D6960 en PDF
D6960 en PDF
1. General application
1.1 Application
As check valves (DIN ISO 1219-1) for free flow in one direction
Check valve
and blocked flow in the opposite direction. (See also sect. 1.4)
As pre-fill valves (hydraulic pilot-operated check valves,
DIN ISO 1219-1) in the press controllers for further-suction and
emptying the press cylinders when closing and opening in rapid
traverse. Zero leakage in the blocked direction (plate-type seat
valves).
1.3 Installation
When directly fitted onto the cylinder, the valves are clamped
between the cylinder base and welding neck flange. For line
installation, they are positioned between the front faces of the
welding neck flanges. The seal diameters are selected so that the
material yield point is not exceeded when normal flanges are
used and when the permissible operating pressures given in
sect. 2.2 are kept to. Sealing rings type A DIN 7603-Cu or flange
seals are used, depending on the size. For details of sealing
surface working of flanges, see sect. 2.2
2. Types available
2.1 Type designation, main data
Coding Pre-fill valve Nomi- Flow Control part on pre-fill valves Mass
nal Qmax Release ratio Control (weight)
Check without with size volume approx. (kg)
valve pre-relief pre-relief (lpm) (k) (cm3) F.. F.. - ..(V)
F 25 F 25-12 F 25-12 V 25 100 4.3 0.45 1 1.1
F 32 F 32-16 F 32-16 V 32 160 3.6 1 1 1.2
F 40 F 40-20 F 40-20 V 40 250 3.9 Valve plate opens 2.1 1.4 1.7
F 50 F 50-25 F 50-25 V 50 400 4.2 at residual pres- 4 2 2.4
F 63 F 63-30 F 63-30 V 63 630 4.2 sure in (press) 7 2.8 3.4
F 80 F 80-36 F 80-36 V 80 1000 4.5 cylinder 12.2 4.4 5.2
F 100 F 100-45 100 1600 4.3 pcyl rest = pSt : k 25.4 9.9 11.7
F 125 F 125-60 125 2500 4.3 59.3 15.8 19.6
F 160 F 160-76 160 4000 4.3 113 43 50
F 200 F 200-100 200 7000 4.0 314 110 120
Reshape flange on valve side to improve flow around Cylinder Pressure side
valve disc, see also sect. 4
1a Standard welding neck flange ND 40 or 64, depending on valve size. The bolt sleeves serve directly to center the valve body
1b Spacer sleeves must be produced for standard flanges of the next-highest pressure class due to larger reference diameter, see table
below
1c Costomer-furnished flanges with rigid, thick flange leaf to be designed so that the valve can be centered without spacer sleeves by as
many screws as possible.
F 25 to F 50-25 V F 63 to F 200-100
Utilized as check or Requested ma- Utilized as Utilized as
pre-fill valve chining toler- check valve pre-fill valve
ance for the Suction side
Flange facial
mounting area
side with com- 2a
of the valve on 2b
mon surface
the facial side of
quality
flange or cylin- 2b
der bottom.
Pressurized side
Copper seal ring conf.
Type DIN 7603-Cu-A.. Type F 63.. F 80.. F 100.. F 125.. F 160.. F 200
F 25.. 38x44x2 2a KANTSIL- FK 343 FK 349 FK 433 FK 441
O-ring FK 447
F 32.. 45x52x2 seal ring 290.00x7.0 90Sh
F 40.. 60x68x2.5 +
F 50.. 75x84x2.5 2b Profil- 6960 898 A 6960 898 B 6960 898 C 6960 898 D 6960 898 E Back-up ring
seal ring 6960 221
Type In- Permissible pressure Spacer sleeve Screws Torque Suct. pipe e.g. 1) If pressure
stal- required 1b Material 8.8 DIN 2448 surges can be
la- pzul Flange used 1) (mm) 3) seamless expected due to
tion (bar) Material C 22 D d h MA (Nm) (non-binding) the way in
pieces / size
which the sys-
1 400 4 / M 16x80 tem is opera-
F 25... C 32x38 DIN 2635 (ND 40) 38x2.6 ted, it is advan-
2 400 4 / M 16x65 tageous to use
1 350 4 / M 16x80 the relevant
F 32... C 40x44.5 DIN 2635 (ND 40) 44.5x2.6 higher stated
2 400 4 / M 16x70 flange - ND-
210 class - for
1 250 4 / M 16x90
F 40... C 50x57 DIN 2635 (ND 40) 57x2.9 greater than
2 350 4 / M 16x75 F 50...
1 250 8 / M 16x90 2)
C 65x76.1 DIN 2635 (ND 40) If a DIN 2637
2 350 8 / M 16x75 flange (ND 100)
F 50... 76.1x2.9
1 400 8 / M 20x110 is used for F80,
E 65x76.1 DIN 2636 (ND 64) 32 20.5 28.5 380 the sleeve
2 400 8 / M 20x90 41x27.5x38 and
1 250 8 / M 16x100 8 screws
C 80x88.9 DIN 2635 (ND 40) --- --- --- 210 M27x110,
2 250 8 / M 16x80 (MA=1000Nm)
F 63... 88.9x3.2 must be used
1 400 8 / M 20x110
E 80x88.9 DIN 2636 (ND 64) 27 20.5 33 380
2 400 8 / M 20x90 3) In the case of
250 C 100x108 DIN 2635 (ND 40) --- --- --- 8 / M 20x90 410 customer-fur-
F 80... 2 108x36 nished flanges,
400 E 100x108 DIN 2636 (ND 64) 31 2) 24.5 38 8 / M 24x110 2) 700 2) it is better to
300 E 125x133 DIN 2636 (ND 64) --- --- --- 8 / M 27x120 1000 use larger num-
F 100.. 2 133x4 bers of smaller
400 E 125x133 DIN 2637 (ND 100) 38 30.5 43.5 8 / M 30x130 1100 screws com-
250 E 150x159 DIN 2636 (ND 64) --- --- --- 8 / M 30x130 bined with at
F 125.. 2 1400 159x4.5 least an equal
400 E 150x159 DIN 2637 (ND 100) 42 30.5 49.5 12 / M 30x140 overall force
200 E 200x219.1 DIN 2636 (ND 64) --- --- --- 12 / M 33x160 630 and, if possible,
a rigid (thick)
F 160.. 2 300 E 200x219.1 DIN 2637 (ND 100) 50 33.5 68.5 12 / M 33x170 1300 219.1x5.9 flange leaf
400 E 200x219.1 DIN 2638 (ND 160) 50 33.5 68.5 12 / M 33x180 2000
F 200.. 2 320 see example in sect. 4.3 --- --- --- 16 / M 36x300 2300 273x6.3
D 6960 page 4
The pressure pipe dimension for instal- The following standards can be used as a basis for working out the pressur pipes:
lation methods 1 as described in sect. DIN 2413-1, -2: Steel pipes: Calculating the wall thickness against internal
2.2 are selected on the basis of the pressure
relevant safety details DIN 2445-1, -2: Seamless steel pipes for dynamic load
DIN 1629 ( ISO 9329-1): Seamless pipes made of unalloyed steels
DIN 2448 ( ISO 4200): Seamless pipes
DIN 2391-1, -2: Seamless precision steel pipes
Both sides must be regarded as pressure sides when the valve is being used as a check valve.
Ensure in the normal way that both parts are joined together without misalignment.
Pressure
flange C 22 is the usual material for welding neck flanges in accordance
with the various standards sheets in accordance with DIN 17 200.
for F 63....
F 160..
F 100..
F 125..
F 200..
F 63...
F 80...
F 25...
F 32...
F 40...
F 50...
Type
... F 200,
for F 25...
... F 50
as per DIN 2635 d1 35 43 54 73 88 (108) (132) (168) (215) (275)
flange
and DIN 2636 t 6 7 9 11 12 (15) (25) (30) (40) 55
From F 80... onwards, it is better to use flanges with rigid flange leaf
when di pipe as described in 1c in sect. 2.2.
< di flange When hollowing out r, ensure that there is still 1... 1.5 mm thickness
up to the converse surface line of the largest internal diameter.
pipe
pipe
Assembly space required for axial travel of the line Side mounting without axial travel of the pipeline
This disassembly possibility is achieved by way of an addi-
Pre-fill valve, Check valve tional spacer ring (to be furnished by the customer, not scope
suction side (in pressure line) of delivery). External diameter same as corresponding the
pre-fill valve.
Suction side
F 63 ... F 200 in
valve body area,
for F 25...F 50
as per DIN 2635 Machining
and DIN 2636 same as in
illustration
on the left
F 40-20(V)
F 50-25(V)
F 63-30(V)
F 80-36(V)
F 25-12(V)
F 32-16(V)
Type
Detail with “A”:
F 50
F 63
F 80
F 40
F 25
F 32
F 25 to
H 1) 12 19 20 30 23 34 32 45 38 52 47 61 F 50-25 (V) For seals,
d1 35 43 54 73 88 108 groove
dimension see
t1 * 0.1 1.2 1.2 1.7 1.7 4.0 4.3
sect. 4.1
t2 0 1 1 1.5 1.5 1
F 200-100
F 160-76
F 100-45
F 125-60
Type
Relief groove, inside diameter approx. #da + 4, 1.5...2 mm
F 160
F 100
F 125
4. Dimensions of units
All dimensions are in mm, subject to change without notice !
Flange
side r 0.6
1) Front face of
Valve side flange refinished,
see sect. 3
Type D3 D4 H1 h da di s 2) s1 t ±0.1 t1
F 125 248 127 127 51 190.6 +0.2 171 -0.3 30 30 5.8 1.5
F 160 310 163 182 70 241.2 +0.2 220 -0.3 37 37 5.6 1.5
Connection
Type ISO 228/1
(BSPP)
A 3) Z H2 d2 a b x
Pre-relief for
F25-12V up to
F 80-36V
D 6960 page 6
Example
Suction flange (general, not binding)
1)
1) Mounting hole
4x M12, 22 deep
Material: St 52-3
Soft iron packing ring, Pre-fill valves type F 63... to F 125... (supplement). The check valves
special version and pre-fill valves F 63.. to F 125.. are available as a special
version with soft iron packing rings if it is not possible to produce
Flange with rigid the surface quality of the mating surfaces on the flange or cylinder
flange leaf base required for the standard flange seal and outlines in sect. 2.2.
It must be kept in mind that standard welding neck flanges cannot
be used. Rather, customer-furnished flanges with a suitably rigid
flange leaf for transferring the screw forces to the soft iron packing
ring are necessary. The screws are best arranged so that their in-
Pre-fill valve ternal converse surface line centers the valve body.
F63 to F125 When ordering, add in plain text that soft iron packing rings No....
(see table) are to be supplied instead of the flange seal.
Cylinder
DG.. acc. ZR
BC.. D 6969 B to
RDF.. D 7540 4) D 5440
ADM 1-... 6)
Directional valve bank 3) Direct. control valve 3)
VB.. acc. to D 7302 G 3-0 B acc. to D 7300 Pre-fill
BWN(H).. acc. to D 7470B/1 WN1H/B 0.7 acc. to D 7470A/1 valves
without
pre-relief
E1
See note in
footnote 5)
page 7
RD.. acc. to
D 7540
Safeguarding against pressure
translation (e.g. error m2 → 0 in
sequence 1), pressure must be
SV 2
min. 30 %. higher than the max.
self induced load pressure
2 Pressure off 0 0 0 0 0 (a) - setting for possible series connection by the DG.
maintenance (on) (a) 1) (a) 2) (a) 2) Observe starting instructions for the pump motor 1)
1) e.g. via time relay. Set it that m1 = a only after the pump motor is started up. Switch over to / while m1 = 0 for !- / start.
2) (a) e.g. for pressed material which is still flexible during the pressing period. The pressure switch unit switches the pump back on when
the pressure drops 1). See for example D 5440 for restarting pressures.
3) Observe the max. permissible operation pressure! (see corresponding pamphlets)
4) The orifice size determines the decompression time; it should be selected in such a way (acc. to the |p-Q-curve), that the flow via the
orifice during start of decompression (current pressure at the cylinder) does not exceed the perm. flow rating of the valve m3.
The decompression period at ZR must be sufficiently set, that m1 → a is activated after the pressure in the cylinder is securely removed.
Example: Directional valve bank m1 ... m4 = VB 21AM-... acc. to D 7302, perm. Qmax = 25 lpm. Max. cylinder pressure pcyl = 350 bar
(end of sequence 2), selected restrictor check valve RDF 31. The suited orifice -# is roughly 1.4 mm (Q , 20 lpm) i.e. RDF 31/1.4 acc. to
the |p-Q-curve in D 7540 for 350 bar. The estimated decompression time for a press cylinder with a volume of 50 lpm will be roughly
6 to 7 sec. The decompression time for a certain volume of a press cylinder Vcyl (l) and a certain RDF- orifice #d (mm) can be roughly
estimated t » 0.014 Vcyl × pcyl / d2
5) If the pump motor is started by the timer from sequence 3, e.g. !-/, ensure that the switchover time from ! to / takes place during the
decompression time sequence 3 4). Otherwise, the !/ contactor would also have to actuate m1→ a when switching over to / if the
switchover time was longer. The time relay ZR is, then, not absolutely essential.
6) ADM... (D 7458) to limit the control pressure to $100 bar (sect. 2.1). Necessary if the pressure for rapid traverse ↑ (sequence 4) is greater
than 100 bar.
D 6960 page 8
Pre-fill valve
Pressure with pre-relief 3)
switch unit Direct. control valve 4)
ADM 1-..-
DG in G 3-0 B acc. to D 7300
acc. to WN1H / B 0.7 SV 3 4)
D 5440 acc. to D 7470A/1
5)
E1 $ 100 bar > pSt
e.g. MV 41E
D 7000/1
Safeguarding against pressure translation (e.g. error m2 → 0 in sequence 1), pressure must be min. 30 %. higher than the max. self
induced load pressure
Ready for
0 on 0 0 0 0 --- ---
operation (idling)
Rapid traverse contact making for The timer for the pressing time can be
1 down (fall) and on a a a 0 sequence 2 with started simultaneously with contact
press. build-up operating pressure making
Maintain off 0 0 0 0 (a) - setting in the event of any series connection by the DG.
2 Follow starting instructions for pump motor !
pressure (on) (a) 1) (a) (a)
1) e.g. via time relay. Set it that m1 = a only after the pump motor is started up. Switch over to / while m1 = 0 for ! - / start.
2) Deblocking of the pre-relief in the pre-fill valves begins after the pump is started when m1→a is switched. During de-compres-
sion, the pump runs against the pressure set in SV 1. The opening of the pre-fill valves, i.e. sequence 4 (rapid traverse up) is
automatically set when the pressure in the cylinder has fallen to the value pcyl = pcontr : k. The control pressure pcontr must
correspond to at least the pressure ppre-relief as described in sect. 2.1 (< 100 bar) here, e.g. set in the pressure reducing valve
ADM 1... in accordance with D 7458 or ADM 11... in accordance with D 7120.
(( ))
3) The decompression time t (sec.) down to a certain pressure p (bar) for a press cylinder volume Vcyl (l) can be roughly estimated,
when the pre-relief (F 25-12V to F 80-36V) is utilized. tt »
»00..042 V × × ppcyl - - p p .
0042Vcyl
cyl cyl
4) Pressure in the SV 3 some what greater than pcontr , should serve only as safety against any control fault in the ADM... if the
pressure setting in SV 1 and the return pressure during opening (sequence 4) is much greater than pcontr
5) It may be necessary for very short sequence times, to enable quick draining of the control cavity causing quick closure of the
pre-fill valve by utilizing a by-pass check valve (sequence 5 → 1). Mostly utilized together with damping BC1 acc. to section 1.4.
A suitable by-pass check valve is type RK 1G acc. to D 7445.