Table of Contents
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IM-P405-46
4057650/5
EMM Issue 5
ABV21i and ABV40i
Air Actuated Boiler Blowdown Valves
Installation and Maintenance Instructions
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
8. Fault finding
© Copyright 2017
IM-P405-46 EMM Issue 5
1
Printed in GB
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Summary of Contents for Spirax Sarco ABV21i
- Page 1 IM-P405-46 4057650/5 EMM Issue 5 ABV21i and ABV40i Air Actuated Boiler Blowdown Valves Installation and Maintenance Instructions 1. Safety information 2. General product information 3. Installation 4. Commissioning 5. Operation 6. Maintenance 7. Spare parts 8. Fault finding © Copyright 2017...
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Page 2: Safety Information
Equipment Directive 2014/68/EU and carry the mark when so required. The products fall within the following Pressure Equipment Directive categories: Group 2 Group 2 Product Gases Liquids DN25 DN32 ABV21i and ABV40i ABV21i DN40 - DN50 ABV40i DN65 IM-P405-46 EMM Issue 5... - Page 3 Group 2 of the above mentioned Pressure Equipment Directive. The products' use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered.
- Page 4 1.9 Tools and consumables Before starting work ensure that you have suitable tools and / or consumables available. Use only genuine Spirax Sarco replacement parts. 1.10 Protective clothing Consider whether you and / or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high / low temperature, radiation, noise, falling objects, and dangers to eyes and face.
- Page 5 1.17 Returning products Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk.
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Page 6: General Product Information
2. General product information 2.1 General description The Spirax Sarco ABV21i and ABV40i are one piece end entry, reduced bore ball valves having ISO mounting as standard. They are fitted with a 90° rotary spring return pneumatic actuator, and a limit switch box. They are used in conjunction with a Spirax Sarco blowdown timer to provide timed control of bottom blowdown, ensuring that the recommended boiler blowdown cycles occur with minimum heat loss, avoiding duplication or omission. - Page 7 Fig. 1 ABV21i LSB31 limit switch box BVA300 series pneumatic actuator Inlet port 'A' Air inlet port Fig. 2 Solenoid valve MV11 / MV12 / MV11 / MV12 General view Solenoid override screw Use '3/2' adapter plate for this application...
- Page 8 2.5 ABV21i - Pressure / temperature limits Pressure psi g Steam saturation curve Pressure bar g The product must not be used in this region. Valve Body design conditions PN40 Maximum allowable pressure 40 bar g @ 120 °C (580 bar g @ 248 °F) Maximum allowable temperature 260 °C @ 0 bar g...
- Page 9 Minimum operating temperature -29 °C (-20 °F) Note: For lower operating temperatures consult Spirax Sarco PMX Maximum differential pressure is limited to the PMO Designed for a maximum cold hydraulic test pressure of: 76.5 bar g (1 109 psi g)
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Page 10: Installation
3. Installation Note: Before actioning any installation read the 'Safety information' in Section 1. Although the valve has great structural integrity, severe misalignment and / or the pulling effect of incorrect pipe length will have a detrimental effect on the valve and must be avoided. Particular attention should be paid to correct pipe alignment such that the inlet pipework and valve are all on the same axis. - Page 11 Fit locating grub screw (in MV solenoid kit) here. Inlet Exhaust port A port B Fig. 3 BVA actuator showing inlet and exhaust ports 3.2 Switch box wiring and terminal connections are shown in Figure 4 The switch box is supplied with Pg 11 cable gland. The switches are suitable for 10 A, 250 Vac operation.
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Page 12: Operation
4. Commissioning After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms or protective devices. 5. Operation The air supply is switched on by the solenoid valve, causing two pistons in the actuator to move apart against spring pressure. -
Page 13: Maintenance
6. Maintenance Actuator Note: Before actioning any maintenance programme read the 'Safety information' in Section 1. 6.1 General Periodically check that all fasteners remain tight. No routine maintenance is required, as the actuator is supplied with sufficient lubrication for a normal working life. Depending on the severity of actuator operating conditions, periodic replacement of the 'O' rings may be required. - Page 14 6.4 Disassembly and reassembly of the actuator 6.4.1 Precautions before disassembly: Isolate and test the air and electrical supplies before working on the actuator. Disconnect the actuator and its accessories from the air tubing and electrical wiring. Disassemble the solenoid from the actuator. Disassemble the actuator from the valve and / or from its couplings.
- Page 15 If everything is in good condition, fit the new 'O' rings, bushings, slide guides and washers included in the Spirax Sarco BVA300 series maintenance kit before reassembling the actuator - see Section 6.4.3. Lubricate the parts of the actuator with Molykote B 2-2 plus grease. Apply a thin layer of grease on the 'O' rings (7, 8 and 16).
- Page 16 - See Table 1. commissioning back into service: Cold hydraulic test to the ABV21i body at 6.9 Reassembly 60 bar g (870 psi g), and the ABV40i body Reassemble in reverse order to instructions at 76.5 bar g (1 ...
- Page 17 6.12 Switch box To adjust switch box mircoswitch settings a) Switch off power supply to switch box. b) Remove switch box cover. c) Remove indicator disc. d) Turn the cam to the required position. e) Replace indicator disc - ensure it is aligned correctly. Replace cover and switch on air and power correctly.
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Page 18: Spare Parts
Note: Before actioning any maintenance programme observe the 'Safety information' in Section 1. Any par ts replacement must be implemented with original Spirax Sarco spare parts, or any warranty implied or expressed is null and void. The manufacturer will not be responsible for any actuator dysfunction, if original Spirax Sarco parts have not been used. - Page 19 Note: all the spares mentioned above are sold together in one spare part kit. Example: 1 - BVA300 series maintenance kit with 'O' rings in NBR for a Spirax Sarco BVA320S /14 pneumatic actuator.
- Page 20 Always order spares by using the description given in the column headed 'Available spares' and state the size and type of ball valve. Example: 1 set of seats, insert 'O' ring and stem seals for a Spirax Sarco DN50 ABV21i boiler blowdown valve.
- Page 21 Insert tool - Required to aid the removal of the ball valve insert (2) Not shown Please note: Spare parts are common for both the ABV21i and ABV40i. Caution: The ball must be installed with the vent hole on the upstream side of the valve.
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Page 22: Fault Finding
8. Fault finding Before dismantling the actuator, consult the instructions given below: 8.1 Actuator with solenoid valve If the actuator does not function check that: 1. The valve is free to rotate. 2. The actuator is of the correct size. 3. - Page 23 5. With spring return actuators, check for misplaced or broken springs. If springs are broken, check the body for scoring. 6. If the actuator and valve are free, reassemble the actuator and retest. If the unit still fails to operate, consult Spirax Sarco. IM-P405-46 EMM Issue 5...
- Page 24 IM-P405-46 EMM Issue 5...
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