ARMATURENWERK

HTENSLEBEN GmbH
INSTRUCTION MANUAL
Butterfly Valve with
Pneumatic Actuator
AWH Armaturenwerk Htensleben GmbH
Schulstrae 5 / 6
D-39393 Htensleben
Germany
Phone: +49 - (0) 3 94 05 / 92 0
Fax: +49 - (0) 3 94 05 / 92 111
http:// www.awh.de
e.mail: awh-edelstahl@t-online.de
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Instruction Manual
Copyright
This document, or parts thereof, may not be reproduced or
divulged to any third party without express permission of AWH.
Violation will in cur prosecution.
All Rights Reserved.
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1 Intended Use
AWH Butterfly valves have been designed and manufactured
for process pipework of hygienic standard with the aim of
shutting off liquid flow in trade and industrial applications (food
industry, chemical industry, pharmaceutical industry, and
minimum-germ processes).
The butterfly valve is remote-controlled and actuated through a
pneumatic drive which automatically guarantees the correcting
range.
A pneumatic drive with integral restoring spring is provided to
shut the valve in the event of (control air) pressure failure.
Minimum control air pressure: 5 6 bar
Maximum control air pressure: 9 - 10 bar
The rated pressure must not exceed 10 bar.
For the Technical Data Sheet please refer to the "Butterfly
valve product pages in the Web. Alternatively, it can be
obtained from AWH Armaturenwerk Htensleben GmbH. After
quoting the AWH reference.
The 'Intended Use' also meets the conditions and requirements
specified by the manufacturer for operation, maintenance and
repair.
This is a technical manual designed to neet the needs of
qualified process engineers.
Definition highly similar to that given in DIN EN-60204-1:
Specialist
A person who, in the light of his/her technical and functional
knowledge and experience as well as expertise with respect to
relevant standards, can judge assigned work and realise
potential risks and hazards that may exist.
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1.1 Materials in Contact with the Product
Refer to Fig. 1-1
Flange (Item 9); 1.4301 / 1.4307 / 1.4404/ 1.4435
Disc (Item 8): 1.4301 / 1.4404
Packing (Item 11) Selected to suit operating conditions
Packing material:
EPDM Max. short-time sterilisation temperature: 130C
VMQ Max. short-time sterilisation temperature: 130C
FPM Max. short-time sterilisation temperature: 140C
The butterfly valve and packing, must be chosen, giving careful
consideration to the environment (i.e. product, temp. and flow)
requirements.
Surfaces
Outer surface: Bright metal / polished
Inner faces in contact with product: Ra < 1.6 m
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1.2 Exploded View, Outline Drawings, and Dimensions

Fig. 1-1 Exploded view
1 Pneumatic actuator
2 Mounting bracket
3 Proximity switch
4 Mount for proximity switch
5 Hex screw
6 Indicator control arm
7 Position indicator
8 Disc
9 Flange
10 Bolts and nuts
11 Packing
12 Bushing
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Typical connecting configurations for the butterfly valve are
shown below. Any mounting position can be chosen.
For dimensions refer to the Tables.
The operating range is 90 for the OPEN and the SHUT
positions.
For the Technical Data please refer to the "Butterfly valve
product pages in the Web. Alternatively, relevant data can be
obtained from AWH Armaturenwerk Htensleben GmbH.

Fig. 1-2 Connection configurations
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Further connecting options are available inch-system
configuration, with clamp connection, flange-mounted
configuration, and with aseptic connection as per DIN 11864.
Dimensions DN 25 DN 32 DN 40 DN 50 DN 65
D
1
26.0 32.0 38.0 50.0 66.0
D
2
87.0 92.0 97.0 110.0 127.0
D
3
89.0 89.0 89.0 89.0 89.0
L
1
64.0 64.0 72.0 72.0 76.0
L
2
40.0 42.0 50.0 50.0 50.0
L
3
84.0 92.0 102.0 106.0 114.0
L
4
90.0 90.0 100.0 100.0 100.0
L
5
236.0 238.0 241.0 247.0 256.0
E Rd 52 x 1/6 Rd 58 x 1/6 Rd 65 x 1/6 Rd 78 x 1/6 Rd 95 x 1/6
Dimensions DN 80 DN 100 DN 125 DN 150 DN 200
D
1
81.0 100.0 125.0 150.0 200.0
D
2
142.0 162.0 200.0 230.0 306.0
D
3
89.0 89.0 129.0 129.0 129.0
L
1
100.0 104.0 112.0 124.0
L
2
60.0 64.0 112.0 124.0
L
3
134.0 152.0 180.0 198.0
L
4
136.0 136.0 168.0 178.0 112.0
L
5
263.0 273.0 305.0 320.0 320.0
E Rd 110 x 1/4 Rd 130 x 1/4 Rd 160 x 1/4 Rd 190 x 1/4
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2 Contents
2.1 Contents
1 INTENDED USE 3
1.1 MATERIALS IN CONTACT WITH THE PRODUCT 4
1.2 Exploded View, Outline Drawings, and Dimensions 5
2 CONTENTS 8
2.1 Contents 8
2.2 List of Figures 8
3 SAFETY / HAZARDS 9
3.1 Informative Signs / Explanatory Notes 9
3.2 Identification of the Butterfly Valve 9
3.3 Safety Standards and Codes 10
3.4 Safety Inspections and Tests 10
4 WARNING NOTICES 11
5 TRANSPORT AND PACKAGING 12
6 INSTALLATION OF BUTTERFLY VALVE 13
6.1 Installing the Butterfly Valve with
- male/ male connection
- Female nut & liner connection 13
6.2 Installing the Butterfly Valve with
- welding ends
- between flanges 14
7 ASSEMBLY 15
7.1 Assembly of Butterfly Valve with Pneumatic Actuator 15
7.2 Assembly of Pneumatic Actuator with Position Feedback
Indication 17
8 MAINTENANCE / CLEANING 19
9 MALFUNCTION, CAUSE, RECTIFICATION 21
10 DISMANTLING / DISPOSAL 22
11 INDEX 23
2.2 List of Figures
Fig. 1-1 Exploded view 5
Fig. 1-2 Connection configurations 6
Fig. 7-1 Assembly of butterfly valve with pneumatic
drive 15
Fig. 7-2 Assembly of pneumatic drive with
position feedback indication 17
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3 Safety / Hazards
3.1 Informative Signs / Explanatory Notes
Warnings
are shown in a frame and identified by a STOP sign.
Danger notices
are shown in a frame and identified by a DANGER warning
triangle.
Important reminders
are shown in a frame and identified by a "Hand".
3.2 Identification of the Butterfly Valve
Type No.
Information provided in this Instruction Manual only applies to
the butterfly valve type as indicated on the title page.
To enable us to respond to your questions properly it is
essential that details as below, are given correctly:
- Nominal diameter (DN);
- Packing material;
- Casing material;
- Connection type (DIN 11851; DIN 11864; welding, etc.)
- Handle;
- Accessories (position feedback indication, etc.).
Unless such information is provided your queries cannot be
properly and quickly handled.
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3.3 Safety Standards and Codes
The butterfly valve is manufactured to conform with the German
versions of the following standards and codes:
1. VBG 5 (1/93);
2. DIN 3230;
3. DIN EN 10204;
4. Druckbehlterverordnung (Pressure Vessel Code);
5. EMV-Gesetz (EMC legislation);
6. Niederspannungs-Richtlinie (Low-voltage directive).
3.4 Safety Inspections and Tests
Conducted by the manufacturer in manufacturer's workshops
(Refer to Data Sheet).
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4 Warning Notices
Butterfly valves, length and quality of piping must meet the
specific requirements. Installation and fitting work to be carried
out by qualified personnel.
Operation and maintenance at fluid temperatures greater than
80C may involve a burn or scalding hazard.
Care must be exercised to ensure that only fluids indicated on
the Data Sheet are used.
Compliance with the specifications in the Data Sheet is of
critical importance.
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5 Transport and Packaging
Butterfly valves manufactured by AWH Armaturenwerk
Htensleben GmbH are thoroughly inspected and carefully
packaged prior to dispatch. Damage may still occur, due to
circumstances beyond our control.
Unpacking:
- Remove the caps from the pipe connections (if provided).
- Remove the remainders of packing materials.
Incoming inspection:
- Check against the delivery note to make sure the equipment
supplied is complete.
In case of damage
- Inspect the consignment for damage (visual inspection).
In case of defects
If the consignment has incurred damage in transit:
- Contact the final carrier immediately.
- Retain the packing material(s) (to enable the carrier to
inspect as necessary, and/or to permit the equipment to be
packed again for return to the consignor).
Packaging for return to consignor
Use the original packing materials if available.
Otherwise, call in a packaging contractor employing skilled
personnel.
In case of queries relating to packaging and precautions to be
taken for transport, please consult AWH Armaturenwerk
Htensleben GmbH.
Seaworthy packaging
For shipment to overseas destinations, the butterfly valves will
be sealed in plastic.
Outdoor storage
Outdoor storage is not acceptable.
In case of seaworthy packaging, the desiccant is designed for
storage periods of less than three months.
Storage in confined spaces
Storage conditions
- Temperature 20C to 30C
- Relative humidity < 60%
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6 Installation of Butterfly Valve
Install the butterfly valve while taking into account the design
configuration of the pipework concerned and the coupling
requirements of the valve.
Face-to-face dimensions are clear from the outline drawings.
Care should be exercised to ensure that clearances and space
are as required for operation and maintenance.
Also, make sure that flanged joints and pipe joints are not
leaky.
Due care is essential during installation to rule out tensile and
compressive stresses on completion.
The construction of valve is such that a manually operated
butterfly valve can be easily converted to a remote-controlled
valve with pneumatic drive without any need for removing the
butterfly valve from the pipework.
6.1 Installing the Butterfly Valve with
- male/ male connection
- Female nut & liner connection
Care should be exercised when installing the butterfly valve to
make sure that the connecting adapters and the slotted nut
conform to an identical standard (e.g. DIN 11851 or
DIN 11864).
Prior to assembly, inspect the sealing ring on the threaded
nipple for damage and check to be sure it is properly fitted;
renew if necessary.
Also, care must be exercised not to damage the thread.
The butterfly valve is mounted by means of the slotted nut using
a C spanner.
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6.2 Installing the Butterfly Valve with
- welding ends
- between flanges
Welding specifications
The valve is welded into piping to DIN 11850.
Welding process: TIG or orbital
Weld type: Square butt weld to DIN 8532
Pre-welding condition
Dismantle the valve prior to welding (Refer to Assembly /
Dismantling).
Weld preparation
- Square the pipe ends.
- Remove burrs from cut faces.
- Align the casing welding ends with the piping in both radial
and axial directions.
The welding ends must be in flat-to-flat contact, and be
welded without any gap.
Filler metals
Base metal Suitable filler metal
1.4301/ 1.4307 1.4302; 1.4316; 1.4551
1.4404 1.4430; 1.4455; 1.4576
1.4435 1.4430; 1.4440
Welding
- Connect forming gas prior to welding.
- Apply 3 or 4 tack welds prior to welding.
Postweld treatment
- No inside postweld treatment is required. The surface finish of
accessible zones can be improved by grinding.
- Outside postweld treatment can be performed by pickling,
brushing, grinding, and polishing.
Cleaning
Clean all welded components prior to assembly.
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7 Assembly
7.1 Assembly of Butterfly Valve with Pneumatic Actuator
Fig. 7-1 Assembly of butterfly valve with pneumatic drive
1 Pneumatic actuator 6 Disc
2 Mounting bracket 7 Packing
3 Hex screw 8 Bolts and nuts
4 Position indicator 9 Bushing
5 Flange
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Refer to Fig. 7-1
The pneumatic actuator (Item 1) and the butterfly valve
form a constructional unit.
To assemble the unit proceed as detailed below:
1. Bolt the pneumatic drive (Item 1) to the mounting bracket
(Item 2) using the hex screws (Item 3).
2. Bolt the pre-assembled butterfly valve (two flanges - one
mid-packing - 1 disc - two bushings) using the hex bolts and
hex nuts (Item 8).
Place the position indicator (Item 4) on the square end such
that it indicates the position of the disc.
When fitting the mounting bracket (Item 2) with the pneumatic
drive (Item 1) bolted in place, to the butterfly valve make sure
that:
- the square end of the disc engages the square socket of the
pneumatic drive;
- the milled recess provided in the mounting bracket (Item 2) is
fitted on the top pair of bolts and fastened.
When assembling, take into account the following:
- The pneumatic drive (Item 1) must be in accurate alignment
with the disc.
- Prior to installing the valve in the piping, check by control
trials to make sure that the desired OPEN or SHUT position
of the disc in the butterfly valve is as required. Otherwise,
install the disc offset 90 deg.
- Where a pneumatic drive (Item 1) is installed so that the
valve is opened under air pressure and shut under spring
action the disc is consistently rotated into home position
should compressed air fail.
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7.2 Assembly of Pneumatic Actuator with Position Feedback Indication
Various configurations of position feedback indication are
available to suit customer's particular needs, e.g. using:
- 1 or 2 proximity switches;
two electric control units;
- one dual sensor.
Where provision for position feedback indication is made, the
relevant parts are fitted underneath the mounting bracket (Item
2) prior to assembly of the pneumatic drive (Item 1) with the
butterfly valve.
Fig. 7-2 Assembly of pneumatic drive with position feedback
indication
1 Pneumatic actuator 7 Position indicator
2 Mounting bracket 8 Disc
3 Proximity switch 9 Flange
4 Mount for proximity switch 10 Bolts and nuts
5 Hex screw 11 Packing
6 Indicator control arm 12 Bushing
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Refer to Fig. 7-2
For assembly proceed as detailed below:
1. Use the hex screw (Item 5) to fasten the mount (Item 4)
jointly with the mounting bracket (Item 2) to the pneumatic
drive (Item 1).
2. Make the indicator control arm (Item 6) a clamp-fit on the
O.D. of the coupling on the square end, being sure that the
end of the indicator control arm (Item 6) is located below and
in accurate alignment with the proximity switch which, in turn,
has been fitted in the hole of the mount (Item 4) normal to
the cylinder of the pneumatic drive (Item 1).
When assembling, be sure to take the following into account:
- Prior to installing the valve in the piping, check to ensure
that, when the disc is in the OPEN or the SHUT position, the
end of the indicator control arm (Item 6) is physically located
below and aligned with one of the proximity switches
- When using different position feedback signalling systems
proceed as detailed in the description and as shown in the
exploded view.
To dismantle the constructional unit reverse the assembly
procedure.
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8 Maintenance / Cleaning
Prior to starting cleaning, maintenance and repair work, check
to make sure that the following steps are taken to de-energise,
deselect and depressurise as applicable.
1. De-energise higher-level equipment / machine / unit .
2. Depressurise pneumatic system
Check to be sure
- that the butterfly valve is depressurised;
- that the valve is in home position.
3. Deselect the fluid
- Check to make sure the butterfly valve is depressurised.
- Remember that for fluid temperatures above 80C a
cooling-down period must be allowed before starting work.
Failure to comply with the above jeopardise personnel's life
and limb!
A servicing unit should be provided for control air to prolong the
useful life of O-rings.
Still, the pneumatic drive can operate on dry air.
Clean the valve in the as-installed condition by rinsing the faces
in contact with the fluid (CIP cleaning).
Cleaning fluids: 3% Nitric acid
3% Caustic-soda solution
Temperature: 80C max.
Care must be exercised to ensure that:
- clean and chlorine-free water is used as a diluent;
- caution: when measuring, avoid excessive concentration of
the cleaning agent;
- the valve is finally rinsed with ample water once cleaning is
completed.
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Make sure that cleaning agents are stored in compliance with
relevant safety codes.
Care should be exercised when handling cleaning agents to
ensure that the safety instructions given on the Data Sheet
issued by the cleaning-agents manufacturer are followed.
Wearing rubber gloves and safety goggles is an essential
requirement to be met when performing cleaning work.
Caution must be used not to touch the butterfly valve or the
piping when hot fluids are being processed or while the
sterilisation process is in progress.
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9 Malfunction, Cause, Rectification
If the proposed rectification fails to cure the trouble, please
contact a specialist contractor or AWH Armaturenwerk
Htensleben GmbH.
Problem Cause Rectification
Valve fails to operate Compressed air failure
Electric control at fault
Drive at fault
Start compressed air supply.
Check and ensure electric
signals.
Check and, if necessary,
renew.
Signals not received Loose cable on proximity switch
Broken cable
Loose indicator control arm
Proximity switch at fault
Electric power supply failure or
at fault
Fasten cable.
Renew cable.
Fasten indicator control arm.
Renew proximity switch.
Check and rectify as necessary.
Valve operates slowly Inadequate compressed air
supply
Drive exhaust port clogged
Boost compressed air supply.
Open up the port.
Valve operates non-uniformly Poor compressed air supply
High fluid pressure
Inconsistent electric signals
Boost compressed air supply.
Check fluid pressure and adjust
as necessary.
Eliminate signal flow trouble.
Valve generates excessive
mechanical noise
Valve or actuator drive at fault Renew the valve and or
actuator.
Leaky valve Faulty or worn packing Renew the packing.
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10 Dismantling / Disposal
The butterfly valve mainly consists of stainless steel (except for
the electrical equipment). For disposal, relevant local
environmental regulations must be complied with.
Contaminated fluids as well as residue of cleaners must be
disposed of while complying with relevant local environmental
regulations.
Care must be exercised to avoid contact with harmful fluids.
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11 Index
Assembly 15
Assembly of pneumatic drive with position feedback indication 17
Assembly of shutoff valve with pneumatic drive 15
Cleaning 19
Contents 8
Damage 12
De-energise system 19
Defects 12
Dismantling 22
Disposal 22
Explanatory notes 9
Exploded view, Dimensions 5
Filler metals 14
German standards and codes 10
Hazards 9
Incoming inspection 12
Informative signs 9
Installation of shutoff valve 13
Intended use 3
List of figures 8
Maintenance 19
Malfunction 21
Materials in contact with the product 4
Note 7
Outdoor storage 12
Packaging 12
Packaging for return to consignor 12
Pre-welding condition 14
Problem solving 21
Rectification 21
Safety 9
Safety standards 10
Safety testing 10
Seaworthy packaging 12
Specialist 3
Transport 12
Warning 19
Warning notices 11
Welding specifications 14