FDV-FVV Diverter valves

DMN-Westinghouse
Operation instruction + Maintenance
Safety instructions

FDV-P Flap Diverter Valve

Size : 50-65-80-100-125-150

FDV-F Flap Diverter Valve

Size : 50-65-80-100-125-150
200-250

FVV Fill Vent Valve

Size : 50-65-80-100-125-150

Customer :

Purchase order no. :

DMN-Westinghouse order no. :

Type :

Serial no. :
DMN-Westinghouse FDV-FVV Diverter Valves

General

- For the promotion of the life span and correct functioning of DMN-Westinghouse
diverters we advise you to respect these operation instructions and to carry out
maintenance work accordingly.
- Should there be any problems, please contact our technical sales department.

Copyright

Copyright © DMN-Westinghouse. All rights reserved. All information including drawings

shown in this manual are covered by copyright. No part of this manual may be
reproduced or published in any form or in any way, electronically, by print, photoprint,
microfilm or any other means without prior written permission from DMN-Westinghouse.

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Contents Page

1. Safety instructions Diverter Valves

1.1 General safety instructions 4
1.2 Symbols 4
1.3 Responsibilities of management and maintenance personnel 4
1.4 Applying the safety instructions when installing a diverter valve 5
1.5 Applying the safety instructions when the diverter is in operation 5
1.6 Applying the safety instructions during maintenance and repair 5

2.1 Operation instructions FDV

2.1.1 General 6
2.1.2 Technical specifications 6
2.1.3 Construction 7
2.1.3.1 General assembly and parts list FDV 7
2.1.4 Installing the flap type diverter in the system 9
2.1.4.1 Installing the flap type diverter 9
2.1.4.2 Connection diagram for the flap type diverter 10
2.1.5 Dismantling and assembling instructions 13
2.1.5.1 Dismantling pneumatic cylinder execution 13
2.1.5.2 Re-assembling pneumatic cylinder execution 14
2.1.5.3 Dismantling torque actuator execution 15
2.1.5.4 Re-assembling torque actuator execution 15

2.2 Operation instructions FVV

2.2.1 General 17
2.2.2 Technical specifications 17
2.2.3 Construction 18
2.2.3.1 General assembly and parts list FVV 18
2.2.4 Installing the Fill-Vent type diverter in the system 19
2.2.4.1 Installing the Fill-Vent type diverter 19
2.2.4.2 Connection diagram for the Fill-Vent type diverter 20
2.2.5 Dismantling and assembling instructions 22
2.2.5.1 Dismantling standard execution 22
2.2.5.2 Re-assembling standard execution 23

3. Maintenance
3.1 General 23
3.2 Maintenance every 6 months or after 4,000 operating hours 24
3.3 Maintenance every 2 years or after 15,000 operating hours 24
3.4 Lubricants 24

4. Malfunctioning
4.1 Probable cause 25

APPENDIX - Declaration by the manufacturer

- Safety instructions / technical data Pneumatic actuator
- Mounting and adjusting instruction Switchmaster

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1. Safety instructions Diverter Valves

1.1 General safety instructions

The safety instructions as described below should be followed by the user when:

- installing the diverter;

- maintaining and repairing the diverter.

The safety instructions should be read carefully both by management and maintenance
personnel before carrying out the above operations.

Failure to follow these safety instructions, may result in one or more of the following:

- the safety of the maintenance personnel could be endangered;

- the valve may not function correctly;
- the system which contains the diverter may be damaged.

Modifications and alterations to the product is not permitted other than by

DMN-Westinghouse trained personnel, to ensure safe operation.

1.2 Symbols

Remark.

Attention.
Failure to follow these instructions, may result in damaging or
breaking the valve.

Warning.
Personal danger.

1.3 Responsibilities of the management and maintenance personnel

The management must take care that:

- the maintenance personnel maintains the safety instructions, as described in this

document;
- all available means which are necessary for working according to the safety
instructions are present;
- the maintenance personnel possess the necessary skills.

Maintenance personnel should follow these safety instructions when carrying out
installation, repair and maintenance.

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1.4 Applying the safety instructions when installing a diverter

After removing the packaging material it is possible to reach the inlet of the diverter.
During this operation do not operate flap.

Do not alter, remove or paint the type specification plates of the diverter, drive unit or
fitted switches.

1.5 Applying the safety instructions when the diverter is in operation

During operation of the diverter it must not be possible to reach moving parts like the
plug, flap or tube.

While the diverter is in operation no maintenance or repair work must

be carried out.

1.6 Applying the safety instructions during maintenance and repair work

When product qualities necessitate supplementary safety instructions and wearing

protective clothes, it is obligatory to follow the local safety instructions.

Before maintenance and repair work is carried out:

- electrical supply to the solenoid valve must be isolated.

- air pressure to pneumatic cylinder must be isolated.

After the maintenance and repair work has been carried out, all safety parts removed
during the work should be re-assembled and their operation should be checked.

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2.1 Operation instructions FDV

2.1.1 General

The DMN-Westinghouse flap type diverter has been specially designed to re-route
powders and pellets in pneumatic conveying systems.

Pipe changeover is achieved by turning the flap in the body.

The unit is driven by means of an integral pneumatic cylinder or torque actuator
actuated by a solenoid valve.
The flap type diverter valve housing is cast and may be of aluminium, iron or stainless
steel, with a pipe or flange fittings.
Sealing is by means of a parabolic style blade of polyurethane or food quality material.
Indication of pipe changeover is by means of magnetic sensors.

The permissible operating conditions indicated in section 2.1.2 must be observed.

Failure to do so and/or improper use and the resulting risks and damage are the
responsibility of the user.

2.1.2 Technical specification

Standard version:
Permissible working pressure : -0.3 to +2 bar
Permissible temperature : -25°C to +80°C
Maximum permissible ambient temperature : -10 to +40°C
Required compressed air pressure for cylinder : 4 to 8 bar

Materials:
Body
Cast aluminium LM25TF7 DIN 1725/2.3716
Cast iron GG25 Din 1691/0.6025
Stainless steel pipe AISI 316 DIN 17445/1.4408
Flap
Stainless steel AISI 316 DIN 17445/1.4408
Seal
Polyurethane
Silicone (Is less durable than polyurethane)

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2.1.3 Construction
2.1.3.1 General assembly drawing and parts list for FDV

Fig. 2.1.3.1 Execution FDV pneumatic cylinder.

001 Flap housing 041 Flap seal 080 Pivot bracket

002 Trouser legs 081 Pivot pin
006 Pipe 071 Cylinder unit 082 Pivot pin
011 Nameplate DMN 072 Solenoid valve 083 Filling ring
012 Bolt 073 Coil 084 Cyl.adjusting screw
013 Washer 075 Reed switch 085 Cylinder screw
014 Nut 076 Reed switch bracket 086 Washer
021 Flap 077 Guard 087 Fitting
022 Clamp plate 078 Actuating arm 088 Fitting
031 Seal 079 Slide bearing 089 Fitting
032 "o"-ring 090 Tube
033 Slide bearing 091 Cylinder screw
035 Counter sunk screw

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Fig. 2.1.3.2 Execution FDV torque actuator.

001 Flap housing 021 Flap 051 Torque actuator unit

002 Trouser legs 022 Clamp plate 052 Switch box
006 Pipe 031 Seal 053 Solenoid valve
011 Nameplate DMN 032 "o"-ring 054 Silencer
012 Bolt 033 Slide bearing 055 Coil
013 Washer 035 Counter sunk screw 056 Mounting plate
014 Nut 061 Fitting
041 Flap seal 062 Counter sunk screw
063 Bolt
064 Washer

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2.1.4 Fitting the flap type diverter in the system

Do not twist the flap.

Danger to fingers and hands.

2.1.4.1 Installation of the flap type diverter

Remove all packing material and preservation.

Check for transport damage.

- Attach the product pipes and ensure that the flap type diverter is adequately
supported and secured.

When fitting the flap type diverter make sure that it is not subject
to uneven loads as a result of external stresses or vibration.

- During operation or testing of the flap type diverter the pipe/flange connections
must not be open or unprotected.
- The solenoid valve must be connected to the correct power supply and to a com-
pressed air supply of at least 4 bar with a 8 mm air hose.
- Connect the position switches to the user's control system.

Check voltage of individual components as these vary according

to customer specification.

Installation sequence

Observe safety instructions.

- Install the diverter without tension

- Connect product pipes
- Connect compressed air to valve
- Connect solenoid valve and position switches
- Check the operation of the flap type diverter

Pipe changeover must only be carried out when the product

pipes are not pressurised.

2.1.4.2 Connection diagram for the flap type diverter

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The flap type diverter is equipped as standard with:

- Pneumatic cylinder, electrically operated 5/2 monostable valve 1/8" and
reed switches.
- Pneumatic torque actuator, electrically operated 5/2 monostable valve 1/4",
micro switches and junction box.

Only an electrical expert is allowed to connect the unit.

Pneumatic cylinder execution.

Double acting cylinder according to ISO 6431 with adjustable pneumatic cushioning
and magnetic piston.
KV automation systems : Type KC
Medium : air filtration lubricated or not up to 10 bar.
Temperature range : -30°C to +70°C
Working pressure : 6 bar.
Tube : φ 6mm

Air consumption:
FDV size 50 65 80 100 125 150 200 250
Pneumatic cylinder
Air consumption
At 6 bar 0,35 0,4 0.7 0.7 0.95 1.1 2.75 2.75
Ltr./stroke

Solenoid valve 5/2 unistable execution with manual control.

KV automation systems : Type KVLE
Medium : air filtration lubricated or not up to 10 bar.
Connection : 1/8"
Electrically operated electro-magnetic.
Protection : IP 65
Socket : Pg 9
Standard voltage : 24 V DC 1.9 Watt
230 V AC 3.8 VA 50/60Hz
Temperature range : -30°C to +50°C

Reed switches
KV automation systems : Type W
Voltage : up to 250 V AC/DC 1A
Protection : IP 65
Temperature range : -20°C to +80°C

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Fig. 2.1.4.2.1 Pneumatic connection pneumatic cylinder.

Pneumatic torque actuator execution.

Double acting pneumatic actuator.

Bar : Type GTD series 90
Medium : air filtration lubricated or not up to 10 bar.
Temperature range : -25°C to +95°C
Working pressure : 6 bar.
Hose : φ 8 mm

Air consumption:
FDV size 50 65 80 100 125 150 200 250
Torque actuator
Air consumption
At 6 bar 0.35 0,4 0.8 0.9 1.6 1.7 4 4
Ltr./stroke

Solenoid valve 5/2 NAMUR unistable execution with manual control.

ASCO Joucomatic : Type SC G551A001 MSM
Medium : air filtration lubricated or not up to 10 bar.
Connection : G 1/4"
Electrically operated electro-magnetic.
Protection : IP 65
Socket : Pg 9p
Standard voltage : 24 V DC 115/230 V AC 50 Hz
Temperature range : -25°C to +60°C

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Position indicator Switchmaster

Protection : IP 67 VDE 0470/EN60529

Temperature range : -20°C...+70°C
Indication range and switching range : 0°….90° pivoting angle
Cable gland : With strain relief, Clamp range 5-14mm
Cable : Ø 5-14mm, max. 2,5mm²

Type A standard: Mechanical Switch

Voltage range : 4V/DC - 250V/AC
Current range : 1mA - 5A
Switching function : Change-over contact,
contacts gold plated

Type B optional: DC sensor

Voltage range : 9...36 V/DC
Current range : 200 mA
Normally open PNP
3-wire

Fig. 2.1.4.2.2 Pneumatic connection torque actuator.

Prior to the delivery the position indication is set for the angle required for the
Pneumatic torque actuator.
If adjusting of the cams is necessary and for instructions for electrical connection
read the mounting and adjusting instructions Switchmaster (see Appendix).

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2.1.5 Disassembly and assembly of the flap type diverter

The DMN-Westinghouse flap type diverter is manufactured and assembled with great
care.

- do not use coarse tools;

- avoid damage such as scratches, burrs, etc.;
- clean all components thoroughly.

When carrying out repair work on the diverter, observe the

safety instructions indicated in section 1.

- Switch off the power supply, block the switch and/or remove the fuses.
- Close the compressed air supply.

2.1.5.1 Disassembly pneumatic cylinder execution

.
Fig. 2.1.5.1.1 Disassembly pneumatic cylinder execution.

- Disconnect electric wiring from solenoid valve and position switches and remove
air hoses.
- Take cover from guard (77) and loosen bolts in the clamp bush of actuating
arm (78).
- Unscrew and remove bolts (85) from pivot bracket (80) and remove the
entire cylinder unit (70 & 71) with the pivot bracket (80) and actuating arm
(78).
- Remove the guard.

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Fig. 2.1.5.1.2 Disassembly flap assembly

- Remove bolts (12) and remove flap housing (01) and flap assembly.
- Remove bearing (33) and "o"-ring from flap assembly (21).
- Disassemble flap assembly and remove seal (31) from trouser legs(02).
- Check flap shaft, flap seal (41) and bearings for damage and replace, if
necessary.
- Replace "o"-rings and seal.

2.1.5.2 Assembly and adjustment pneumatic cylinder execution.

After cleaning and checking or replacement of parts, the diverter can be re-assembled
as follows:

- To assemble flap, fit seal (41) between flap (21) and flap clamp (22) and secure
with counter sunk screws (35).
- Slip "o"-rings and bearings over shaft.
- Place seal (31) inside trouser legs and position flap assembly in recess,
before assembly, grease "o"-ring and seal lightly.
- Slip flap housing (01) over flap and secure to connecting piece (02) with
bolts (12), washer (13) and nuts (14).
- Replace guard, pivot bracket with cylinder unit and actuating arm.
- Set de flap arm so that when the cylinder operates, the flap edge seal is
compressed equally against the insides of both strokes of the cylinder.
- Secure bolts in the clamp bush of actuating arm.
- Connect electrical wiring in accordance with the connection diagram and
attach air hoses.

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2.1.5.3 Disassembly torque actuator execution

Fig. 2.1.5.3 Disassembly torque actuator execution.

- Disconnect electric wiring from solenoid valve and position switches and
remove air hoses.
- Remove bolts (63).
- Remove Mounting plate (56) including actuator unit (51/52/53).
- Remove bolts (12) and remove flap housing (01) and flap assembly.
- Remove bearing (33) and "o"-ring (32) from flap assembly.
- Disassemble flap assembly and remove seal (31) from trouser legs
(02).
- Check flap shaft (21), flap seal and bearings for damage and replace, if
necessary.
- Replace "o"-rings and seal.

2.1.5.4 Assembly torque actuator execution.

After cleaning and checking or replacement of parts, the diverter can be re-
assembled as follows:

- To assemble flap, fit seal (41) between flap (21) and flap clamp (22) and
secure with counter sunk screws (35).
- Slip "o"-rings and bearings over shaft.
- Place seal inside trouser legs (02) and position flap assembly in
recess, before assembly, grease ""-ring and seal lightly.

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- Slip flap housing (01) over flap and secure to connecting piece (02)
with bolts (12), washer (13) and nuts (14).
- Secure mounting plate (56) together with actuator unit using bolts (63).
Prior to delivery the flap position is set at the right angle.
- Connect electrical wiring in accordance with the connection diagram
and attach air hoses.

After assembly test run the diverter valve.

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2.2 Operation instructions FVV

2.2.1 General

The DMN Fill-Vent diverter valve (Scale valve) has been specially designed to use in
small bulk handling systems whereby powders and pellets are pneumatically conveyed
to a hopper or bin which is process weighed.

Fill-Vent valves may be sited above weigh hoppers in such a way that when a
predetermined weight is reached, diversion takes place immediately. The product is
then either conveyed to the next weigh station or back to the main storage silo.

Diversion is achieved by turning the two parabolic flap seals in the body.
The unit is driven by means of an torque actuator actuated by a solenoid valve.
The Fill-Vent type diverter valve housing is cast and may be of aluminium, iron or
stainless steel, with a pipe or flange fittings.
Sealing is by means of a parabolic style blade of polyurethane or food quality material.
Indication of pipe changeover is by means of micro switches.

The permissible operating conditions indicated in section 2.2.2 must be observed.

Failure to do so and/or improper use and the resulting risks and damage are the
responsibility of the user.

2.2.2 Technical specification

Standard version:
Permissible working pressure : -0.3 to +1 bar
Permissible temperature : -25°C to +80°C
Maximum permissible ambient temperature : -10 to +40°C
Required compressed air pressure for cylinder : 4 to 8 bar

Materials:
Body
Cast aluminium LM25TF7 DIN 1725/2.3716
Cast iron GG25 Din 1691/0.6025
Stainless steel pipe AISI 316 DIN 17445/1.4408
Flap
Stainless steel AISI 316 DIN 17445/1.4408
Seal
Polyurethane
silicone (Is less durable than polyurethane)

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2.2.3 Construction
2.2.3.1 General assembly drawing and parts list for FVV

Fig. 2.2.3 Execution FVV.

001 Flap housing 021 Flap 051 Torque actuator unit

002 Connecting piece 022 Clamp plate 052 Switch box
006 Pipe 023 Retainer ring 053 Solenoid valve
008 Plate 031 Seal 054 Silencer
011 Nameplate DMN 032 "o"-ring 055 Coil
012 Bolt 033 Slide bearing 056 Mounting plate
013 Washer 034 Adjusting screw 061 Fitting
014 Nut 035 Counter sunk screw 062 Counter sunk screw
015 Bolt 063 Bolt
041 Flap seal 064 Washer
065 Adjusting screw

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2.2.4 Fitting the Fill-Vent type diverter in the system

Do not twist the flap.

Danger to fingers and hands.

2.2.4.1 Installation of the Fill-Vent type diverter

Remove all packing material and preservation.

Check for transport damage.

Recommendations:
1. Maintain minimum of 5x pipe diameter between valve and product.
2. Position valve centrally or at least 3x pipe diameter from vessel sides.
3. If mounting valve on spacing piece ensure installation is gas-tight
between laden and clean gas ducts right down to the receiving vessel.
The separation plate should extend down into the vessel by 2x pipe
diameter.
4. High-level controls should be installed to ensure overfilling of the vessel
cannot occur to the point where re-entrainment is possible.

- Attach the product pipes and ensure that the Fill-Vent type diverter is
adequately supported and secured.

When fitting the Fill-Vent type diverter make sure that it is not
subject to uneven loads as a result of external stresses or
vibration.

- During operation or testing of the Fill-Vent type diverter the pipe/flange

connections must not be open or unprotected.
- The solenoid valve must be connected to the correct power supply and to a
compressed air supply of at least 4 bar with a 8 mm air hose.

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- Connect the position switches to the user's control system.

Check voltage of individual components as these vary

according to customer specification.

Installation sequence

Observe safety instructions.

- Install the diverter without tension

- Connect product pipes
- Connect compressed air to valve
- Connect solenoid valve and position switches
- Check the operation of the Fill-Vent type diverter

2.2.4.2 Connection diagram for the Fill-Vent type diverter

The Fill-Vent type diverter is equipped as standard with:

- Pneumatic torque actuator, electrically operated 5/2 monostable valve

1/4", micro switches and junction box.

Double acting pneumatic actuator.

Bar : Type GTD series 90
Medium : air filtration lubricated or not up to 10 bar.
Temperature range : -25°C to +95°C
Working pressure : 6 bar.
Hose : φ 8 mm
Air consumption:

FVV size 50 65 80 100 125 150 200 250

Air consumption
At 6 bar 0.65 0.8 1.6 1.75 3.15 3.25 8 8
Ltr./stroke

Solenoid valve 5/2 NAMUR unistable execution with manual control.

ASCO Joucomatic : Type SC G551A001 MSM
Medium : air filtration lubricated or not up to 10 bar.
Connection : G 1/4"
Electrically operated electro-magnetic.
Protection : IP 65
Socket : Pg 9p
Standard voltage : 24 V DC 115/230 V AC 50 Hz
Temperature range : -25°C to +60°C

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Fig.2.2.4 Pneumatic connection.

Position indicator Switchmaster

Protection : IP 67 VDE 0470/EN60529

Temperature range : -20°C...+70°C
Indication range and switching range : 0°….90° pivoting angle
Cable gland : With strain relief, Clamp range 5-14mm
Cable : Ø 5-14mm, max. 2,5mm²

Type A standard: Mechanical Switch

Voltage range : 4V/DC - 250V/AC
Current range : 1mA - 5A
Switching function : Change-over contact,
contacts gold plated

Type B optional: DC sensor 3-wire

Voltage range : 9...36 V/DC
Current range : 200 mA
Normally open PNP

Prior to the delivery the position indication is set for the angle required for the
Pneumatic torque actuator.
If adjusting of the cams is necessary and for instructions for electrical connection
read the mounting and adjusting instructions Switchmaster (see Appendix).

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2.2.5 Disassembly and assembly of the Fill-Vent type diverter

The DMN Fill-Vent type diverter is manufactured and assembled with great care.

- do not use coarse tools;

- avoid damage such as scratches, burrs, etc.;
- clean all components thoroughly.

When carrying out repair work on the Fill-Vent type diverter,

observe the safety instructions indicated in section 1.

- Switch off the power supply, block the switch and/or remove the fuses.
- Close the compressed air supply.

2.2.5.1 Disassembly torque actuator execution

Fig. 2.2.5 Disassembly FVV execution.

- Disconnect electric wiring from solenoid valve and position switches and
remove air hoses.
- Remove bolts (63).
- Remove Mounting plate (56) including actuator unit (51/52/53).
- Remove retainer ring (23) at non drive end.
- Remove bolts (12) and remove flap housing (01) and flap assembly.

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- Remove bearing (33) and "o"-ring (32) from flap assembly.

- Disassemble flap assembly and remove seal (31) from connecting
piece (02).
- Check flap shaft (21), flap seal and bearings for damage and replace, if
necessary.
- Replace "o"-rings and seal.

2.2.5.2 Assembly torque actuator execution.

After cleaning and checking or replacement of parts, the diverter can be re-
assembled as follows:

- To assemble flap, fit seal (41) between flap (21) and flap clamp (22) and
secure with counter sunk screws (35).
- Slip "o"-rings and bearings over shaft.
- Place seal inside connecting piece (02) and position flap assembly in
recess, before assembly, grease "o"-ring and seal lightly.
- Slip flap housing (01) over flap and secure to connecting piece (02)
with bolts (12), washer (13) and nuts (14).
- Secure mounting plate (56) together with actuator unit using bolts (63).
Prior to delivery the flap position is set at the right angle.
- Connect electrical wiring in accordance with the connection diagram
and attach air hoses.

After assembly test run the diverter valve.

3. Maintenance

3.1 General

The interval between overhauls will vary with the product being handled and should
be based on total operating time. To a large degree the rate of wear for a particular
application would be ascertained by practical experience.

Maintenance apart from planned overhaul should be adequately covered by regular

and frequent attention to the seals.

It is recommended that the complete diverter valve is dismantled for cleaning,

inspection and overhaul as necessary at regular intervals.

When carrying out maintenance work on the diverter valve

observe the safety instructions in section 1.

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3.2 Maintenance every 6 months or after 4,000 operating hours

- Check the operation of the diverter valve.

- Check control pressure and re-adjust, if necessary.
- Check the air supply filter and clean, if necessary.

3.3 General maintenance every 2 years or after 15,000 operating hours

- Remove the diverter valve and clean it thoroughly.

- Check sealing.
- Replace damaged or worn parts.
- Check cylinder and replace worn parts, if necessary.
- Check operation of solenoid valve, replace silencers.
- Check position switches.
- Fit the diverter valve

3.4 Lubricants

Lubricant Type Supplier Application

Bolt Cassida Shell Nederland General
Seal Cassida Shell Nederland General

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4 Malfunctioning
Common disturbances and possible solutions are stated below.
If you are not able to solve the problem, please contact our service department.

4.1 Probable cause

Problem Cause Solution

- Pipe changeover does - Diverter dirty - Clean inside of diverter
not take place
- Object between moving parts - Remove object

- Compressed air pressure too - Increase pressure

low

- Proximity switch faulty - Replace proximity switch

- Pneumatic cylinder faulty - Replace pneumatic cylinder

- Leakage of diverter valve - Damaged sealing - Replace seals

- No compressed air - No system pressure - Check compressor unit

pressure at cylinder
- Solenoid valve faulty - Replace solenoid valve

- Air hose faulty - Replace air hose

- No voltage - Fuse faulty - Replace fuse

- Break in power supply - Check power supply

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