Full Text Searchable PDF User Manual
Gestramat
Cooling-Water Control Valve
CW 44
CW 44k
E N
E n g l i s h
Original Installation Instructions
819615-00
Table of contents
Foreword ............................................................................................................................................ 3
Availability ............................................................................................................................................ 3
Formatting features in the document ...................................................................................................... 3
Formatting features for warnings in the document................................................................................... 3
Formatting features for warnings of property damages ............................................................................ 3
Safety ................................................................................................................................................. 4
Usage for the intended purpose ............................................................................................................. 4
Basic safety notes ................................................................................................................................. 4
Information on property damages or malfunctions ................................................................................... 4
Personnel qualifications ......................................................................................................................... 5
Protective clothing ................................................................................................................................ 5
Further information ........................................................................................................................... 5
Application of European Directives ......................................................................................................... 5
Product package and description of equipment ....................................................................................... 6
Task and function .................................................................................................................................. 7
Storing and transporting the equipment .......................................................................................... 7
Storing the equipment ........................................................................................................................... 7
Transporting the equipment ................................................................................................................... 7
Installing, connecting and dismantling the equipment ................................................................... 8
Preparations for installation ................................................................................................................... 8
Connecting the equipment ..................................................................................................................... 8
Operation ............................................................................................................................................. 9
Adjusting the equipment ........................................................................................................................ 9
After operation ...................................................................................................................................... 9
Servicing the equipment ...................................................................................................................... 10
Spare parts ......................................................................................................................................... 10
Removing the equipment ..................................................................................................................... 10
Disposal of the equipment ................................................................................................................... 10
Technical data .................................................................................................................................. 11
Dimensions and weights ...................................................................................................................... 11
Pressure & temperature ratings ........................................................................................................... 11
Troubleshooting ............................................................................................................................... 11
Manufacturer's declaration ............................................................................................................. 12
3
Foreword
This Installation & Operating Manual will help ensure
proper, safe and cost-efficient use of the following
valve models:
◗
CW 44
◗
CW 44k
These valves are referred to below simply as
equipment.
This Installation & Operating Manual is intended for
all persons bringing this equipment into service, and
operating, using, servicing, cleaning or disposing of
the equipment. In particular, the Installation & Oper-
ating Manual is aimed at service technicians, trained
specialist personnel, and qualified and authorised
operating personnel.
Each of the above must have read and understood
the content of this Installation & Operating Manual.
Following the instructions in the Installation & Oper-
ating Manual helps to avoid danger and increases
the reliability and service life of the equipment.
In addition to the instructions in this Installation &
Operating Manual, compliance with the applica-
ble binding rules on accident prevention in the
country and location of use, and with the generally
recognised technical regulations for safe and proper
working, is essential.
Availability
Always keep this Installation & Operating Manual
together with the system documentation. Make sure
that the Installation & Operating Manual is available
to the operator.
The Installation & Operating Manual is part of the
equipment package. Hand over this Installation &
Operating Manual if you sell or pass on the equip-
ment to a third party.
Formatting features in the docu-
ment
Different types of information in the Installation &
Operating Manual are formatted in different ways.
This helps you to distinguish easily between the
following types of information:
Normal text
Cross references
◗
Lists
◗
Bullet points in lists
➢
Action to be taken.
These tips contain additional informa-
tion, e.g. about cost-efficient use of the
equipment.
Formatting features for
warnings in the document
DANGER
Instructions with the word DANGER warn of
a dangerous situation that results in death
or serious injury.
WARNING
Instructions with the word WARNING warn
of a dangerous situation that may possibly
result in death or serious injury.
CAUTION
Instructions with the word CAUTION warn
of a situation that may result in minor or
moderate injury.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation result-
ing in property damage.
4
Safety
Usage for the intended purpose
The following types of cooling-water control valve
are employed in the cooling-circuit return, in order
to maintain a constant return temperature:
◗
CW 44
◗
CW 44k
The equipment may only be used within the ad-
missible pressure and temperature limits, with due
consideration of chemical and corrosive influences.
Usage for the intended purpose also includes read-
ing and adhering to all instructions in this manual,
particularly the safety notes.
Any other use of the equipment shall be considered
as improper use.
Improper use also includes using equipment made
of materials that are unsuitable for the fluid used.
Basic safety notes
Risk of serious injury
◗
The equipment is under pressure during opera-
tion and can get hot or cold. Only perform work
on the equipment if the following conditions are
satisfied:
◗
The pipes must be isolated from pressure.
◗
All fluid must be thoroughly removed from
pipes and the equipment.
◗
Before carrying out any work, the higher-level
system must be switched off and secured so
it cannot be switched back on by unauthor-
ised persons.
◗
The pipes and equipment must have cooled
to around 20 °C (lukewarm).
◗
The equipment may only be used with fluids that
are not aggressive in contact with its material
and seals. Otherwise, leaks may occur and hot
or toxic fluid may escape.
◗
The equipment and its components may only
be installed or removed by specialist personnel.
Specialist personnel must have knowledge and
experience of the following areas:
◗
Connecting pipes.
◗
If the admissible pressure and temperature
ratings are exceeded, the equipment may be
destroyed causing hot or pressurised fluid to
escape.
◗
Make sure the equipment is always used
within the admissible pressure and tempera-
ture ratings
.
You can find information on the pressure and
temperature ratings on the rating plate and in the
"Technical data" section.
Risk of minor injury
◗
There is a risk of cuts from sharp-edged internal
parts of the equipment. Always wear protective
gloves when working on the equipment.
◗
If the equipment is inadequately supported
during installation, there is a risk of getting
squashed if it falls. During installation, secure
the equipment so it cannot fall. Wear sturdy
safety boots.
Information on property damages
or malfunctions
◗
Installing the equipment against the specified
direction of flow or in the wrong location will
result in malfunctions. This could cause damage
to the equipment or the higher-level system.
Install the equipment in the pipe in the direction
of flow indicated on the body.
◗
Equipment made from materials unsuitable
for the fluid used wear faster. This can cause
the fluid to escape. Make sure the material is
suitable for the fluid used.
5
Personnel qualifications
Specialist personnel must have knowledge and
experience of the following areas:
◗
Explosion and fire precautions and occupational
health & safety provisions applicable at the site
of installation
◗
Work on pressure equipment
◗
Producing connections on pipes
◗
Work with hazardous (hot or pressurised) fluids
◗
All information in this Installation & Operating
Manual and other applicable documentation
Protective clothing
The plant operator must ensure that the protective
clothing prescribed for the particular activity is worn
during all work at the site of installation. Protective
clothing must be selected as suitable for the fluid to
be used. It must ensure protection from the risks to
be expected during the respective activity at the site
of installation. In particular, protective clothing must
protect against the following risks:
◗
Head injuries
◗
Eye injuries
◗
Bodily injuries
◗
Hand injuries
◗
Foot injuries
◗
Damage to hearing
This list is not exhaustive. The plant operator must
compile instructions for additional protective clothing
in accordance with the specific risks at the site of
installation.
Further information
Application of
European Directives
Pressure Equipment Directive
The equipment conforms to this directive (see
"Manufacturer's Declaration" section) and can be
used for the following fluids:
CW 44
◗
Fluid group 2
CW 44k
◗
Fluid groups 1 and 2
ATEX Directive
The equipment does not have its own potential
ignition source and is therefore not subject to this
directive (see "Manufacturer's Declaration" section).
Once installed, static electricity may arise between
the equipment and the connected system.
During use in potentially explosive atmospheres,
the discharge or prevention of possible electrostatic
charging is the responsibility of the manufacturer or
owner of the system.
If there is a possibility that fluid might escape, e.g.
via actuating devices or leaks in screwed couplings,
the manufacturer or owner of the system must take
this into consideration when dividing the area into
zones.
6
No.
Designation
1
Body
2
Cover
3
Name plate
4
Body gasket
5
Direction of flow arrow
6
Bleed flow adjustment unit
7
Outlet temperature adjustment unit
8
Bolts (4x)
9
Sealing plug for drainage
10
Sealing ring
Name plate
On the name plate, you will find the following
information:
◗
Manufacturer
◗
Type designation
◗
Version
◗
Nominal size
◗
Pressure rating
◗
Maximum admissible differential pressure
On the body, you will find the following information:
◗
Date of manufacture
◗
Material
◗
Direction of flow
◗
Batch identification
There are two types of thermostat for different outlet
temperatures:
◗
n-thermostat for an outlet temperature
from -2 to 106 °C (CW 44)
◗
k-thermostat for an outlet temperature
from -32 to 71 °C (CW 44k)
Product package and
description of equipment
Types of connection
The equipment can be supplied with the following
types of connection:
◗
Screwed end
PM
X
16
ba
r /
232
psi
MA
DE
BY
GE
ST
RA
PMA
25
ba
r /
363
psig
TM
A
120
°C
/ 248
°F
1/2”
15PN25
GESTRA
CW
44
7
8
6
5
3
1
4
2
10
9
7
Task and function
Task
Cooling-water control valves are directly actuated
proportional controllers. They are used to maintain
a constant return temperature in a cooling-water or
cooling-solution return. The return temperature can
be adjusted.
This enables a higher return temperature and there-
fore increased heat absorption by the cooling water
or cooling solution. The consumption of coolant and
energy is therefore reduced.
Cooling-water control valves also ensure the
demand-based supply of coolant to heat exchangers
connected in parallel.
Function
When the equipment becomes hot, the expansion
material in the thermostat expands in volume. When
the return temperature increases, a pin is pushed
out of the thermostat. This opens the orifice. and
increases the flow rate.
A bleed flow is continually present, even when the
equipment is closed. The bleed flow enables the
equipment to react quickly to changes in the return
temperature.
Storing and transporting
the equipment
Attention!
Storing or transporting the equipment
incorrectly can damage it.
➢
Seal off all openings with the supplied –
or comparable – covers.
➢
Make sure the equipment remains dry
and is protected against a corrosive
atmosphere.
Storing the equipment
Store the equipment solely in the following
conditions:
◗
Connecting and sealing surfaces must be
protected against mechanical damage.
◗
The equipment and all components must be
protected against jolts and impacts.
◗
The equipment may only be stored in closed
rooms in the following ambient conditions:
◗
Air humidity below 50%, non-condensing
◗
Clean room air, not salty or corrosive in other
ways
◗
Temperature 5–40 °C.
Make sure that these conditions are constantly
maintained throughout storage.
Transporting the equipment
CAUTION
Risk of injury from the equipment falling.
➢
Support the equipment during transport
and installation.
➢
Wear sturdy safety boots.
8
Installing, connecting and
dismantling the equipment
DANGER
Risk of severe injury or death due to burns
or intoxication during work on pipes.
➢
Make sure there are no hot or hazard-
ous fluids in the equipment or pipes.
➢
Make sure the pipes to the equipment
are not under pressure.
➢
Make sure the system is switched off
and secured so that it cannot be turned
on by an unauthorised person.
➢
Make sure the equipment and pipes
have cooled to a lukewarm tempera-
ture.
➢
Wear suitable protective clothing for
the fluid, and use suitable personal
protective equipment if necessary.
You will find information on suitable protective cloth-
ing and personal protective equipment in the safety
data sheet for the fluid used.
Preparations for installation
➢
Inspect the equipment for transport damage.
➢
If you discover transport damage, please contact
the manufacturer.
Connections may be sealed with plugs on delivery.
➢
Remove sealing plugs before installation.
➢
Switch off the system and secure so that it
cannot be turned on by an unauthorised person.
➢
Shut off the supply lines to the equipment.
➢
Drain the pipes.
Connecting the equipment
Installation with a horizontal direction of flow and the
cover facing down ensures optimum function.
◗
Install the equipment in the cooling-water return
as close as possible to the heat exchanger.
◗
Install the equipment in a water pocket.
◗
If the fluid is dirty or contains foreign bodies,
install a dirt trap upstream of the equipment.
◗
If there are chalk deposits, use a water softener.
◗
If the equipment is being used as an end valve,
make sure that it cannot run empty.
Otherwise,
drying out or deposits are possible.
◗
If there is a risk of freezing, install a drainage
valve in the water pocket.
The equipment can be damaged if connections are
too weak.
➢
Make sure connections are sufficiently sturdy to
withstand the weight of the equipment and the
forces to be expected during operation.
➢
Make sure the system's pipework is clean.
➢
Make sure the equipment is free of foreign
bodies.
➢
Install the equipment in the desired direction
of flow. Make sure the direction of flow in the
pipe matches the flow direction arrow on the
equipment.
➢
Correctly connect the equipment to the pipes as
suitable for the type of connection provided.
9
Operation
Adjustment
You can adjust the equipment using a size 5 Allen
key
➢
Remove the plastic plugs from the adjustment
units.
Adjusting the bleed flow
➢
Adjust the bleed flow on the adjustment unit (6).
Turning it anti-clockwise increases the bleed
flow.
A 1/8 turn changes the flow by a factor of 1.4.
As a rule, no more than a quarter to a half turn is
required.
Adjusting the outlet temperature
➢
Adjust the outlet temperature using the adjust-
ment unit (7). Turning anti-clockwise raises the
outlet temperature, turning clockwise lowers it.
➢
Wait 5 minutes until the system has adapted to
the new setting.
Total travel of temperature adjustment:
approx. 23 turns from the lower to the upper limit.
1 turn equals a travel of
1 mm = approx. 4.5 to 5.0 K temperature differ-
ence.
Basic setting
The orifice is still straight in its seat, then rotate it
1 turn clockwise, i.e. the valve is now open. In the
basic setting the outlet temperature is approx. 16 ±
2 °C at an ambient temperature of 21 ± 2 °C.
Starting from the upper limit, the basic setting corre-
sponds to approx. 17 turns clockwise.
Adjustment aid: Point of reference T1
Measured with a depth gauge from the upper edge
of the adjuster to the lower end of the hole in the
adjusting screw Allen key:
– The upper limit is approx. 8-9 mm, or max.
outlet temperature
– Basic setting approx. 25- 26 mm
After operation
Attention!
Frost damage can occur when the system
is not in operation.
➢
Drain the equipment if there is a risk of
frost.
6
7
T1
10
Servicing the equipment
The equipment does not require any particular
maintenance work. You must remove the equipment
prior to any cleaning or repair work.
Spare parts
No.
Designation
Order no.
6
Bleed flow adjustment unit
355249
7
Outlet temperature adjust-
ment unit
355250
4
Body gasket (20x)
560493
The following tools are required for working on the
equipment:
◗
Size 5 and 8 Allen keys
◗
Size 19 and 22 open-end spanners
Tightening torques
No.
6
7
8
9
Nm
40
40
35
40
Removing the equipment
➢
Drain the pipes.
➢
Shut off the supply lines to the equipment.
➢
In the event of back pressure, block off the
drainage line downstream of the equipment.
To drain the equipment, proceed as follows:
➢
Make sure that fluid exiting the system is
caught.
➢
Slacken the sealing plugs slightly.
Fluid exits the system.
➢
Wait until the pressure has dissipated and the
equipment has drained.
➢
Unscrew the sealing plug from under the cover.
➢
Remove the sealing ring.
Dispose of the sealing ring in accordance with
regulations at the location of use.
➢
Slacken the screwed ends.
Attention!
The equipment is under spring tension.
➢
Completely unscrew the screws evenly
in turn.
Assembling the equipment
Use new gaskets.
➢
Lubricate all threads and contact surfaces of
nuts and bolts with temperature-resistant lubri-
cant.
The lubricant must have the same properties as
OKS
®
217.
Disposal of the equipment
The equipment consists of the following materials:
Component
Material
Body
1.0460/A105
Inner parts
Brass/ stainless steel
Cover
1.0460/A105
Bolts
1.7225
Body gasket
Graphite CrNi
O-ring
EPDM
PM
X
16
ba
r /
232
psi
MA
DE
BY
GE
ST
RA
PMA
25
ba
r /
363
psig
TM
A
120
°C
/ 248
°F
1/2”
15PN25
GESTRA
CW
44
7
8
6
5
3
1
4
2
10
9
11
Technical data
Dimensions and weights
◗
CW 44, CW 44k
Weights
Nominal size
G 3/8
G 1/2
G 3/4
G 1
Weight [kg]
3.2
3.1
3.1
3.0
Temperature & pressure ratings
Pressure
p [barg]
25
Temperature
T [°C]
120 (CW 44)
85 (CW 44k)
Maximum differential pressure
∆PMX [bar]
16
Adjustable outlet temperature
[°C]
n-thermostat: -2/106 (CW 44)
k-thermostat: -37/71 (CW 44k)
Troubleshooting
Problem
Cause
Action
The flow rate is too low.
The planned return temperature is
not reached.
The size and design of the
equipment differ from the
system data.
Change the equipment settings.
Check the size.
Use equipment of a size that conforms
to the system data.
Fluid is escaping (leakage).
The equipment or body is
damaged.
Replace the equipment.
Fluid is escaping (leakage).
A gasket is damaged.
Replace the damaged gasket.
Clean the sealing surfaces.
The equipment does not regulate
the flow perfectly.
The control unit is damaged
or worn.
Replace the equipment.
The equipment is working irreg-
ularly. 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.
Check the equipment settings.
Reduce the bleed flow.
The movement of inner parts
is obstructed by deposits.
Check the equipment settings.
Reduce the bleed flow.
Clean the equipment.
Make sure that the movement of inner
parts is not obstructed.
95 mm
~190 mm
GESTRA AG
Münchener Strasse 77
28215 Bremen
Germany
Tel.
+49 421 3503-0
Fax
+49 421 3503-393
E-mail info@de.gestra.com
Web www.gestra.com
819615-00/10-2017cm (808968-00) · GESTRA AG · Bremen · Printed in Germany
Manufacturer's Declaration
You can find details on the conformity assessment in
accordance with European Directives in our Declara-
tion of Conformity or Manufacturer's Declaration.
You can request the valid Declaration of Conformity
or Manufacturer's Declaration from the address
below.
Modifications to the equipment not approved by us
will cause this Declaration to become invalid.
You can find our authorised agents around the world at:
www.gestra.com
Agencies all over the world:
www.gestra.de