5 CCV Booklet

Actuators for heating,
ventilation, air-conditioning
BELIMO Asia Pacific 1
New CCV Range

Control ball valves and rotary actuators for floating and modulating control

Open/close control refers to the detailed datasheet.

What's New in Larger CCV Valves

Technical data R6..A characterized control valves, 2-way
Flow media Cold and hot water, water with glycol up to 50% by volume
Temperature of medium +5C...100C (lower temperatures to order)
Rated pressure ps 2760 kPa(PN27)
Pipe connections Flange PN16 (ISO7005-2)
Closing pressure Dps 680 kPa
Angle of rotation 90(working range 15...90)
Mounting position Vertical to horizontal (referred to the spindle)
Specification subjected to technical changes.

Flow rate equivalent to DN100!
High close off pressure!
Value for money!


C Ch ha ar ra ac ct te er ri iz ze ed d C Co on nt tr ro ol l V Va al lv ve e a an nd d
B Be el li im mo o E El le ec ct tr ri ic ca al l A Ac ct tu ua at to or rs s
Characterized Control Valve Technology
Belimo Characterized Control Valves feature a special shaped
disc fitted inside the inlet port which modifies the flow (Kvs).

An equal percentage flow characteristic is provided and the
resulting heating or cooling coil output is linear.

Parts and properties of the CCV (control ball valve)
Simple direct mounting with a central bolt. The rotary actuator
can be mounted in four different positions
Identical mounting flange
for all nominal sizes
Square stem end for positive
coupling to the rotary
Stem sealed with two O-
rings for long service
Ball and stem in stainless steel
Forged body,
nickel-plated brass
Characterizing disk to
produce an equal-percentage
flow characteristic
rotary
Internal screw connection
PTFE seat
Why make the seat seals of PTFE ?
This thermoplastic fluorocarbonate material is a Dupont
product and is better known than Teflon

Excellent low friction
Chemically resistant to most hydro carbonates and acids
Resists very high temperatures up to more than 260C
Is used for ball-valve and globe-valve gland seals
Why make the O-rings of EPDM ?
The valve industry has used it successfully for more than 30 years
It can be used for stem gland seals in
cooling-water systems
hot-water systems
EPDM has good chemical resistance (except to mineral oil) and can resist both
high and low temperatures
Its limits of application are -50C to 130C


Why make the characterizing disk of Tefzel
?
PTFE is a thermoplastic fluorocarbonate made by Dupont

It is suitable for heavy mechanical loads
has a wide thermal range of application
can tolerate high and low ambient temperatures
is chemically resistant
Typical applications are bearings, valve lining, piping and water pumps
it can tolerate continuous temperatures of up to 150C
it does not absorb water and does not swell. Its water absorption coefficient is 0.007%
it has a low coefficient of friction
Belimo has taught the ball valve how to be a control device
Flow

100%
Heat exchanger
characteristic
Equal-percentage flow
characteristic Belimo
control ball valve
Amount of opening
Characterizing Disc
Open Close
80% open 50% open 20% open

Benefits of the BELIMO characterizing disk
It produces an equal-percentage flow characteristic
It ensures excellent stability of control
High Close Off pressure, using with Belimo Rotary actuators
The k
VS
values are comparable with those of globe valves of the same nominal sizes
Fewer pipe reducers are needed
The better controllability eliminates control loop hunting and increases service life expectancy
Several k
VS
values for the same nominal size
DN15-50
R309

R318 R322

R209 R210 R211 R212 R213 R217 R214 R218 R222 R219 R223 R229 R224 R231 R238 R239 R248
0.63 k
vs
(m
3
/h)
DN (mm) 15 20 25 32 40 50
1 1
Better controllability
Lower installation costs
The Belimo range of control ball valves includes both 2-way and 3-way types
They are available with k
VS
values comparable with those of globe valves

R249
R310 R311

R312

R313

R317

R323 R329

R331 R338

R348

1 1.6 2.5 4 4 6.3 6.3 6.3 8.6 10 10 16 16 16 25 25 40
15 15 15 15 20 20 25 25 32 40 15 50
Ball 1 1 1

Several k
VS
DN65-80
k
vs
(m
3
/h)
DN (mm)
Ball
65
2 1/2

New Flanged 2 way CCV
Highest Performance
Flow rate equivalent to DN100-controlled, DN125-open/close
They are available with k
VS
values comparable with those of
globe valves

Flow characteristics of characterized control valves
2-way and 3-way characterized control
valves work as tight-sealing shut-off
devices between 0 and 15 rotation.
Between 15 and 90 rotation they work
as control devices.
Angle of rotation
R662A
78
65
2 1/2
R663A

112
80
3
R678A

112
80
3
R679A

155

Several k
VS
With the 3-way characterized
control valve the flow through the
bypass (B-AB) is designed for 70%
of the nominal flow (A-AB).
Application notes for 3-way characterized control valves
Because it uses a ball the 3-way
characterized control valve is only
of limited use for conventional
supply-temperature control
systems. Therefore, it is advisable
for supply-temperature control
systems to be executed in the
form of double mixing circuits.
There are no such restrictions on
mixing circuits for air preheaters
and injection circuits.

The working range of characterized control valves
1. Example: Ideal
Xp controller adapted for
3...10 V,
Characterized control valve
working range 3...10 V

2. Example: Small error Xp
controller adapted for 2...10 V,

3. Example: Large error
Xp controller adapted for
0...10 V,

Correction w (f) Xp needed !
characterized control valves: Prescribed directions of flow

Adjust the working range of the Valve on the NR Actuator
Application - cold and hot water, up to 50% glycol
Flow characteristic - equal-percentage (not for Open / Close)
Motion - 90 rotation (CCW to open, CW to close)
Nominal sizes - 1/2 to 3 (DN15...80, flow equivalent to DN100 )
k
VS
from 0.63 to 155 (228 Open/Close)
Connections - internal screw (ISO7/1)
- flange PN16 (ISO7005-2)
Key features of the BELIMO characterized control valves


The Belimo Characterized Control Valve
delivers more! Find out below why the Belimo
Control Ball Valve
is one of the most excite new developments in
HVAC!

What is a characterizing disc and why do I need one?
Belimos characterizing disc (patent pending) provides a simple
solution to a long-standing problem with HVAC ball valves. Always
attractive from a cost standpoint, ball valves were used where
accurate control was not important. A traditional full port ball valve
has a poor flow characteristic in that it has a large flow coefficient
(Kvs) in relation to its size. This means that the valve will supply
the required flow when it is only slightly open. Thereby utilizing just
a small portion of its operating range. Stable control is difficult to
achieve because a slight change in valve position results in a
disproportionately large change in the heating or cooling output of
the controlled device. Energy consumption is increased, people
are less comfortable, and life span of valves and actuators is
shortened because they never come to rest. Belimo characterized
Control Valves have changed all that. They feature a special disc
fitted inside the inlet port. A key in the disc prevents rotation. One side of the disc is
concave and matches the surface of the ball. Flow is controlled by the opening in the
ball and by a V-shaped opening in the disc. This reduces the flow coefficient (Kvs). The
valve increases flow slowly, especially when it begins to open. Therefore, equal
percentage flow characteristic is provided and the resulting heat output is linear.

Why are there multiple Kvs choices for one valve
size?
Characterizing discs with different shaped openings are available
so that a number of Kvs values can be offered for each valve size.
This allows you to size more valves equal to pipe size, so you
spend less time and money on pipe reductions, and can easily
achieve accurate control.

Then determine which pipe diameter could be used. When pipe
diameter is equal to valve diameter there is no reduction in pipe
size and better overall cost for an installed valve.
Support
Information
of CCV


Why do I need a ball valve with Kvss typical of globe valve Kvss?
Piping systems are still designed with globe valve flow requirements in mind. The Kvs
ratings of the Belimo Characterized Control Valves were based on typical globe valve
Kvs ratings. Therefore, you can size a project as you would if using globe valves, but
can easily select our valve. This is your assurance that the Belimo Characterized
Control Valve will give you the performance of a typical globe valve, and more, at a more
favorable price!

Why do I need accurate valve control?
Better valve control prevents hunting of the control loop in which the system is
constantly adjusting itself to maintain set point. When the operating conditions of the
actuator are improved and the full operating range is used, system
life span is increased, energy consumption is reduced, and
customers and their tenets are satisfied.

Why two O-rings?
Two heavy duty O-rings in the stem eliminate leaks and ensure
long maintenance-free service life. Double O-ring eliminate the
need for a packing nut which in HVAC applications may require
frequent tightening.

The inner O-ring seals against the water pressure. It is lubricated
and protected by the outer O-ring, which prevents debris from
entering the stem seal. Non-water-soluble grease between the two
rings prevents sticking.

Why a flanged-type bonnet?
Extremely accurate control capability comes from the mechanical advantage of direct
coupling combined with the flow efficiency of the characterizing disc. The actuator
connects square and true to a special bonnet flange. This eliminates any lateral stem
movement that would wear stem components and cause leaks. Four different
actuator/pipe orientations can be achieved.

What is TEFZEL
TM
?
TEFZEL
TM
, is a tough, enhanced Teflon
material used in industrial

applications such as bearings, valve linings, tubing and water
pumps. TEFZEL
TM
offers broad thermal capability, corrosion
resistance, and low coefficient of friction and water absorption. The
characterizing disc is made of this unique material, which allows the
ball to move freely against the disc and maintains fluid motion.

What about cavitations?
Because of improved operating characteristics, the Belimo Characterized Control Valve
is far less prone to cavitations than the standard ball valve. Cavitations occur when
vapor bubbles form and implode in a liquid due to an increase then decrease in pressure
as liquid flows through a restriction. The imploding vapor bubbles erode the surrounding
material and cause an intense noise. Like globe valves, no cavitations should occur if
the valve is sized properly.

Support
Information
of CCV


What is that small hole near the top of the flanged bonnet?
This vent hole prevents any condensation built-up in cooling applications from entering
the linkage and actuator-one of the many small steps weve taken to ensure complete
reliability.

The Belimo Characterized Control Valve is an improvement over
traditional ball valves, but is it better than globe valves?
Yes! The Rangeability factor defines a valves capability to control small flows. The
higher the number, the better. On typical small globe valves (15mm) the rangeability is
5:1, and on a large valve (50mm) it is 75:1. The Belimo control valve has a rangeability
of 500:1 for greatly improved control, especially at low loads.

OK, Im convinced the engineering is good, but does it work?
Absolutely. The Belimo Characterized Control Valve design has been extensively tested
with respect to pressure, temperature, leakage and life cycle.

Does this control valve have the same actuator Im used to from
Belimo?
You bet, Enjoy the same benefits youve always had with Belimo!

Fast and easy mounting (a single screw attaches actuator to valve)
Three-foot cable for fast installation
Manual override
Overload proof
True fail-safe with mechanical spring return
On/off, floating point, and 2-10 VDC (or 4 to 20mA) proportional control with
feedback
Brushless DC motor for accuracy, repeatability and long service life.

What about product support?

Expect the same top quality customer service Belimo has always delivered.
Expedited shipment at no extra handling cost
Two-year unconditional warranty

Support
Information
of CCV


Test Report

BELIMO CHARACTERIZED CONTROL VALVE
ENGINEERING DATA SHEET R215/ R215B

Maximum k
vs
: 8.5 (Tested according to ISA S75.02-1996, 20C Water)
Range ability: 136 (Tested according to ISA S75.11-1985)
Valve Flow Characteristics (Tested according to ISA S75.02-1996, 20C Water):

R215 / R215B Valve Performance
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
2 3 4 5 6 7 8 9 10
Voltage (V)
K
v
s


ENGINEERING DATA SHEET R209/R209B

Maximum k
vs

0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Voltage (V)
K
v
s


Maximum k
vs

0
1
2
3
4
5
6
7
8
9
10
2 3 4 5 6 7 8 9 10
Voltage (V)
K
v
s



Maximum k
vs

0
2
4
6
8
10
12
14
16
18
2 3 4 5 6 7 8 9 10
Voltage (V)
K
v
s


ENGINEERING DATA SHEET R318/ R318B, R322/ R322B

Maximum A-Port k
vs
Maximum B-Port k
vs

R318 / R322 Valve Performance
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
2 3 4 5 6 7 8 9 10
Voltage (V)
K
v
s


Test Number: TRD-02058
City:
State:
Lexington
Ky
Quantity Tested:
Date Started:
Date Completed:
4, CCV, 3 GV
8/22/02
8/28/02
Test Objective:

To determine the effects of calcium carbonate scale buildup on the durability of Belimo
CCV and Competitor Globe Valves.
Conclusion:

After 100,000 cycles, the Belimo CCV appears to be unaffected by the presence of
scale. The competitor valves can no longer close off.
Action:

None at this time. Test was originally scheduled to run past 100,000 cycles, but that is
cancelled at this time due to the nature of the globe valve failure.
Summary of
Results:

Belimo break away torques collected before and after testing for Belimo CCV (globe
valves not tested for torque since Belimo does not have a linear torque tester):

Maximum allowable torque is 35 inch pounds. The presence of scale did not increase
torques enough to cause failure.

After 101,611 cycles, 2 CCV and 1 globe valve were removed from a bath containing
water with an LSI >0.05 at an ambient temperature of 150
O
F. Belimo valves 1 and 2
achieved a 100 psi close off against running water. No leakage was seen through the
stem area. The globe valve 1 achieved a 30 psi close off against running water. No
leakage was seen through the stem area.

After 105,048 cycles, 2 CCV and 2 globe valves were removed from a life test fixture
containing room temperature water with an LSI greater than 0.05. The fixture is designed
to allow 30 psi of head pressure on the valves to simulate running water. This is the
same test setup as the previous life test done with water having an LSI of 0. Belimo
CCVs 3 and 4 both achieved a close off of 100 psi against running water. No leakage
was seen through the stem. Globe valves 3 and 4 would not close off, even against 10
psi. (See figure 1) The valves were assembled to competitor actuators set for fail closed.
No leakage was seen at the stem area.

Date Cycles Torque #1 Torque #2 Torque #3 Torque #4
22-Aug
New 0
cycles
18 21 20 17
22-Aug
Dirty ball 0
cycles
22 29 31 29
28-Aug
Dirty ball
105,000
cycles
11 9 10 14


Figure 1.
Leakage during close off pressure test. Photo taken with a P of 15 psi.

Valves were then disassembled for piece-by-piece inspection.

All Belimo CCVs were in good physical condition. The outside of the ball showed no
buildup of scale, but scratches were seen showing the original presence of scale. (See
figures 2-4)

Figure 2.
CCV Ball with scale before life test


Figures 3 and 4.
CCV Balls after life test. Note scratches on ball. Presence of scratches did not
affect close off or operation of the valve

The valve stem was then removed and inspected for wear. Both stem O-rings were in
good condition and grease was still present. (See figure 5)

Figure 5.
CCV Stem after life test. Note that O-rings still have shape and the presence of
grease on the assembly.

All other components of the valve, including the Teflon seats and the O-rings behind
them, were in good condition as well.

The globe valves were then disassembled to determine the cause of the close off failure.
The globe valve stems were removed and a patch of heavy scratching and a patch of
wear were found. The wear and the scratching were found exactly opposite of each other
on the valve. (See figures 6 and 7.)


Figures 6 and 7.
Wear patterns on competitor Globe Valves

Due to the presence of the wear patch, asymmetric loading of the valve stem was
assumed to be the cause of valve failure. The competitor pneumatic actuator was
inspected to see if it was possible for the installation of the actuator to create the side
loading. It was found that the actuator was self-centering and could not have caused any
side loads. (See figure 8)


Figure 8.
Bottom view of pneumatic actuator. The brass nut fastens to the valve stem. The
spring base is then self-centering underneath the diaphragm.

The inside of the valve was then inspected and excessive wear was seen on the valve
seats and packing on the upstream side of the valve only. It is assumed that the scale
and debris of the valve collected on the upstream side of the valve stem, and that over a
period of time, was able to amass enough to cause a side loading. This same life test
was conducted using the same actuators without the presence of scale. In that test, all
valves functioned properly after 100,000 cycles.

Test Methods:

2 Belimo CCVs and 2 GVs will be piped into standard life test configuration and the
water will be placed under pressure. Water to have an LSI value greater than 0.05 and
be at room temperature.

2 Belimo CCVs and 1 GV are to be placed in a bath of water with an LSI greater than
0.05. This bath to be heated to 140F. Failure of pneumatic actuator during this test shall
NOT be considered failure of the unit. This test shall run for 100,000 cycles only.

All valves to be cycled using pneumatic actuation with a period of 2 seconds, ON; 2
seconds OFF.

All valves to be disassembled for inspection after 100,000 cycles.

Other Information:

Attachments:

Innovation, Quality and Consultancy:
A partnership for motorizing HVAC actuators
Standard actuators and
spring-return actuators
for air control dampers
in HVAC systems
Safety actuators for
motorizing fire and
smoke extraction
dampers
VAV systems for indi-
vidual room air control
Mixing actuators and
motorized ball valves for
HVAC water circuits
Globe valves and intelli-
gent linear actuators
Air applications Water applications
Or contact your nearest Sales Representative
AU BELIMO Actuators Pty. Ltd.
Unit 10, 266 Osborne Ave.
Clayton South VIC 3169, Australia
Tel. + 61 3 9551 0201
Fax: + 61 3 9551 0215
E-Mail: belimo@belimoactuators.com
HK BELIMO Actuators Ltd.
Room 208 2F New Commerce Centre
19 On Sum Street
Shatin N.T., Hong Kong
Tel. + 852 2687 1716
Fax: + 852 2687 1795
E-Mail: hongkong@belimo.ch
SH BELIMO Actuators Ltd.
Room 1305 Financial Square
No. 333 Jiujiang Road
Shanghai, China 200001
Tel. + 86 21 6360 8980
Fax: + 86 21 6360 8981
E-Mail: shanghai@belimo.ch
BJ BELIMO Beijing
Room 605 Beijing Hai Chang Edifice
44 Liang Ma Qiao Road
Chao Yang District
Beijing, China 100016
Tel. + 86 10 6462 1382
Fax: + 86 10 6462 1383
E-Mail: beijing@belimo.ch
Control Laboratory
Suite 611 Lions Plaza Ikebukuro 27-5,
4-Chome Higashi Ikebukuro
Toshima-ku Tokyo 170-0013, Japan
Tel. + 81 3 3981 1309
Fax: + 81 3 3980 1048
E-mail: controllabo@sirius.ocn.ne.jp
JP
BELIMO Automation AG
Shanghai Support Office
Room 1305 Financial Square
No. 333 Jiujiang Road
Shanghai, China 200001
Tel. + 86 21 6360 8980
Fax: + 86 21 6360 8981
E-Mail: sales.ap@belimo.ch
Website: www.belimo.ch
CN US BELIMO Holding AG
Brunnenbachstrasse 18340
Hinwil, Switzerland
Tel. + 41 (0)43 843 61 11
Fax: + 41 (0)43 843 62 68
E-Mail: info@belimo.ch
Website: www.belimo.ch
CH
Hanmo Corporation
3F Yeosam Building
648-23 Yeoksam-Dong Gangnam-Gu
Seoul, Korea
Tel. + 822 3453 8225
Fax: + 822 3453 8228
E-mail: sbyun@hanmo.co.kr
KR
BELIMO Actuators Pte Ltd.
Support Office
2 Jurong East Street 21
#04-31F IMM Building,
Singapore 609601
Tel. + 65 6564 9828
Fax + 65 6564 9038
E-Mail: singapore@belimo.ch
SG
Air Controls Engineering Pte Ltd.
605B Macpherson Road #07-08
Citimac Industrial Complex,
Singapore 368241
Tel. + 65 6285 3809
Fax + 65 6285 4697
E-mail: actrol@starhub.net.sg
Chianseng Enterprise Co., Ltd.
2F No. 21 Tung Fong Street
Taipei, Taiwan
Tel. + 886 2 2708 7780
Fax: + 886 2 2702 9090
E-mail: jasont@ms3.hinet.net
TW
ENYE LTD. CORP.
Room 507, 5F Anita Bldg
1300 Quezon Ave. cor. Timog Ave.
Quezon City 1103, Philippines
Tel. + 632 373 5440
Fax: + 632 373 5424
E-mail: enye.ltd@pacific.net.ph
Rite Products, Inc.
Room 205 Jocfer Building
Commonwealth Ave.
Quezon City 1121, Philippines
Tel. + 632 932 7944
Fax: + 632 932 7935
E-mail: marcdelrosario@riteproducts.com.ph
PH
Eurotec Instruments Ltd.
PO Box 14 543
Panmure 750 Great South Road
Penrose Auckland, New Zealand
Tel. + 64 9 579 1990
Fax: + 64 9 525 3334
E-mail: sales@eurotec.co.nz
NZ
IN Vitek Air Controls
C-114 First Floor Lancelot
S.V. Road Borivali-West
Mumbai - 400 092, India
Tel. + 91 22 5695 9439
Fax: + 91 22 2806 2163 / 2806 3975
E-mail: bvac@vsnl.com
TH Thai Air Conditioning Manufacturing
Co., Ltd
12/555 Moo 15 Kulab Tower 8F
Room A-2 Bangna-Trad Road
Bangkaew Bangplee
Samutprakarn 10540, Thailand
Tel. + 662 3161401 - 6
Fax: + 662 3161407
E-mail: info@tam.co.th
ID Piping System Indonesia pt.
Jl. Jembatan Dua Raya No.16-06
Jakarta 14450, Indonesia
Tel. + 62 21 661 8888
Fax: + 62 21 669 7061
E-mail: calvin@pipingsystem.com
MY Source Code Asia SDN BHD
12-2 Floor Jalan PJU 6A/3A
Kayu Ara Business Park
47400 Petal i ng Jaya Sel angor
Malaysia
Tel. + 603 5635 7878
Fax: + 603 5635 8878
E-mail: sales@sca.com.my
PK Overseas Enterprises
37-38 Liaquat Market M.A.
Jinnah Road P.O. Box No. 6647
Karachi-74000, Pakistan
Tel. + 92 21 2410571 / 2412243
Fax: + 92 21 2420329
E-mail: ksaigal@cyber.net.pk
BELIMO Aircontrols (USA), Inc.
43 Old Ridgebury Road Danbury,
CT 06810
Tel. + 800 543-9038 / 203 791-9915
Fax: + 800 228-8283 / 203 791-9919

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Actuators for heating,

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