ENGLISH EXTREME ELECTRIC BUTTERFLY VALVE ENGLISH EXTREME ELECTRIC BUTTERFLY VALVE

2.2 EXTREME BUTTERFLY VALVE BARE SHAFT Fig. 2 5

EXTREME
11
N DESCRIPTION MATERIAL DN50- DN250- 4
DN200 DN300

BUTTERFLY VALVES
12
1 Body PP-GR 1 1
13
2 Sealing gasket EPDM / FPM 1 1

Electric actuator
10
3 Disc PVC-U/PPH/CPVC/PVDF/ABS 1 1
8
4 Upper Bearing POM 2 2
5 Auxiliary bearing POM 1 1 1

6 Lower bearing POM 1 1 3

INSTALLATION AND 7 Lower washer POM 1 1

8 Shaft Stainless steel AISI-630 1 1
MAINTENANCE MANUAL 9 Cap PP 1 1 2
10 Ring DIN-471 Stainless steel AISI-304 1 1
PVC-U (EPDM/FPM) 11 O-ring EPDM / FPM 2 4
CPVC (EPDM/FPM) 12 O-ring EPDM / FPM 2 4
PPH (EPDM/FPM) 13 O-ring EPDM / FPM 2 4
PVDF (EPDM/FPM) 0045
14 Screw DIN-912 Stainless steel AISI-304 1 1 6
ABS (EPDM/FPM)
7
3. ELECTRICALLY ACTUATED BUTTERFLY 14
VALVE TECHNICAL SPECIFICATIONS
9
3.1 VERICATION OF VALVE TYPE
Important: This instruction manual contains essential information regarding the safety measures to adopt when installing and On opening the packaging please check that the valve is the model ordered.
starting up the equipment. It is therefore essential that the user reads these instructions before installing and starting to use the Check that the actuator model corresponds with the code number ordered. Make especially sure Kv / % opening (G 3.2)
apparatus. that the voltage indicated on the actuator label corresponds to that of your mains supply (actuators Flow / valve opening
Caudal / Apertura
do no incorporate valves, meaning that incorrect voltage will cause irreparable damage to the
100
In order to get the most from your actuated valve, it is advisable to carefully read the instructions below. device).
90
All valves are electrically and hydraulically tested in the factory. Valves will always be replaced in the
These symbols indicate potential danger should you not follow the advice set out here. event of any justifiable claim. 80

DANGER. Risk of electrocution. Failure to follow the advice set out here may result in electrocution. For more technical information about the actuators, please refer to the instruction manuals attached 70

DANGER. Failure to follow the advice set out here may result in personal harm or damage to the apparatus. to the valve documentation. 60

% Kv
50
WARNING. Failure to follow the advice set out here may result in damage to the automatic valve or apparatus.
3.2 GUARANTEE 40

This equipment has been extensively tested in the factory, thus guaranteeing it is in perfect working 30
GENERAL SAFETY ADVICE condition. This guarantee will be applicable assuming the device has been properly installed and 20
The valves described in this manual are especially designed to ensure a correct flow circulation in all working phases. not used in an incorrectly. For this reason, this equipment must be installed by a suitably qualified 10
Apparatus should be installed in accordance with the specific instructions for each installation. All existing safety legislation person. 0
should be respected at all times in order to avoid accidents. 0 10 20 30 40 50 60 70 80 90 100
% valve opening / % apertura
Any modification to the electric actuator requires the prior authorisation of the manufacturer. Spare parts and accessories 3.3 TECHNICAL CHARACTERISTICS
authorised by the manufacturer are a guarantee of greater safety. The manufacturer of this actuated valve is exempt from all DN65 DN80 DN100

responsibility for damage arising from unauthorised spare parts and accessories. Pressure / Temperature Chart. (G 3.1-3.2) DN125 DN150 DN250

During operation, the electrical parts of this apparatus will have electrical current running through them. All work on the psi bar

automatic valve and other related equipment should only be carried out having first disconnected the start up mechanism. psi bar

The user should ensure that all assembly and maintenance work is carried out by suitably authorised, qualified personnel, and PVC-U
PVC-C PVDF
that these have previously read the installation and service instructions set out in this manual. PP-H ABS

Safe usage of this actuated valve can only be guaranteed by closely following the installation and service instructions laid out DN63-DN200
DN63-DN200
here.
Voltage limits should not be exceeded under any circumstances.
In case of malfunction or breakdown, contact the nearest factory representative or technical assistance service department. DN250-DN315 DN250-DN315

Avoid shocks during transport, since they may damage the body and mechanism of the valve.
Store the valve in the original packaging, protected against humidity and direct sunlight.

ºC -30
ELECTRIC BUTTERFLY VALVE WARNINGS ºC 0 10 20 30 40 50 60 70 80 90 100 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
ºF 32 50 68 86 104 122 140 158 176 194 212 ºF -22 -4 14 32 50 68 86 104 122 140 158 176 194 212 230 248

The maximum service life of the valve is specified in EN ISO 16136. It is verified on the production plant by aging tests specified
Pressure loss table (T3.1) Pressure loss chart (G 3.3) Kv / % opening (G 3.4)
in the standard.
Correct installation and handling of the valve, as well as adherence to the maximum pressure and temperature conditions 1 Flow / valve opening
D DN Kv (l/min) Cv (GPM) Caudal / Apertura
specified in this manual are essential for preserving the service life of the valve. 100
The driven liquid must be compatible with the valve materials. Consult chemical resistance charts published by Cepex or 63-75 (2 1/2”) DN65 1568 110 90

consult the technical department. 90 (3”) DN80 4980 349 Pérdida de carga (bar) 80
0,1
Using tools for opening or closing the manual valve control is not recommended. Pressure loss (bar) 70
110 (4”) DN100 7212 505
Before carrying out any maintenance operations on the pipe or valve, ensure that the system is depressurised by releasing the 60

% Kv
50
pressure and emptying the pipes, following the specific safety regulations of each product. 125-140 (5”) DN125 12320 863 40
Before installation, check that the valve is undamaged and that it contains all the parts required for installation. 160 (6”) DN150 25447 1134 0,01
30
After long periods of inactivity, check the grease on the gasket and follow the maintenance instructions set out in this manual. 20

The grease must be compatible with the valve materials. 200-225 (8”) DN200 35778 2505 10

It is important to avoid rapid closure of valves to eliminate the possibility of water hammer causing damage to the pipeline. 250 (10”) DN250 65222 4567
0
0 10 20 30 40 50 60 70 80 90 100
When using the valve as the final element of a installation, take into account the risks of the liquid and control the pressure and % valve opening / % apertura
temperature, according to the standards of safety of each product. 315 (12”) DN300 94660 6629 0,001
10 100 1000 10000 100000
DN65 DN80
Caudal (l/min)
Flow (l/min) DN100 DN125

Make all connections following the instruction referring to electrical supply as set out in this manual. Ensure that all cables are DN150 DN200, DN250, DN300
Valve operating torque
correctly connected.
Should you need to open the box at the end of the run, on closing again, check that it is correctly positioned to avoid any water Operating torque values at rated pressure (PN) and 20 °C in as new direct from the factory condition. Installation (flange tightening)
contact. Also check that connectors are correctly situated. and operating (pressure and temperature) conditions will affect these values.
At all times, avoid contact, albeit accidental, with the actuated valve’s moving parts during operation and/or before it has come The actuator that is required for an automatic operation must be calculated according to some safety factors that were determined
to a complete stop. in life tests carried out in the factory.
Before beginning any electrical, ensure that the start-up mechanisms are blocked. It is advisable to follow the following steps Operating torque table (N·m) (T3.2)
before any alteration to the actuated valve:
1.- Disconnect the electrovalve from the main supply. DN65 DN80 DN100 DN125 DN150 DN200 DN250 DN300
2.- Block the system’s start-up mechanisms.
N·m 25 28 35 85 110 110 180 250
3.- Make certain that their is no voltage running through the circuits, including the auxiliary circuits and supplementary services.
All the above should be taken as indicative and not directly tied to safety procedure as specific safety norms may be in place in lbf·inch 221 248 310 752 974 974 1593 2213
some cases. T 4.1 (mm)
IMPORTANT: As a result of the complexity of the subject, the installation, usage and maintenance instructions to be found in this 4. DIMENSIONS. Fig. 3
manual are not designed to cover all imaginable service and maintenance scenarios. Should you require further instructions or DN A B E F H K HOLES
encounter specific problems, please do not hesitate to contact the distributor or valve manufacturer. 65 201 156 120 18 48 125-145 4

1. DEFINITION 80 232 190 136 19 52 150-170 8

Butterfly valve for isolating the flow in liquid handling systems. The liquid can flow in both directions. 100 255 212 148 19 59 180-192 8
Design based on the EN ISO 16136 Standard in accordance with the 97/23/EC Directive.
125 284 238 164 22 66 190-215 8
The valve is available with PVC-U, CPVC, PP-H, PVDF and ABS discs and EPDM and FPM sealing gaskets. The choice of material for the
disc and gasket depends on the type of liquid to be carried and on the working temperature of the liquid, in accordance with the che- 150 314 265 180 24 72 240 8
mical resistance tables available on our website and the pressure/temperature chart in this Manual.
200 378 320 217 23 73 270-298 8
The electric actuator controls the positions of the valve (closed / opened).
250 450 453 310 29 114 329-355 12
2. COMPONENTS 300 545 477 310 29 114 384-427 12
2.1 GENERAL ASSEMBLY
See the actuator manual to check the dimensions
Fig. 1 N DESCRIPTION MATERIAL Q M, N and L.

1 Butterfly Valve PVC-U, CPVC, PP-H, PVDF, ABS 1

Fig. 4
2 Coupling bush AISI-304 Stainless steel 1
4
3 Mounting clamp PP-GR 1

4 Electric actuator PA housing 1

5 Screw DIN-912 Stainless steel AISI-304 4

6 Screw DIN-912 Stainless steel AISI-304 4

5
7 Washer DIN-925 Stainless steel AISI-304 4
Actuator coupling dimensions (T4.2)
3
DN ISO FLANGE SQUARE (mm)
8 Nut DIN-934 Stainless steel AISI-304 4
6
65 F07 14 / 17
2
80 F07 17
100 F07 17

7 125 F07 17 / 22
8 150 F07 17 / 22
200 F07/F10 17 / 22
1
250 F07/F10/F12 22 / 27
300 F07/F10/F12 22 / 27

Valve design Flanged dimensions Valve connections Other connections Actuator coupling

ISO 16136: 2005 EN 558-1,ANSI B16.5 Class 150,JIS B2220, BS/E EN 1090-1 ISO15494, ISO15493, ISO10931 EN/ISO 5211
 ENGLISH EXTREME ELECTRIC BUTTERFLY VALVE ENGLISH EXTREME ELECTRIC BUTTERFLY VALVE

5. INSTALLATION AND COMMISSIONING 8. BUTTERFLY VALVE / ELECTRIC ACTUATOR

Before commencing the installation process, check that you have all the parts needed for the valve assembly, and that the materials,
connection type and nominal pressure are suitable for the installation.
SPRING RETURN PNEUMATIC ACTUATOR
For solvent or welded connections, ensure also that the parts to be connected are of the same material and that you are using the correct
solvent or welding tools. JJ Mounting kit
To install the valve, follow best installation practice recommendations provided on the Cepex website, paying particular attention to DN Bare shaft valve
24V 85-240V
thermal expansion and pipe alignment.
When filling the pipes with liquid, check that all the air is purged from the system and that the initial pressure does not exceed the nominal DN50-DN65 30677 57498
pressure of the valve, or of the system element with the lowest nominal pressure rating.
Valve assembly using standard ISO-DIN, ANSI, JIS and BS/E flanges. Flat gaskets are not needed in the socket couplings, as they are DN80 30677 35901
incorporated in the valve itself. Observe the tightening sequence of the screws on the flanges (Fig. 5) and the maximum tightening DN100 30677 35901
torque. It is essential that all the screws are installed in order to ensure proper operation of the valve. SEE TECHNICAL
The PP/PE sockets for butt welding must be chamfered as indicated in the diagram (Fig. 6) and table (T6.2), to ensure correct opening and DN125 CATALOG TO 30673 30678 35904
closing of the disc. KNOW THE
DN150 30673 30678 35904
Install the valve once the sockets are solvent-bonded and dry, to avoid problems with the adhesive (entry of the latter into the valve). SPECIFIC CODE
Flanges must be well centred on the valve (pay special attention to measurements DN100-DN125 and DN200). Assembly misalignment DN200 30674 30679 35908
could cause problems with the valve operation.
DN250 30674 30679 35912

Fig. 5 Fig. 6 Screws and screw tightening torque T 5.1 DN300 30674 30679 35912

D DN inch Screws (A2) Screws Screws

Torque Torque
(N·m) (inch·lbs)

63 50 - 4xM16x120 25 221

75 65 2 1/2” 4xM16x140 25 221 9. TROUBLESHOOTING T 9.1

90 80 3” 8xM16x150 25 221
Fig. 7 PP/PE sockets DN D min. x FAULT POSSIBLE CAUSE FAULT CLEARANCE
Pipe and chamfer 110 100 4” 8xM16x160 30 265
measurements 65 50.5 30º The disc does not fully open or close. The sockets were not correctly bevelled. Disassemble the valve and bevel the sockets as indicated
125 125 - 8xM16x170 35 310 in table T5.2.
T 5.2 80 70 30º
140 125 5” 8xM16x170 35 310 Foreign materials in the compartment (adhesive, etc.). Disassemble the valve and check for obstructions in the
100 91.5 30º disc and gasket contact area.
160 150 6” 8xM20x200 40 354
125 113 30º Excessive opening or closing torque. The valve has been inactive for a long time. Operate with an auxiliary release key (not plastic handle).
200 200 - 8xM20x210 50 442 Disassemble the valve and lubricate the sealing gasket.
150 141 30º
225 200 8” 8xM20x230 50 442 Overtemperature or chemical attack cause damage to Check the chemical compatibility of the liquid with the
200 191.5 20º the gasket. disc and the working temperature. Replace the gasket.
250 250 - 12xM20x270 80 708
250 226 20º Excessive flange torque. Tighten flanges as indicated in table T5.1.
280 250 10” 12xM20x270 80 708
300 296.5 20º Misalignment between sockets and valve. Disassemble the valve and reassemble with concentric
315 300 12” 12xM20x310 80 708 alignment (observe the correct tightening sequence and
torque).

6. OPERATION OF THE ACTUATOR The valve is not fully watertight at Misalignment between sockets and valve. Disassemble the valve and reassemble with concentric
the sockets. alignment (observe the correct tightening sequence and
The motorised valve consists of an electronic actuator mounted on a conventional valve. torque).
OPERATION. When an electric signal is received, the motor turns to either “OPEN” or “CLOSE” depending on the switching signal until the
Flange screws not tight enough. Tighten flanges as indicated in table T5.1.
internal cam connects to the microswitch, bringing the motor to a stop. When it receives an electric signal again, the motor will turn in the
opposite direction. The valve is not completely Inadequate chemicals. Check compliance with the specifications in this
- Reversible monophase motor with visual position indicator and exit signal. watertight at the sealing gasket . Temperature out of range. document.
- Applications: In 90° turns (or 180° in the case of the three-way ball valve). Excess pressure.
- Both AC and DC power supply. Both positions possible with the same actuator. Always follow the connection diagram on the actuator label. Conduction of abrasive elements.
- Emergency manual operation. The motor will be automatically disconnected by putting the lever in the M (Manual) position. Damaged sealing gasket. Replace the gasket.
- Additional auxiliary contacts for transmission position signal.
- WARNING. Do not connect low voltage actuators to higher voltage sources. Similarly do not connect high-voltage actuators The valve does not open or close. Lack of current. Check current supply to the actuator
to lower voltage sources. Actuators do not have fuses and incorrect voltages can cause irreparable damage to the device.
The valve does not close completely. The actuator stroke is not properly adjusted to the Check adjustment limits according to the actuator manual.
valve.
J+J Characteristics
- Thermostat controlled temperature: Incorporation of a thermostat-controlled 4W heating system, working temperature between 20°C and The torque of the valve has increased above the Check the valve: obstructions in the disc or malfunction
30°C (68°F to 86°F). In order for the system to work correctly it is important to keep the voltage running through the actuator. calculated value. of the valve.
- Safety: The actuator features an automatic electronic cut-off system in case the maximum torque is exceeded. Should this happen, the
device may be manually operated using the handle on the actuator.
- A permanently lit internal LED indicates that the actuator is working correctly. If it starts flashing, this means something is wrong and the
power supply to the actuator will automatically switch off.

Optional accessories:
- Digital positioning System
- Safety block. Independent terminal providing power supply to the actuator in the event of power failure

5.1 COMPLIANCE TO STANDARDS

J+J Actuator
ISO 5211 - DIN 3337 (valve connection) EN 60204 (safety)
EN 50081-1 / EN 50081-2 / EN 50082-1 / EN 50082-2 / EN 61000-4-2 / EN 61000-4-3 / EN 61000-4-4 / EN 61000-4-5 / EN 61000-4-6 / EN 61000-
4-11 (electromagnetic compatibility)
Valpes Actuator:
ISO 5211 - DIN 3337 (valve connection)
EN 61000-6-2 / EN 61000-6-4 (electromagnetic compatibility) EN 60947-1 (1999) (low-voltage equipment)

7. OPERATION AND MAINTENANCE INSTRUCTIONS

It is recommended that the condition of the sealing gasket is checked regularly, since it may display signs of mechanical wear due
to pressure, handling and contact with the liquid. The sealing gasket should be greased in the disc contact area (the grease must be
compatible with the materials of the gasket and the disc). It is also advisable to check regularly that the flange fixing nuts are tightened
correctly, as per the recommended torque values specified above (T6.1).
It is recommended to force a periodic movement to avoid the lock of the valve in long periods of time in closed position. It is advisable to
pass the liquid before maneuvering the valve.

Declaración de conformidad CE / EC Declaration of Conformity

Fig. 11 Fig. 12 El fabricante / the manufacturer: CEPEX S.A.U.
7.1 REPLACING THE SEALING GASKET Avinguda Ramon Ciurans 40 ( Parcel.la 6) - P. I. Congost
08530 LA GARRIGA
Should it be necessary to replace the sealing gasket, proceed as follows: Declara que nuevas vávulas / declares that our valves:
· Ensure that the system is depressurised by releasing the pressure and emptying the pipes, following the Tipo / Type: Válvulas de Mariposa / Butterfly valves
specific safety regulations of each product. Also check the temperature of the liquid and follow safety Modelos / Models: INDUSTRIAL and EXTREME SERIES
standards of temperature. Compuerta / Gate: PVC-U / CPVC / PPH / PVDF
· Remove the valve from the installation. Cumplen con los requisitos establecidos por la Unión Europea para EQUIPOS A PRESIÓN según
· Remove the handle as per 7.2, screws (20), nuts (21) and throttle plate (17). Directiva 97/23/CE (PED), categoria II modulo A1, de acuerdo con las normas harmonizadas:
· Remove the ring (8). Take off the cap (7) and remove the screw (12). - EN ISO 16136 VÁLVULAS INDUSTRIALES: Válvulas de mariposa de materiales termoplásticos.
· Tap on the shaft (6) with a rubber mallet until the bearing (4) is exposed from the bottom (Fig. 7). Meets the requirements established by the European Union for PRESSURE EQUIPMENT according to Directive 97/23/EC (PED), category II module A1, in accordance with the
harmonized standards:
· Once the bearing is out, remove the shaft (6), turn it and re-insert it (Fig. 8) from the bottom.
- EN ISO 16135 INDUSTRIAL VALVES: Butterfly valves of thermoplastic materials.
· Tap again until the bearings (4 and 5) emerge from the top. Remove the shaft again. La marca CE sobre la válvula hace referencia a esta conformidad. Según la directiva 97/23/CE solamente las válvulas mayores a DN25 pueden ir marcadas con CE.
· Remove the disc by pressing in the direction of the liquid. The CE marking on the valve refers to this conformity. According to Directive 97/23/EC only valves larger than DN25 can be marked with CE.
· Remove the sealing gasket. Fit the new sealing gasket; it needs to be warped and placed so that it lines up Organismo certificador / Notified Body: TÜV NORD Systems GmbH & Co. KG
with the shaft, according to the indication tab of the gasket (Fig. 9). Große Bahnstrasse 31 , D-22525 Hamburg / Germany
WARNING: Before installing the new gasket, check the condition of the O-rings (9 and 11). N.º de identificación / Identification number : 0045
Yasmin Fernández
Fig. 13 Quality management

La Garriga, April 2015

7.2 MOUNT AND DISMANTLE THE ACTUATOR Fig. 14

Should it be necessary to replace the actuator or the valve, proceed as follows:
1. Move the butterfly valve to the closed position.
2. Depressurize and drain the plant or the plant component.
3. Depressurize the control medium.
4. Remove the control medium line(s) from the actuator.
5. Remove the screws, the washers and the nuts (7, 8 and 9, Fig. 1).
6. Remove the assembly of the electric actuator (4) with the mounting clamp (5) from the bare shaft
valve (Fig. 14).
7. Remove the screws (6) in order to dismount the actuator from the mounting clamp.
8. In case that the actuator should be substituted by a handle, remove also the coupling bush (4 Fig.1).

To mount a new actuator or a new valve, proceed in opposite sense of the previous description.

CODE: C584075MEXT - Version 1: 2017/07

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