pipes...

Page 13: ...ing Do not apply the tool directly to the measuring equipment Attach parts supplied loose on delivery before assembling the equipment To attach the thermometer 8 proceed as follows Remove the screw plug and sealing ring from the right hand connection 20 Insert the sealing ring 18 in the right hand connection on the body Lubricate all threads and the contact surfaces of nuts and bolts with temperat...

Page 14: ... connections for the respective type of end connection CAUTION Do not drop the equipment If it falls down it may cause bruises and injuries To transport and mount the equipment safely use suitable lifting gear Connect the noose strap of the lifting gear to the body Provide sufficient support for the equipment during transport and installation Wear protective safety footwear Lightweight equipment m...

Page 15: ...erature you can change the setting The table overleaf contains the scale values for the outlet temperatures of the various types of equipment To lower the scale value screw the adjusting key further into the body To increase the scale value screw the adjusting key further out of the body The table below provides a rough guide for setting the desired outlet temperature during commissioning To preve...

Page 16: ...8 60 107 72 45 81 48 54 100 65 43 77 42 16 50 93 58 41 72 37 47 86 51 39 67 32 14 44 79 44 37 63 27 68 114 79 41 72 37 36 58 23 12 54 100 65 38 65 30 34 53 18 47 82 51 36 58 23 33 49 14 10 41 72 37 33 51 16 31 44 9 36 58 23 31 44 9 30 39 4 8 31 44 9 28 37 2 27 35 0 25 30 5 25 30 5 25 30 5 6 18 16 19 20 23 12 20 25 10 3 32 16 19 21 14 4 9 26 16 19 3 32 11 24 2 7 28 3 32 0 1 The odd values in betwee...

Page 17: ...s of life After working on the equipment make sure that all connections and valves are tight Make sure that the gaskets of the body are leakproof DANGER Personnel working on pipes are exposed to safety risks and may suffer severe injuries poisoning or even loss of life Make sure that no hot or hazardous fluid is in the equipment or the pipes Make sure that the pipes upstream and downstream of the ...

Page 18: ...lation is shut down Drain the equipment if ambient temperatures below 0 C frost are to be expected If there is a risk of freezing you must completely drain the equipment after operation To do this you can install a drainage valve in the water pocket To drain the equipment proceed as follows Make sure that medium exiting the system is caught Unscrew the adjuster at the bottom out of the body Medium...

Page 19: ...19 Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage Spare parts for CW 41 ...

Page 20: ...30000 r cone complete with O ring 184283 184288 184292 18 Sealing ring2 000992 21 Adjusting key 004962 24 Sealing ring DN25 50 order number 010333 DN 80 100 order number 010510 25 Circlip 010332 26 O ring for r double cone 030092 030093 031493 1 Required no of parts dependent on type DN25 1x DN40 DN50 2x DN80 DN100 3x 2 For thermometers and screw plugs 4x required To install the pressure gauge sui...

Page 21: ...21 Spare parts for CW 41 4 ...

Page 22: ...Sealing ring DN25 50 Order number 010333 DN 80 100 Order number 010510 25 Circlip 010332 26 Sealing ring for r double cone 030092 030093 031493 27 Adjuster with adapter DN25 50 Order number 031135 DN 80 100 Order number 184376 28 Pressure gauge with adapter 031154 29 Thermometer with installed length 105 mm 184597 30 Thermometer with adapter 184598 1 Required no of parts dependent on type DN25 1x ...

Page 23: ...zardous fluid is in the equipment or the pipes Make sure that the pipes upstream and downstream of the equipment are depressurised Make sure that the installation is switched off and protected against unauthorised or unintended activation Make sure that the equipment and the pipes have cooled down to room temperatures Wear protective clothing that is suitable for the fluid and if necessary wear pr...

Page 24: ...the lifting gear to the body Provide sufficient support for the equipment during transport and installation Wear protective safety footwear Lightweight equipment may be transported and mounted without using any lifting gear To lift equipment the weight of which exceeds approx 25 kg you need the help of a second person or suitable lifting gear Your physical strength and on site regulations and cond...

Page 25: ...w 7 Unscrew the adjusting key 21 out of the adjuster completely The spring tension in the equipment has now been reduced and you can take off the lid Slacken the four hex nuts 31 in the body evenly crosswise The lid 1 lifts off due to spring tension Remove the hex nuts Remove the lid from the body Remove the body gasket 2 Dispose of the body gasket in accordance with regulations at the location of...

Page 26: ...Remove the double cone from the body as described on page 25 Using needle nose pliers squeeze the ends of the circlip 25 together Take the circlip out of the grooves 32 Take the thermostat 11 out of the double cone To install the new thermostat proceed as follows Replace the thermostat with a new one of the same type Check the condition of the circlip 25 Replace a damaged circlip with a new one Yo...

Page 27: ...s lying against the collar of the double cone You can now install the double cone in the body Insert the double cone in the body with the opening facing downwards Position the spring on the double cone Fit a new body gasket on the four setscrews on the body opening Lubricate all threads and the contact surfaces of nuts and bolts with temperature resistant lubricant The lubricant must have the same...

Page 28: ...with spindle in the body Fit the lid with diaphragm actuator to the body as described on page 27 Screw the two hex nuts 34 onto the spindle 17 Tighten the hex nuts hand tight Converting standard equipment to diaphragm actuator To convert the equipment to work with a diaphragm actuator proceed as follows Remove the lid 1 as described on page 25 Take the double cone out of the body Take the thermost...

Page 29: ... control unit is damaged or worn Replace the control unit The equipment is working irregularly Inner parts open and close at intervals The pipe between the heat exchanger and the equipment is too long Increase the bleed flow Install the equipment immediately downstream of the heat exchanger The flow rate is too high The planned return temperature is not reached The equipment is incorrectly set Che...

Page 30: ...mental damage may be caused by poisonous fluid residues Before disposing of the equipment make sure that it is clean and free of fluid residues For the disposal of all materials observe the pertinent legal regulations concerning waste disposal Remove all residues from the equipment For the disposal of all residues observe the pertinent legal regulations concerning waste disposal Removing the equip...

Page 31: ... strength Detach the end connections of the equipment from the pipes Put the equipment onto a suitable base Store the equipment as described on page 11 Re using equipment after storage Observe the following instructions if you want to remove the equipment and use it again somewhere else Make sure that the equipment is free of any fluid residues Make sure that all connections are in good condition ...

Page 32: ...of all materials observe the pertinent legal regulations concerning waste disposal The equipment is made from the following materials Component CW 41 CW 41 4 Body 5 3103 Inner parts Brass rust proof steel Stainless steel Lid DN25 50 1 0460 A105 Lid DN80 100 5 3103 Setscrews on body Steel Hex nuts Steel galvanised Body gasket Graphite CrNi O ring EDPM FPM The diaphragm actuator is made of galvanise...

Page 33: ...0 200 230 310 350 W mm 80 95 95 145 145 H1 mm 97 128 128 166 166 H2 mm 216 255 255 316 316 Weight kg 7 12 14 33 34 Dimensions for flange connection PN 16 CL125 weights for flange connection EN PN 16 Nominal size 1 1 2 3 4 L in 6 3 7 9 9 1 12 2 13 8 W in 3 1 3 7 3 7 5 7 5 7 H1 in 3 8 5 0 5 0 6 5 6 5 H2 in 8 5 10 0 10 0 12 4 12 4 Weight lb 15 4 26 5 30 9 72 8 75 0 ...

Page 34: ...34 MCW 41 and MCW 41 4 ...

Page 35: ...5 145 145 H1 mm 165 165 165 227 227 H2 mm 216 255 255 316 316 Weight kg 10 15 17 36 5 37 5 Dimensions for flange connection PN 16 CL125 weights for flange connection EN PN 16 Nominal size 1 1 2 3 4 L in 6 3 7 9 9 1 12 2 13 8 W in 3 1 3 7 3 7 5 7 5 7 H1 in 6 5 6 5 6 5 8 9 8 9 H2 in 8 5 10 0 10 0 12 4 12 4 Weight lb 22 33 1 37 5 80 5 82 7 ...

Page 36: ...o EN 1092 2 Pressure p barg 16 16 Temperature T C 10 20 120 Maximum differential pressure ΔPMX bar 6 ΔPMX psi 87 Maximum allowable operating temperature TMO C F n thermostat 100 C 212 F w thermostat 60 C 140 F k thermostat 74 C 165 F Pressure p psig 232 232 Temperature T F 14 68 248 You can find further information in the equipment data sheet ...

Page 37: ...turer To download the current Declaration of Conformity or Declaration by Manufacturer go to www gestra com documents or contact GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon 49 421 3503 0 Telefax 49 421 3503 393 E Mail info de gestra com Web www gestra de This declaration is no longer valid if modifications are made to the equipment without consultation with us ...

Page 38: ...38 ...

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Page 40: ...rld www gestra de GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon 49 421 3503 0 Telefax 49 421 3503 393 E Mail info de gestra com Web www gestra de 819468 01 07 2017 kx_mm 802993 02 GESTRA AG Bremen Printed in Germany ...

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