Before starting the installation, make sure that you have carefully read the User Manual and Safety Instructions associated with the brand and type of valve. Go straight to the installation tips for:
Installation of solenoid valves
Before starting the installation, it is important to verify that the solenoid valve is suitable and safe for the desired application. Check the valve properties on the type label and verify if the specifications match with the requirements of the application. The image below shows an example of type labels with an explanation of the various parameters.
- Make sure that the circuit is not under pressure and that the system is cooled down before proceeding.
- Check the pipes for dirt (rust particles, cuttings, leaves etc). It is recommendable to flush the pipes before installing the valve. Small particles of dirt in the pipe can enter the valve and lead to blockages or leakage. This is one of the main reasons why solenoid valves malfunction. This problem can be solved by opening and cleaning the valve, but it is better to prevent dirt from entering the valve. If you are not sure that the medium is absolutely clean, you can install a pipe filter on the inlet side of the solenoid valve.
Positioning of the solenoid valve
- It is recommended to install the valve in a dry and ventilated environment. The valve gets hot during use. To allow for cooling, sufficient space must be maintained around the valve.
- Most solenoid valves can be used in one flow direction only. Be aware of the flow direction of the medium when installing the valve. Often the correct flow direction is indicated by an arrow on the valve body. The pipes on both sides of the valve must be securely fastened. Use a wrench for both the valve and the pipe while tightening. Prevent unnecessary stresses in the system.
- The best way to install the valve is with the coil facing upward with a maximum deviation of 90 degrees (see picture). This reduces the risk of collecting dirt in the valve.
Mounting the coil
Mount the coil on the solenoid valve. Never connect the coil to the power supply when it is not mounted on the solenoid valve! The coil may burn out. Follow the user manual to ensure correct assembly of the parts. Tighten the nut sufficiently to make sure that the coil does not rotate or vibrate, but avoid over tightening in order to prevent damage. A guideline for the tightening torque is 5 Nm.
Installation of the connector
Follow this step if the coil is fitted with a DIN-A or DIN-B connector.
- Use a round cable. Connect terminals (1) and (2) to the power supply. The polarity does not matter.
- Always connect the ground. Never use the piping as earthing.
- Connect the connector to the coil. Make sure that no moisture can come between the coil and the connector. Use a torque of 0.5Nm for the mounting screw.
- Position the cable in a way that (condensation) drops can not slide along the cable into the connector.
Only turn on the power supply when the valve is correctly installed and can be started safely. Please note that pressure may be present in the system.
During use the coil gets hot.
In case the solenoid valve does not function properly after installation, in most cases this is easily corrected. These are the most common reasons:
- The valve is blocked because of dirt. Small dirt particles can block the small channels and openings in the valve. Although the pipes seem clean during installation, it still regularly happens that the pipes contain dirt like rust particles, sand, cutting chips etc. If this happens, open the valve carefully and clean the parts. Always follow the instructions in the user manual. Ensure that the valve is properly reassembled.
- The valve is connected in the wrong flow direction. Check the flow direction that is indicated on the valve body with an arrow or text and reverse the valve if necessary.
- The valve is indirectly operated and the differential pressure is too low. If the pressure across the indirect operated valve is too low (less than 0.5 bar), the valve will not properly open. In this case, a (semi-)direct operated valve should be used.
- You experience water hammer. Water hammer is a typical consequence of a high flow rate and pressure in pipes with small diameters. There are several solutions for this problem:
- Increase the pipe diameter to reduce the fluid velocity.
- Reduce the pressure with a pressure reducing valve before the solenoid valve.
- Dampen the water hammer by using a flexible hose or buffer before the solenoid valve.
- Use a solenoid valve with a longer response time. This reduces the pressure transients.
Installing electric ball valves
These installation tips are specially meant for electric ball valves from the BW series of JP Fluid Control. Before starting the installation, please read the safety instructions carefully and verify that the electric ball valve is suitable and safe for the application. Check if the valve specifications on the type label on the actuator match with the application requirements. The image below shows an example of a label with an explanation of the various parameters.
- The actuators of the AW series are splash proof, but not resistant to severe weather conditions. It is therefore advisable to install electric ball valves in a dry, sheltered spot.
- Make sure that the piping is not under pressure and cooled down before you start.
- Check the pipes for dirt and clean the pipes if necessary. Ball valves are less sensitive to dirt than solenoid valves, but it is still advisable to avoid dirt if possible. Dirt may increase the wear of the valve. Optionally you can install a pipe filter on the inlet side of the valve.
- Use thread sealant such as Teflon tape or Loxeal for the pipe thread. Avoid entry of the sealant into the valve as this may lead to blockage.
- Use the correct fittings between the valve and the pipes. While tightening, only excert force at designated areas on the valve, never exert force on the actuator. Avoid stresses in the piping and fix the pipe securely to the wall or frame to avoid vibrations in the pipes.
Positioning of the electric ball valve
- The valve must be securely fastened to the pipes using the right type of fittings. Use a wrench for both the valve and the pipe while tightening. Prevent unnecessary stress in the system.
- It is recommended to install the valve with the actuator facing upward with a maximum deviation of 90 degrees (see picture). This reduces the risk of collecting moisture in the actuator.
- Set the ball to the correct angular position, for example with a wrench. The 2-way ball valves are closed in their standard position. The 3-way ball valves can be set up in two different ways by rotating the ball 180°. The following diagram shows how the 2-way and 3-way valves can be used.
- Make sure that the position of the ball in the valve is properly adjusted, so the actuator fits on the valve. Tighten the nut of the actuator by hand.
- Check the actuator type and use the correct wiring diagram. Improper connection of the wires or using a wrong voltage can cause permanent damage to the actuator!
- The rotational direction of the actuator can not be changed by reversing the polarity of the control wires.
- The actuators are equipped with two internal end switches. Therefore, energy is only consumed during opening or closing.
- The AW1 actuator (JP Fluid Control) opens and closes electrically. There is no spring in the actuator.
- Ensure that drops cannot slip along the cable and enter the actuator.