BULLETIN E-RE-06. Sizes: 1-1/2" to 4" Absolutely Leak-tight Extremely Temperature-stable Best Surface Finish Easy Installation

Transcription

1 BULLETIN E-RE-06 Sizes: 1-1/2" to 4" For Sizes 1/4" to 1" see Bulletin E-RE-01B, ZeroCon -Crown Absolutely Leak-tight Extremely Temperature-stable Best Surface Finish Easy Installation 1

2 Contents Technical Description... 3 Features... 3 Materials... 4 Pipe dimensions... 4 Material traceability... 4 Pressure rating... 4 Temperature stability... 4 Portings... 4 Cleaning... 4 Ultra-purity application... 4 Leak-testing... 4 Bacteria swab testing... 4 ZeroCon -Flange Components... 5 Ordering information... 5 Complete connection, incl. sealing ring & flange with welding hub & set of screws... 5 Flange with welding hub... 6 Blind flange... 7 Sealing ring... 8 Screw set... 8 Application Examples / Benefits... 9 Assembly Instructions Disassembly Instructions ROSS DALE-Poppet Valves & ZeroCon PLEASE NOTE: When making your selection from the offering described in this Bulletin, be sure to consider the application criteria of all parts in your system and its environment in order to secure trouble-free functioning and safe use of the respective products/components. Careful consideration of all relevant parameters concerning function, field of use, material compatibility, performance data, operation limits as well as proper system-start-up, handling and maintenance are subject to the responsibility of the user or the system planner, respectively. We reserve the right to introduce technical changes without prior notice. 2

3 Technical Description FEATURES ZeroCon -Flange is made of solid high-purity stainless steel and serves as a safe and quick connection of pipe networks, pipe joints and welded systems. (1) Absolutely leak-tight Consistent material quality - Helium-leak-rate is mbar s -1 (2) Zero dead spaces Space between sealing and joint 10µm (3) Perfect pharmaceutical barrier No risk of bio-burdening aseptic design Robust connection Suitable for application under high-pressure, critical vacuum and extreme temperature conditions Dynamic stress resistance Interlocking geometry designed to prevent influence of external forces and moments. Temperature-stable, from -273 C to +450 C Zero flow disturbances Highest-grade surface finish Ra 0,4 µm Zero material outgassing Stainless steel acc. to EN Easy installation Self-centering, end stop and integrated leak test port Zero maintenance No preventive elastomer maintenance required Full component traceability Marking of all components Flange with welding hub Integrated leak test port Silver-plated screws for easy, consistent installation Best surface finish for all components Ra 0,4 µm Sealing ring Flange with welding hub Solid connection Rotation is prevented by the pressing force of four screws located at 90 angle on the pitch circle. 3

4 Technical Description Materials Component Seal ring Flange with welding hub Blind flange Screw Washer Material* * / S (316L) * / S (316L) A2 inside silver-plated DIN 125 A4 *Restricted values: Sulphur 0,017%, Phospor < 0,035%, Delta Ferrit < 0,5%. Plating ZeroCon -Flange screws are silver-plated on the inside. This surface treatment reduces friction during assembly / disassembly, and ensures proper mounting position. *Other materials available on request. Pipe dimensions Imperial: ISO 2037/BS 4825 Part 1 ISO: DIN EN ISO 1127 Metric: DIN 11850, Row 1 and Row 2 Material traceability Acceptance test certificate 3.1 acc. to DIN EN for primary materials and marking transfer documents for materials and products are available on request. Pressure ratings All pressure ratings (maximum operating pressure) are based on calculations for straight pipes/tubes, at room temperature (20 C/ 68 F), acc. to EN , and for predominantly static loads. Temperature stability All ZeroCon -Flange components are made of the same material high-grade stainless steel. There are no elastomers involved which would limit temperature stability. Part Lowest Temperature Maximum Temperature C / F C / F Seal ring -273 / -459,4 450 / 842 Flange with welding hub -273 / -459,4 450 / 842 Portings Welding hubs are prepared ready for orbital welding. Cleaning Prior to packaging, all ZeroCon -Flange components are cleaned and rinsed in ultra-pure water to meet the requirements. The parts are free from production residues such as oil, lubricant and loose particles. All components are packed as separate units in individually sealed bags. Ultra-purity applications On request, all joints, seals and nuts are available with electro-polished finish and rinsed in ultra-pure water to meet clean room and ultra-pure fluid application requirements. Leak-testing ZeroCon -Flange shows absolute leak-tightness by helium leak test. Based on state-of-the-art measurement technology ( ), a leak-rate of mbar s -1 is measured. Bacteria swab testing Maximum space between sealing and joint is 10 µm which is smaller than the size of the smallest being (fungus, 20 µm). Therefore, ZeroCon -Flange prevents any accumulation of bacteria or other micro-small beings. Bacteria swab test results are available upon request. 4

5 ZeroCon -Flange Components Ordering information All dimensions are given for reference only, and are subject to change. Other system variations can be composed individually. Complete Connection, including Seal, Flange with Welding Hub & Screw Set D d s L A L IMPERIAL Operating Pressure System Inch Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 1-1/2 RE ,10 1,65 65,00 76,00 21, RE ,80 1,65 65,00 90,00 21, /2 RE ,50 1,65 65,00 105,00 21, RE ,20 1,65 65,00 120,00 21, RE ,60 2,11 65,00 147,00 21, ISO Operating Pressure System ND Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 20 RE ,90 1,60 65,00 76,00 21, RE ,70 2,00 65,00 76,00 21, RE ,40 2,00 65,00 90,00 21, RE ,30 2,00 65,00 90,00 21, RE ,30 2,00 65,00 105,00 21, RE ,10 2,00 65,00 120,00 21, RE ,90 2,30 65,00 147,00 21, METRIC Operating Pressure System ND Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 25 RE ,00 1,50 65,00 76,00 21, RE ,00 1,50 65,00 76,00 21, RE ,00 1,50 65,00 76,00 21, RE ,00 1,50 65,00 90,00 21, RE ,00 2,0 65,00 105,00 21, RE ,00 2,0 65,00 120,00 21, RE ,00 2,0 65,00 147,00 21,

6 ZeroCon -Flange Components Flange with Welding Hub D d s L A IMPERIAL Operating Pressure System Inch Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 1-1/2 RE ,10 1,65 32,50 76,00 21, RE ,80 1,65 32,50 90,00 21, /2 RE ,50 1,65 32,50 105,00 21, RE ,20 1,65 32,50 120,00 21, RE ,60 2,11 32,50 147,00 21, ISO Operating Pressure System ND Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 20 RE ,90 1,60 32,50 76,00 21, RE ,70 2,00 32,50 76,00 21, RE ,40 2,00 32,50 90,00 21, RE ,30 2,00 32,50 90,00 21, RE ,30 2,00 32,50 105,00 21, RE ,10 2,00 32,50 120,00 21, RE ,90 2,30 32,50 147,00 21, METRIC Operating Pressure System ND Model Number d [mm] s [mm] A [mm] D [mm] L [mm] [bar] [psi] 2 25 RE ,00 1,50 32,50 76,00 21, RE ,00 1,50 32,50 76,00 21, RE ,00 1,50 32,50 76,00 21, RE ,00 1,50 32,50 90,00 21, RE ,00 2,0 32,50 105,00 21, RE ,00 2,0 32,50 120,00 21, RE ,00 2,0 32,50 147,00 21,

7 ZeroCon -Flange Components Blind Flanges D A IMPERIAL System Inch Model Number A [mm] D [mm] 2 1-1/2 RE ,50 76, RE ,50 90, /2 RE ,50 105, RE ,50 120, RE ,50 147,00 ISO System ND Model Number A [mm] D [mm] 2 20 RE ,50 76, RE ,50 76, RE ,50 90, RE ,50 90, RE ,50 105, RE ,50 120, RE ,50 147,00 METRIC System ND Model Number A [mm] D [mm] 2 25 RE ,50 76, RE ,50 76, RE ,50 76, RE ,50 90, RE ,50 105, RE ,50 120, RE ,50 147,00 7

8 ZeroCon -Flange Components Seal Ring d s IMPERIAL System Inch Model Number d [mm] s [mm] 2 1-1/2 RE ,90 4, RE ,60 4, /2 RE ,30 4, RE ,00 4, RE ,50 4,00 ISO System ND Model Number d [mm] s [mm] 2 20 RE ,80 4, RE ,80 4, RE ,50 4, RE ,40 4, RE ,40 4, RE ,20 4, RE ,40 4,00 METRIC System ND Model Number d [mm] s [mm] 2 25 RE ,10 4, RE ,10 4, RE ,10 4, RE ,10 4, RE ,10 4, RE ,10 4, RE ,10 4,00 Screw Set Consisting of 4 silver-plated screws with washer. System Model Number [Torx] [Hex] 1, 2, 3, 4, 5 RE * TX 45 6 RE * HX 8 *Screw: silver-plated (see Page 4). 8

9 ZeroCon Premium Quality. No Compromise! Industries using the ZeroCon system. Your Benefits: Semi-Conductor Industry Pharmaceutical Industry Fine Chemical Industry Metallurgical Industries Food Industry Process Industry Test Bench Offshore Steel Industry As leak-tight as a welding seam, up to high-pressure level No medium losses / no spilling of toxic media into the environment, no contamination of the medium. No particle deposits / no formation of cultures / no bacteria films 100% sterilization, and shorter wash-down times. No negative, outside impact of forces and / or moments on the connection No loosening of the connection through torsion forces. Self-centering, due to interlock design. No turbulences, no flow restrictions Suitable for ultra-high vacuum 100% stainless steel; no elastomer No contamination of the process medium caused by material outgassing. Temperature-stable from (-273 C to C). Easy hot-steam sterilization. Much higher resistance to aggressive media as compared to resilient-type seals. Easy and clear switch to other dimensions Clearly arranged and simplified product range (sealing) Meets highest purity standards Quick and easy assembly and disassembly No danger of damages due to excessive torque rating Easy and fast leak test in installed condition Frequent re-usability of flanges and nut Easy and simple joining of the system with downstream pipe / line networks For use in explosive environments High resistance to environmental influences (sodium liquids, brine,etc.) No maintenance required Markings provide full traceability of all components 9

10 Assembly Instructions Flange with welding hub S (316L) / Screw Set S (316L) / silver-plated, DIN 125 A4 Seal S (316L) / Step 1 Insert all 4 screws in flange 1 from the weld joint side 1. Place the washer on each screw. 2. Screw all four screws completely through flange 1. Step 2 Put seal and flanges in tightening position 1. Place the seal between flange 1 and flange Align the two flanges by inserting the screws into the unthreaded zone of the bores in flanges 1 and 2. The flange system will be self-centered by the seal. Screw with washer Weld joint side Unthreaded zone Sealing side Flange 1 Step 3 Pre-tighten flange system manually. 1. Turn the screws into flange 2 until the threaded zone is reached. 2. Flange 1 and flange 2 are now in parallel position. Unthreaded zone, Flange 2 Flange 1 Flange 2 Seal Step 4 Tightening the screws. 1. Turn the first screw by Continue tightening the remaining screws in the same way. The installation is complete when the required torque of 20 Nm is achieved on all screws. 3. Doublecheck the torque 20 Nm for all screws. Unthreaded zone 60 turn Flange 1 Flange 2 Seal 10

11 Disassembly Instructions Flange with welding hub S (316L) / Screw set S (316L) / silver-plated, DIN 125 A4 Seal S (316L) / Step 1 Turning back the screws 1. Loosen two opposite screws (green) and turn them back into the thread of flange 1. The screws are in their proper position, when the space between the washer and the back side of the flange is approximately 11 mm (7/16"). 2. Loosen all remaining screws and remove them from both flanges. Step 2 Loosen flanges by turning locking screws 1. Insert two of the removed screws (yellow) in flange 2, until these get in contact with the two (green) screws in flange Turn the two yellow screws into flange 2, alternately, by 90 steps. The flanges will be separated, but the seal continues to be located in one of the two flanges. Unthreaded zone Screw with washer Locking screws, for loosening the connection Threaded zone Flange 1 Flange 2 Seal Flange 1 Flange 2 Seal Step 3 Removing the seal from the flange 1. Turn two screws into the flange on the weld joint side, the seal still in its proper position. Install the screws at facing ends. 2. Turn in the screws until these reach an overhang position of approximately 1,4 mm (1/16") on the back of the flange. 3. Loosen the seal ring, by alternately levering out the seal with a screwdriver (direction of F 1 forces, as shown in illustration). The ends of the screws serve as a bearing surface to avoid damages of the flange surface when removing the seal. Screw driver F 1 Locking screws, to avoid damages on the flange surface. Screw driver F 1 11

12 ROSS DALE-Poppet Valves & ZeroCon Connections The perfect match. No leaks involved. ZeroCon -Crown 1/4" to 1" LT-Valve Manifolds 3/4-Way Valves, G 1/4 ZeroCon -Flange 1-1/2" to 4" CP & CX 3/2-Way Valves, G 3/4 und G 1 Application Example: Leak Testing The ROSS-DALE Series is an excellent fit for processes requiring leak-tight valves. DALE valves feature poppet construction for zero leakage and high dirt tolerance. Practically every pressure-containing vessel is leak-tested during production or assembly. DALE valves are specifically designed for leak-free operation at high pressure levels. Series CX and LX valves are not only absolutely leak-proof, they also stand out for the fact that they allow flow in both directions. Thus, they are the perfect choice for vacuum applications or helium-leak-test challenges. Why is it important that the valves used in testing procedures are absolutely leak-tight? If the valves being used to control the test are themselves leaking, it is impossible to tell if the product under test is leaking. Benefits of the DALE Valve Line at a Glance: Solenoid actuated Bubble-Tight. The patented DALE poppet design makes sure that no internal leakages occur. High Flow. Leak tight plus high flow equals minimized test time. Independent Pressure Ports. Provides the ability to have pressure or vacuum on any port at any time. Integrated Sensor Ports. The manifolds customized for leak-testing come with integrated sensor ports. Compact Installation. The compact manifolds eliminate spacing between valves. Full port flow Speed control Dynamic sealing For detailed information, consult ROSS Bulletin 200. ROSS' application experts will be happy to assist you in finding optimum opportunities for integrating ZeroCon and DALE into your pneumatic system. Internally or externally piloted Port plate flexibility 12

13 ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D Langen Phone: Fax: info@rosseuropa.com DIMAFLUID S.A.S. 69/73 Boulevard Victor Hugo Bâtiment Saint-Ouen, France Phone: Fax: dimafluid@dimafluid.com ROSS CONTROLS 1250 Stephenson Hwy. Troy, Michigan U.S.A. Phone: Fax: ROSS UK Ltd. sales.uk@rosscontrols.com ROSS ASIA K.K. ROSS SOUTH AMERICA Ltda. vendas@ross-sulamerica.com.br ROSS CONTROLS INDIA Pvt. Ltd. ROSS CONTROLS (CHINA) Ltd. GLOBAL Reach with a LOCAL Touch. ROSS is a reputed manufacturer of premium pneumatics, well-established on all continents. Our potential to develop unique, customized products and ready-for-use control units is widely appreciated. ROSS experts are familiar with the processes and technical challenges in all major industries so that our customers can look forward to fluid power solutions on highest productivity levels. ROSS' extensive design-, distribution- and service network provides GLOBALLY exemplary performance power which is LOCALLY available for further enhancement of your processes. Be sure that ROSS will always be ready to help YOU! Warranty and Important Notes. Standard ROSS Warranties and Application Notes apply. We will be glad to inform you in full detail. For more information, please visit ROSS EUROPA's website (). Printed in Germany - Rev , ROSS EUROPA GmbH. ALL RIGHTS RESERVED. RE-E-A10216a 13