PENSTOCK INSTALLATION OPERATION AND MAINTENANCE MANUAL(WELDING)

• This manual describes the recommended procedures for installation, operation, maintenance, and safety precautions for the FCV WELDING MODEL model Penstock (slide gates).
• Please read thoroughly all the instructions in the manual prior to installation and contact an FCV representative in case of any questions.
• FCV assumes no responsibility or liability if the Penstock (slide gates) is not installed, operated, and maintained in strict accordance with the procedures described in this manual.
• The manual makes reference to the “General Arrangement Drawing” (GAD). The GAD is the drawing that is sent to and approved by the customer prior to the production of the Penstock (slide gates).

• The FCV Penstock (slide gates) must be transported lying flat on its rear side and in almost closed position.
• Stems and extensions that are shipped separately shall be supported over their entire length to prevent any bending or distortion while in storage.
• Stems have precision surfaces and should never be used as a means to lift the Penstock (slide gates).
• The FCV Penstock (slide gates) must be stored lying flat on its rear side.
• The elastomeric parts (seals) must be protected against direct sunlight and/or UV radiation as otherwise their long-term sealing function cannot be guaranteed. Store the Penstock in a dark, dry, and well-aerated place. The direct exposure of the Penstocks to radiation heat emitted by sources of heat should be avoided. Protect any assembly units important for proper function such as the stem, stem nut, sealing ring, or gate against dust and other dirt by adequate covering.
• The Penstock(slide gates) can be stored in ambient temperatures ranging from -20 °C to +50 °C (protected by adequate covers). If the Penstock(slide gates) is stored at temperatures below 0 °C, it should be warmed up to at least +5 °C before installation and before it is put into operation.
• Do not stack Penstock(slide gates).

• First, the Penstock (slide gate) is installed (wall mounted, concrete wall mounted)
• Once the gate is installed, stem Extension, stem guides and floor stand must be installed

• Penstock (slide gates) are installed by means of Anchor Bolts. Depending on the size and working conditions they shall be either of the mechanical or chemical type. In order to get the expected performance of the anchor bolts, the minimum concrete strength shall be 25Mpa (3,625 PSI).
• In order to avoid leakage between the concrete wall and the frame construction sealant shall be used. (Sikabond or Sikaflex 11FC Sealant or equivalent, 200ml per meter of opening perimeter). As an alternative, self-adhesive commercial sponge EPDM strips, approximately 20mm/0,80” wide by 10mm/0,40” thick, can be used and glued to the slide gate around the hole.
• For detailed information about the type, size and quantity of the required anchor bolts, or any other specific installation notes or materials, please refer to the notes on the ‘General Arrangement Drawing’.

• First check whether the clear dimension of the opening matches the nominal diameter of the Penstock (slide gate). The clear dimension of the opening must never be larger than the nominal width of the Penstock (slide gate).
• The concrete construction shall be flat, level and plumb, and shall be in accordance with DIN 18202 or ACI 117-06 standards (see section 5). If necessary, use non-shrink grout in order to meet the specified standard.
• Concrete wall surface shall be dry (so the construction sealant sets effectively). If it is necessary. the wall can be dried with the help of a blowtorch or a hot air fan.

• The Penstock (slide gate) may now be used as a drilling template. With a suitable drill, the holes for the anchor bolts are drilled through the holes of the attachment claws. Afterward, the holes must be blown out. Any loose drilling dust remaining in the holes will affect the bonding strength of the chemical reaction holes.
• Any incorrectly drilled holes must be properly closed before the Penstock (slide gate) is attached. This prevents the steel reinforcement of the concrete exposed by drilling from carrying
• corrosion into the structure.
• Anchor bolts (chemical reaction anchors)must be installed according to the instruction of the suppliers of the chemical reaction anchors. Please only use the attachment material included in the scope of supply and observe the instructions provided on the proper handling of chemical anchors (Picture 5).
• After the setting, time unfasten the Penstock (slide gate) to remove any excess synthetic mortar which may have emerged from the holes with a screwdriver or chisel. Any excess adhesive that remains outside the holes prevents the correct seating of the Penstock (slide gate) wall seal on the structure and thus affects the sealing effect.
• Before the full load is applied to the Penstock (slide gate), the prescribed setting time of the chemical reaction anchor bolts must have expired.
• For the next steps, please refer to 2.1.4

• 2.4.1. Connect the stem extension (item 3) to the shaft (item 1) on top of the yoke (see Figure 6-A, Detail B).
• 2.4.2. Insert all stem guides from the top of the stem extension. Align stem extension, and especially make sure that it is aligned with the vertical axis of the opening (see Figure 6-B).
• 2.4.3. Next, install all stem guides. (drill and tighten anchor bolts). Refer to General Arrangement Drawing for dimensions (“Dist 1” in Figure 6).
• 2.4.4. Position the floor stand and the operator. Engage the shaft of the stem extension with the operator. Make sure that the stem extension is perfectly aligned and parallel to the wall surface, adjusting the offset if necessary of the Stem-Guides’ inserts (see Figure 6-C). Once, the stem extension is perfectly aligned, install the floor stand (drill and tighten anchor bolts).

OPERATION

Initial Operation:

Before cycling the slide gate, make sure there are no foreign deposits or materials on the seals, guides, or sealing area. Gate seals could be damaged if the area is not cleaned and coated with light grease. Please refer to the section “Materials needed for maintenance and seal replacement” for detailed information about the grease type (see section 4.1)

• Manual
  • Apply light grease on the stem before the initial operation after the installation. If the operation is difficult due to high torque, stop the operation of the gate and check stem alignment.

• Electric actuator
  • Refer to the electric actuator manufacturer’s instruction manual before commissioning the slide gate.
  • Electric actuators must be limited with limit and torque switches. Electric actuators without these limiters shall not be used with FCV Penstock (slide gates). Electric actuators must be adjusted at the time of installation on site (except in the case of a self-contained frame and yoke-mounted actuators; in this case the motor is factory-set). To adjust the limit switches, follow the next instructions using the values of the GAD:
    • 1)Position the slide in the nearly closed position (leave 10mm/0,40” open). From this position, manually (using the handwheel) operate the slide until it is completely closed (check tightness with a 0,05mm/0,002” gauge). In this position, set the limit switch for the CLOSED position.
    • 2)Position the slide in the nearly open position (leave 10mm/0,40” closed). From this position, manually (using the handwheel) operate the slide until it is completely open. In this position, set the limit switch for the OPEN position.
  • Be aware when the gate is almost fully OPEN or CLOSED. If the gate does not stop once the fully open or fully closed position is reached, stop immediately and correct adjusting again the limit and torque switches.

• CAUTION! Do not force the operator to close the gate, as it may cause damage to the stem and does not improve the sealing system. The maximum applicable force on the handwheel is 25 kg /55 lbs.
• The FCV Penstock (slide gate) is closed by a clockwise rotation and opened by a counter-clockwise rotation of the operator.
• The FCV Penstock (slide gate) is designed to be self-locking so that the slide maintains its position in any position.

• FCV Penstock (slide gates) need practically no maintenance. In order to assure maximum performance of the Penstock (slide gates), the following maintenance inspections shall be carried out periodically every 6 months:
  • Stem and stem nuts shall be cleaned and greased. For non-rising stem configurations, the stem may be in contact with water and dirt. Under these conditions, the threads of the stem and/or stem nut may wear, and they shall be checked every 3 months.
  • Clean the gate with clear water and remove any deposits, especially on the seals and in the guides.
  • Check the seals and make sure they are not damaged. Seals shall be replaced if damaged.
  • Seals shall be wet while operating. If the Penstock (slide gates) has not been used for a long period of time under dry conditions, the seals shall be wetted with clear water before operating the slide gate. If the slide gate is operated with dry seals, a higher operating torque will be required, and the seals may be damaged.