Interceptor®-FV®

Installation and Operation Manual

CV Technology, Inc.
15852 Mercantile Court
Jupiter, FL 33478
Phone: 561-694-9588
www.cvtechnology.com

October 11th, 2017

Document 3024
Revision 1
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Table of Contents
1.) General Overview

2.) Application Limitations

3.) Basic Dimensions, Weights and Components

4.) Installation and Operation

5.) Maintenance Requirements

NOTE: It is essential that all instructions in this manual be followed precisely to ensure
proper operation of the equipment
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1.)General
1.) GeneralOverview
Overview
This is the third generation of The Interceptor®-FV® explosion isolation valve. This generation includes
new features such as external flap position monitoring and improved performance. The second
generation featured a dust accumulation sensor feature. The first generation featured the first ever
valve with a normally open flap and low pressure drops. Refer to the appropriate I&O manual for
previous generation valves.

The Interceptor®-FV® is a passive explosion isolation valve designed to stop a propagating dust
deflagration from traveling onward in an interconnected process pipe or duct. In normal operating
conditions, the flap valve is mechanically retained in the open position. During an upset condition, the
regular flow is interrupted and a flux of pressure coming from the opposite direction is designed to slam
and lock the flap shut. See Figure 1.1 for a visual representation of the valve’s operation. Each
Interceptor®-FV® will also come equipped with an integrated position indicator for signaling a complete
closure of the valve. This consists of an inductive sensor and if purchased a relay module. The inductive
sensor will be activated upon complete closure of the flap portion of the valve. The relay module will be
remotely mounted and should be supplied with the appropriate power supply. The relay module will
have a relay that will change state upon activation of the inductive sensor.

Direction of flow
Stage 1: The regular flow of air and/or
material is flowing through the
interconnected pipe or duct in its intended
direction. The dust deflagration has been
initiated in the interconnected equipment.

Stage 2: The flux of pressure traveling the

opposite direction of the regular flow has
de-hinged the flap from its mechanical
retainer.

Stage 3: The flux of pressure traveling the

opposite direction of the regular flow has
slammed and locked the flap shut.

Figure 1.1 - Visual representation of Flap Valve operation

operation
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2.) Application
ApplicationLimitations
Limitations
A. The Interceptor®-FV® MUST be installed in process pipes or ducts where the direction of flow
and the direction of the potential dust deflagration are in opposite directions. See Figure 2.1 for
a visual representation of this requirement.

1.) Filter
2.) Process Fan
3.) Rotary Airlock
4.) Interceptor®-FV® Valve
5.) Explosion Panel

Airflow

Explosion

Figure 2.1 - Example Installation Schematic

B. Table 2.1 shows the Pred design limitations as well as the dust classifications limitations for all
sizes of Interceptor®-FV® valves. Higher Pred may be possible but the minimum vessel volume
must be increased. Contact CV Technology for guidance.

Table 2.1 - Flap Valve Design Limitations

Maximum Pred Design of vessel Suitable Dust
Valve Size
being isolated (bar) Class
4” through 8” 0.6 / 0.6 ST1 / ST2
10” through 16” 0.45 / 0.35 ST1 / ST2
18” through 20” 0.35 ST1
22” through 25” 0.45 ST1
28” through 32” 0.45 ST1

C. The maximum process velocity through the pipe or duct being isolated with an
Interceptor®-FV® valve is 115 ft/sec [35 m/s].

D. The maximum process temperature through the pipe or duct being isolated with an
Interceptor®-FV® valve is 176°F [80°C].

E. The minimum ambient temperature surrounding an Interceptor®-FV® valve is -40°F [-40° C]. If
any Interceptor®-FV® is to be installed in an environment colder than this, proper heat tracing
around the flap connections and the top access panel shall be applied.
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F. The Interceptor®-FV® valve must be installed on a horizontal process line and the lid of the valve
must be installed in the upright position.

G. The Interceptor®-FV® valve can only be utilized for clean air induction and dust collection lines.
The Interceptor®-FV® valve is not recommended to product transfer lines that are dilute or
dense phase conveying.

H. The flap portion of the Interceptor®-FV® valve is designed to shut when the positive pressure
moving in the opposite direction of flow increases to 1.5 PSI (0.1 bar).

I. Table 2.2 outlines the maximum process pressure drop across every Interceptor®-FV® valve size
assuming a line velocity of 65.5 ft/s (20 m/s).

Table 2.2 – Maximum Pressure Drop Across Valve

ST1 Dusts ST2 Dusts
Maximum Pressure Maximum Pressure Maximum Pressure Maximum Pressure
Valve Size Drop Drop Drop Drop
[mbar] [inches of water] [mbar] [inches of water]
4” [DN 100] 3.5 1.29 5.0 2.01
5” [DN 125] 2.15 0.86 2.8 1.13
6” [DN 150] 2.2 0.88 3.0 1.21
8” [DN 200] 2.3 0.92 3.2 1.29
10” [DN 250] 2.7 1.09 4.0 1.61
12” [DN 300] 2.7 1.09 4.3 1.73
12.5” [DN 315] 2.9 1.17 4.8 1.93
14” [DN 355] 3.2 1.29 4.9 1.97
16” [DN 400] 3.3 1.33 5.0 2.01
18” [DN 450] 4.5 1.81 / /
20” [DN 500] 5.0 2.01 / /
22” [DN 560] 5.0 2.01 / /
25” [DN 630] 5.5 2.21 / /
28” [DN 710] 5.0 2.01 / /
32” [DN 800] 5.0 2.01 / /
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3.) Basic Dimensions, Weights and Components

Figure 3.1 - Basic Dimensions and Weights

Table 3.1 - Basic Dimensions and Weights

Fundamental flange dimensions

Size in
Inches A
B C D x E F G H I
(DN) INCHES
INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm]
[mm]
4”
5.98-[152] 5.20-[132] 3.94-[100] 4x0.37-[9.5] 7.4-[188] 8.27-[210] 3.15-[80] 4.92-[125]
(DN 100)
5”
6.97-[177] 6.18-[157] 4.92-[125] 4x0.37-[9.5] 8.39-[213] 9.25-[235] 3.94-[100] 5.71-[145]
(DN 125)
6”
7.95-[202] 7.17-[182] 5.91-[150] 6x0.37-[9.5] 9.37-[238] 10.24-[260] 4.92-[125] 6.69-[170]
(DN 150)
8”
9.96-[253] 9.17-[233] 7.87-[200] 6x0.37-[9.5] 11.34-[288] 12.20-[310] 6.69-[170] 8.46-[215]
(DN 200)
10”
11.93-[303] 11.14-[283] 9.84-[250] 6x0.37-[9.5] 12.24-[311] 13.54-[344] 7.87-[200] 10.63-[270]
(DN 250)
12”
14.29-[363] 13.27-[337] 11.81-[300] 8x0.37-[9.5] 14.21-[361] 15.51-[394] 9.65-[245] 12.40-[315]
(DN 300)
12.5”
14.88-[378] 13.86-[352] 12.40-[315] 8x0.37-[9.5] 14.8-[376] 16.10-[409] 10.04-[255] 12.80-[325]
(DN 315)
14”
16.46-[418] 15.43-[392] 13.98-[355] 8x0.37-[9.5] 16.3-[414] 17.60-[447] 11.42-[290] 14.17-[360]
(DN 355)
16”
18.27-[464] 17.24-[438] 15.75-[400] 8x0.37-[9.5] 18.19-[462] 19.49-[495] 13.00-[330] 15.75-[400]
(DN 400)
18”
20.24-[514] 19.21-[488] 17.72-[450] 8x0.37-[9.5] 20.04-[509] 21.34-[542] 14.84-[377] 17.60-[447]
(DN 450)
20”
22.20-[564] 21.18-[538] 19.69-[500] 8x0.37-[9.5] 22.01-[559] 23.31-[592] 16.54-[420] 19.29-[490]
(DN 500)
22”
26.14-[664] 24.76-[629] 22.05-[560] 16x0.37-[14] 25-[635] 26.38-[670] 19.29-[490] 22.05-[560]
(DN 560)
25”
28.90-[734] 27.48-[698] 24.80-[630] 16x0.55-[14] 27.76-[705] 29.13-[740] 21.65-[550] 24.41-[620]
(DN 630)
28”
32.05-[814] 30.51-[775] 27.95-[710] 16x0.55-[14] 30.91-[785] 32.52-[826] 24.21-[615] 26.97-[685]
(DN 710)
32”
35.59-[904] 33.89-[861] 31.49-[800] 24x0.55-[14] 34.45-[875] 36.06-[916] 27.76-[705] 30.51-[775]
(DN 800)
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Table 3.1 - Basic Dimensions and Weights (continued)

Fundamental flange dimensions

Size in
Mass –
Inches J K Length L - M Height N - O P lbs. [kg]
(DN) INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm] INCHES [mm]
4”
0.39-[10] 0.98-[25] 11.02-[280] 12.13-[308] 11.30-[287] 3.90-[99] 9.61-[244] 19-[9]
(DN 100)
5”
0.39-[10] 0.98-[25] 12.01-[305] 12.32-[313] 12.13-[308] 4.39-[111.5] 10.59-[269] 24-[11]
(DN 125)
6”
0.39-[10] 0.98-[25] 13.00-[330] 14.09-[358] 13.27-[337] 4.88-[124] 11.57-[294] 28-[13]
(DN 150)
8”
0.39-[10] 0.98-[25] 15.35-[390] 16.46-[418] 15.24-[387] 5.87-[149] 13.54-[344] 40-[18]
(DN 200)
10”
0.47-[12] 1.26-[32] 20.08-[510] 21.42-[544] 19.76-[502] 7.56-[192] 16.42-[417] 88-[40]
(DN 250)
12”
0.47-[12] 1.26-[32] 22.83-[580] 24.17-[614] 21.73-[552] 8.54-[217] 18.39-[467] 110-[50]
(DN 300)
12.5”
0.47-[12] 1.26-[32] 23.62-[600] 24.96-[634] 22.32-[567] 8.84-[224.5] 18.98-[482] 117-[53]
(DN 315)
14”
0.47-[12] 1.26-[32] 26.57-[630] 26.14-[664] 23.90-[607] 9.63-[244.5] 20.55-[522] 134-[61]
(DN 355)
16”
0.47-[12] 1.26-[32] 27.36-[695] 28.70-[729] 25.67-[652] 10.53-[267.5] 22.36-[568] 170-[77]
(DN 400)
18”
0.47-[12] 1.26-[32] 29.53-[750] 30.94-[786] 27.64-[702] 11.54-[293] 24.37-[619] 194-[88]
(DN 450)
20”
0.47-[12] 1.26-[32] 31.50-[800] 32.91-[836] 29.61-[752] 12.52-[318] 26.34-[669] 223-[101]
(DN 500)
22”
0.55-[14] 1.34-[34] 36.61-[930] 38.03-[966] 33.00-[838] 14.57-[370] 29.33-[745] 346-[157]
(DN 560)
25”
0.55-[14] 1.34-[34] 39.57-[1005] 40.98-[1041] 35.75-[908] 15.94-[405] 32.09-[815] 396 -[180]
(DN 630)
28”
0.71-[18] 1.50-[38] 45.51-[1156] 47.56-[1208] 43.43-[1103] 17.79-[451.8] 37.87-[962] 719-[326]
(DN 710)
32”
0.71-[18] 1.50-[38] 49.05-[1246] 51.10-[1298] 46.97-[1193] 19.55-[496.5] 41.42-[1052] 816-[370]
(DN 800)
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1 – Flap Valve Body

2 – Closing Element (a.k.a. the flap)
3 – Lock Handle Release
4 – Position Indicator
5 – Flap Valve Lid
6 – Crane Lugs
7 – Dust Accumulation Sensor Inlet

Figure 3.2 - Interceptor®-FV® Components

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4.) Installation and Operation

4.1 Flap Valve Installation:

A. The Interceptor®-FV® must be installed in lines where the direction of regular flow and the direction
of the potential deflagration are in opposite directions.

B. The Interceptor®-FV® must be installed so that the flow is in the same direction as the actuation of
the flap. See figure 4.1 for a visual representation.

Flap in normal operation

Figure 4.1 - Direction of Flow and Flap Representation

C. See Table 4.1 for the required distances that the Interceptor®-FV® must be installed in with reference
to the vessel being isolated and Figure 4.2 for a visual representation.

Table 4.1 – Installation Distances for Flap Valves

Size Minimum Installation distance away from Maximum Installation distance away from
vessel being isolated Lmin - feet (meters) vessel being isolated Lmax - feet (meters)
4” through 8” 10 (3) 23 (7)
10” through 16” 13 (4) 23 (7)
18” through 20” 13 (4) 23 (7)
22” through 25” 13 (4) 23 (7)
28” through 32” 10 (3) 23 (7)

Figure 4.2 – Installation Distance Diagram

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D. The Interceptor®-FV® must be installed in horizontal pipe or duct and the top lid of the Interceptor®-
FV® must be in the upright position. Additionally, follow the instructions and details in Table 4.3 for
proper installation location and orientation. NOTE: The maximum allowable inclination angle for
installation is 30° for valve sizes from 4” (DN100) to 25” (DN630) and 5° for valve sizes from 28”
(DN710) to 32” (DN800)

Figure 4.3 – Flap Valve Orientation

E. The Interceptor®-FV® Label displays the direction of airflow and serial number.

Figure 4.4 – Flap Valve Label

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E. In addition, the Interceptor®-FV® must be installed with sufficient clearance above the valve’s lid to
facilitate the opening of the lid. The required clearance distance, Lv, is shown on Figure 4.5 below.

Figure 4.5 – Installation Clearance above the Lid

Table 4.3 – Installation Clearance Distance above the Lid

Size Required Clearance Distance above the Lid

- feet (meters)
4” through 12” 1.65 (0.5)
14” through 25” 2.63 (0.8)
28” 3.30 (1.0)
30” 3.61 (1.1)
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Table 4.4 – Additional Installation Orientation Requirements for Proper Install

Situation Description Scheme

The valve should ideally have a Explosion direction
Ductwork
straight duct of 5X the diameter
connected to
(D) of the pipe upstream of the
the valve
valve.
It has an effect on the explosion
Changing the
pressure. If the pipe diameter
pipe diameter
and the diameter of the valve
before the
are different, the spacer must be
valve in the
mounted directly in front of the
direction of
valve. The gradient of the spacer
the explosion.
cone should be less than 16°.
Max/Min
The maximum permissible
allowable
deviation between the
change in
diameters (DN) must correspond
diameter in
to the formula:
the direction
When D1 > DN →(D1)² ≤ 2x (DN)²
of the
When DN > D1 →(DN)² ≤ 2x (D1)²
explosion.
Dust deposits are undesirable for
the proper operation of the
valve. For the maximum
Dust deposits
elimination of deposits follow
the proper cleaning procedure in
Section 5.

G. During the transportation, handling and installation of the 4” through 10” Interceptor®-FV® flap
valves, use saddles around the flanges on both ends for lifting. During the transportation, handling and
installation of the 12” through 32” Interceptor®-FV® flap valves, use the integrated lifting lugs provided
for lifting.
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Figure 4.6 – Lifting Lug Locations

H. The connection flanges of the pipe or duct and the Interceptor®-FV® must match. The two-(2)
mating flanges required (not supplied) should be ¼” think at a minimum and must be capable of
withstanding the Pred design of the vessel being isolated. See Table 3.1 for bolt hole details.

The valve’s supplied flange material must be connected to the pipe flange. The tightening bolt torques
are:

M5 = 3 Nm
M6 = 5 Nm
M8 = 12 Nm
M10 = 25 Nm
M12 = 43 Nm

1 – Screw
2 – Earthing Cable
3 – Fan-shaped Washer
4 – Nut

Figure 4.7 – Earthing Cable for Electrically Conductive Connection

I. At least one connecting screw on the inlet and outlet flanges must be provided on both sides with fan-
shaped washers. The entire pipeline must be conductively connected and earthed.

J. Carefully clean all flange sealing surfaces as well as the flange gaskets to ensure a tight seal. The
overall length of the valve and gaskets should be considered when installing in a line. The gaskets are
1/10” thick each.
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Figure 4.8 – Valve Lay Length

K. Position the Interceptor®-FV® and then tighten all bolts in a criss-cross fashion. The connecting bolts
must be fitted with fan washers to allow grounding of the valve.

L. The pipe or duct must be supported on both sides of the valve in accordance with standard piping
practice so that the weight of the process line is not supported by the valve itself.

M. Once installed, the lid of the Interceptor®-FV® shall be removed and the functioning portion of the
valve shall be tested to ensure proper functioning. For valve sizes up to 25” (DN630), when closed, the
flap can be opened by pulling the locking release handle and physically moving the flap. Once function
is confirmed, the flap should be set in the open position by securing the mechanical arm on the flap into
the holder section highlighted in the Figure 4.9. Finally, the lid shall be re-fastened and all bolts must be
tightened to their original positions. To remove the lid on the 28” and 32” valves, loosen the bolts on
the hinge to remove the pressure on the gasket below the lid, and then loosen all bolts.

Figures 4.9 – Securing the Flap to Stay Open and Door Removal
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N. When adjusting the locking mechanism, it is necessary to check the correct distance between the balls of the
spring-loaded screws. For the 28” and 32” valves, two pairs of these screws are used and the distance must be met
for both pairs. The correct distance “x” is shown in Table 4.4. In addition, it is necessary to tighten the locking
screw and secure it with a safety nut so the flap’s opening angle isn’t exceeded per the manufacturer’s design
requirements. Using a gauge, assure to check the correct distance between the screws of the locking
mechanism.

1 – Screw with Spring-Loaded Ball

2 – Safety Nut for the Screw with Spring-Loaded Ball
3 – Welded Piece to the Valve
4 – Locking Screw
5 – Safety Nut for the Locking Screw
6 – Bar Holding Flap in the Open Position

Figures 4.10 – Minimum distance between the screws in the locking mechanism
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Table 4.4 – Required distances for the locking mechanism

TYPE (DN) DISTANCE X (mm)

DN 100 0.9 mm
DN 125 0.7 mm
DN 150 2.0 mm
DN 200 1.8 mm
DN 250 2.2 mm
DN 300 2.0 mm
DN 355 1.9 mm
DN 400 1.7 mm
DN 450 1.5 mm
DN 500 0.7 mm
DN 560 0.5 mm
DN 630 2.6 mm
DN 710 2.2 mm
DN 800 2.0 mm

O. As briefly mentioned above, the larger flap valves, 28” (DN710) and larger, utilize a double lock
release on the flap once it has been closed. In order to release the flap, first remove the door on the
lower lock release. Then turn the unlocking screw clockwise to compress the spring and allow the flap
to release (see Figure 4.11 for details). Next, pull the lever on the upper lock release and set the flap
back into the operation position. Finally, the lower lock release screw needs to be turned so the spring
is no longer compressed and the lower lock release door must be secured back onto the valve.
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Figures 4.11 – 28” and Larger Flap Valve Lower Lock Release Access

1 – Cover
2 – Gasket
3 – Fasteners
4 – Bar Holding Flap in the Closed Position
5 – Arresting Screw
6 – Spring
7 – Flap

Figures 4.12 – Flap Position When the Flap is Set for Operation
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Figures 4.13 – Flap Valves with Doors Secured (left shows 4” to 25” valves; right shows 28” and 32” valves)

5.) Dust Sensor Wiring and Installation

The dust accumulation sensor is an electronic device used to detect and indicate the amount of material
accumulated inside the flap valve. This information can be transferred from the accumulation sensor to
the customer control system for further analysis. The sensor comes with a 6.5 feet (2 m) connecting
cable, which is connected to an intrinsically safe relay.

5.1 Dust Accumulation Sensor Mechanical Installation:

NOTE: The “plug” already comes attached to the Interceptor®-FV® valve.

To install the dust accumulation sensor, the customer must carefully remove the plug from the flap
valve. Figure 5.1 provides a general picture of the plug’s attachment to the flap valve and the location
where the sensor must be installed.

Figure 5.1 Valve with the plug attached

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Next, screw in the dust accumulation sensor with your hands into the adaptor until it is tight against the
borosilicate glass. Use the retaining nut (M36) to tighten the sensor in place. Observe Figure 5.2 with the
final arrangement of the mechanical installation.

1 – Borosilicate Glass
2 – Silicone O-Ring
3 – Adaptor
4 – Safety Nut
5 – Dust Accumulation Sensor
6 – Plug (M30x1.5)
7 – Stainless Steel Cap
8 – Gasket

Figure 5.2 Final arrangement of installation

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Figure 5.3 Dust Accumulation Sensor with Cable

5.2 Wiring Details of Interceptor-FV Valve:

A. Dust Accumulation Sensor Only Wiring Details:

Power Connection: Terminals #14 and #15 of the KF Module shall be supplied with power depending on
the KF Module selected (24 VDC, 115 VAC, or 240 VAC).

Junction Box Connection: The brown wire from the dust accumulation sensor shall be connected to
Terminal #3 in the Junction Box and the blue wire from the dust accumulation sensor shall be connected
to Terminal #4 in the Junction Box.

NOTE: The position indicator is always connected to Terminals #1 and #2.

KF Module Connection: Terminals #1 and #3 of the KF Module shall be connected to the leads of the
dust accumulation sensor terminated in the Junction Box. Terminal #1 from the KF Module shall be
landed in terminal #3 in the Junction Box and Terminal #3 from the KF Module shall be landed in
terminal #4 in the Junction Box.

NOTE: If the Interceptor®-FV® valve is installed in a Class II, Div I OR Class I, Div I area, the KF Module
shall be mounted in a separate, non-classified area.
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Process Control Interface: Two of the switches on the face of the Signaling unit, #2 & #3, should be to
the “I” position, and switch #1 should be to the “II” position. Refer to Figure 5.3 for a detailed image.

Figure 5.3 – Switches on Signaling Unit

When no power is supplied to the Signaling Unit there is continuity between contacts #7 and #9. As a
result, contacts #7 and #9 are normally closed, and in the event of a power failure will fail closed.

When power is supplied to the Signaling Unit there is continuity between #7 and #8 in normal operation.
If the position indicator is activated, continuity is broken between #7 and #8 and established between
#7 and #9. See Figure 5.4 for the wiring diagram.

Figure 5.4 – Wiring Schematic

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B. Position Indicator Only Wiring Details:

Power Connection: Terminals #14 and #15 of the KF Module shall be supplied with power depending on
the KF Module selected (24 VDC, 115 VAC, or 240 VAC).

Junction Box Connection: The brown wire from the Inductive sensor shall be connected to Terminal #1
in the Junction Box and the blue wire from the Inductive sensor shall be connected to Terminal #2 in the
Junction Box.

KF Module Connection: Terminals #1 and #3 of the KF Module shall be connected to the leads of the
Inductive Sensor terminated in the Junction Box. Terminal #1 from the KF Module shall be landed in
terminal #1 in the Junction Box and Terminal #3 from the KF Module shall be landed in terminal #2 in
the Junction Box.

NOTE: If the Interceptor®-FV® valve is installed in a Class II, Div I OR Class I, Div I area, the KF Module
shall be mounted in a separate, non-classified area.

Process Control Interface: The three switches on the face of the Signaling unit, #1, #2, & #3, should be to
the “I” position. Refer to Figure 5.5 for a detailed image.

Figure 5.5 – Switches on Signaling Unit

When no power is supplied to the Signaling Unit there is continuity between contacts #7 and #9. As a
result, contacts #7 and #9 are normally closed, and in the event of a power failure will fail closed.
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When power is supplied to the Signaling Unit there is continuity between #7 and #8 in normal operation.
If the position indicator is activated, continuity is broken between #7 and #8 and established between
#7 and #9. See Figure 5.6 for the wiring diagram.

Figure 5.6 – Wiring Schematic

C. Dust Accumulation Sensor and Position Indicator Wiring Details:

Power Connection: Terminals #14 and #15 of the KF Module shall be supplied with power depending on
the KF Module selected (24 VDC, 115 VAC, or 240 VAC).

Junction Box Connection: The brown wire from the Inductive sensor shall be connected to Terminal #1
in the Junction Box and the blue wire from the Inductive sensor shall be connected to Terminal #2 in the
Junction Box. The brown wire from the dust accumulation sensor shall be connected to Terminal #3 in
the Junction Box and the blue wire from the dust accumulation sensor shall be connected to Terminal #4
in the Junction Box.

KF Module Connection: Terminals #1 and #3 of the KF Module shall be connected to the leads of the
Inductive Sensor terminated in the Junction Box. Terminal #1 from the KF Module shall be landed in
terminal #1 in the Junction Box and Terminal #3 from the KF Module shall be landed in terminal #2 in
the Junction Box. Terminals #4 and #6 of the KF Module shall be connected to the leads of the Dust
Accumulation Sensor terminated in the Junction Box. Terminal #4 from the KF Module shall be landed in
terminal #3 in the Junction Box and Terminal #6 from the KF Module shall be landed in terminal #4 in
the Junction Box.

NOTE: If the Interceptor®-FV® valve is installed in a Class II, Div I OR Class I, Div I area, the KF Module
shall be mounted in a separate, non-classified area.

Process Control Interface: Two of the switches on the face of the Signaling unit, #1 & #3, should be to
the “I” position and switch #2 on the face of the Signaling unit should be to the “II” position. Refer to
Figure 5.7 for a detailed image.
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Figure 5.7 – Switches on Signaling Unit

When no power is supplied to the Signaling Unit there is continuity between contacts #7 and #9, and
#10 and #12. As a result, contacts #7 and #9, and #10 and #12 are normally closed, and in the event of a
power failure will fail closed.

When power is supplied to the Signaling Unit there is continuity between #7 and #8, and #10 and #11 in
normal operation. If the position indicator is activated, continuity is broken between #7 and #8, but will
remain the same in #10 and #11, and established between #7 and #9. If the dust accumulation sensor is
activated, continuity is broken between #10 and #11, but will remain the same between #7 and #8, and
established between #10 and #12. Thirdly, if the position indicator and the dust accumulation sensor are
activated, continuity is broken between #7 and #8, and #10 and #11, and established between #7 and
#9, and #10 and #11. See Figure 5.8 for the wiring diagram.

Figure 5.8 – Wiring Schematic

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Inductive Sensor Specifications:

Power: Up to 15 VDC (from an intrinsically safe relay)

Electrical Connection: Two-wire connection
Sensor Range: 0.04 inch (1 mm)
Sleeve Length (without cable): 1.18 inch (30 mm)
Connecting Cable: Approx. 1.5 m long, 2 x 0.14 mm2
External Thread: M8 x 1
Ambient Temperature: -4 to 176°F (-20 to 80°C)
Housing: IP 67
Weight: 0.094 kg
Certifications: II 1D Ex iaD 20 T 90°C Ta: -20 ... 70°C
II 1D Ex iaD 20 T 100°C Ta: -20 ... 80°C
II 1G Ex ia IIC T6 Ta: -20 ... 55°C
II 1G Ex ia IIC T5 Ta: -20 ... 65°C
II 2G Ex ia IIC T6 Ta: -20 ... 70°C
II 2G Ex ia IIC T5 Ta: -20 ... 80°C

KF Module Specifications (if purchased):

Power: 120 VAC (230 VAC and 24 VDC variants are

available), 45 to 65 Hz
Power Consumption: 1W
Ambient Temperature: -4 to 140°F (-20 to 60°C)
Dimensions: 0.8 x 4.7 x 4.5 inches (20 x 119 x 115 mm)
Weight: 0.33 lb. (150 g)
Mounting: Mounts in 35 mm DIN mounting rail
SIL: SIL 2 acc. IEC 61508/IEC 61511
Approvals: FM Approval 116-0035, UL Approval 116-0145,
CSA Approval 116-0047
Certifications: II 1G EX ia IIC
II 1D Ex ia IIIC
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D. Assembly and Disassembly:

NOTE: All assemblies associated with the closed-flap sensor must be done by CV Technology or an
authorized representative.

The inductive sensor is directly installed into the perforated hole in the check valve’s body and is
secured by adjusting both nuts after determining the correct position of the sensor. The intrinsically safe
relay must be installed in proximity to the check valve.
1 – Inductive Sensor
2 – Inductive Sensor Holder
3 – Position Indicator Device
4 – Terminal Box

Figure 5.9 – Correct position of the inductive sensor

The inductive sensor is installed in the inductive sensor holder, where its position is adjusted
accordingly. A distance of approximately 1 mm was determined between the inductive sensor and the
end of the rotating shaft of the flap. It is important to verify the functionality of the signaling device.
Note that the intrinsically safe relay is installed in the junction box.
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6.) Maintenance Requirements

Upon the completion of every Interceptor®-FV® valve installation, the following check list of
maintenance and service procedures shall be performed after one month of operation OR sooner if
heavy product buildup is anticipated from prior process evaluations.

1.) Remove the lid of the Interceptor®-FV®

2.) Check to ensure there is no excessive buildup of process product in the chamber of the valve. If
there is, clean out the valve in any suitable fashion that will not compromise the structural
integrity of the valve.
• NOTE: Additional attention shall be given to the seat of the valve where the flap portion
shuts and locks in place. This area must be cleaned of process product.
3.) Check for any mechanical damage of the valve and components.
4.) Close and lock the flap portion shut. Check all sealing surfaces to ensure a tight fitting is still
held. Check to ensure that the position indicator and the KF Module are still operating in their
intended fashion.

If there isn’t any excessive buildup of process material and all components of the valve were in working
order after this initial one month maintenance inspection, increase the periodic maintenance schedule
to every three months. Continue this quarterly inspection of the valve for the duration of its use unless
excessive buildup begins to occur.

If, however, there is excessive buildup or there was compromise of any one of the components within
the valve, take the appropriate measures to clean and/or fix the valve and continue this once a month
(OR sooner) maintenance inspection for the duration of its use.

If the valve was actuated in the event of deflagration, contact CV Technology, Inc. immediately for re-
build conditions and procedures.

6.1 Maintenance Procedure:

1) Open the valve lid once the process is safe to do so.

2) Visually inspect the internal area of the valve.

3) In case of heavy deposits or build ups, use either appropriate mechanical cleaning tools or an
appropriate industrial vacuum cleaner to clean it.

4) Visually inspect the mechanical integrity of the valve.

5) Verify that the valve flap can easily shut and lock. Also verify that the position indicator is signaling
when the flap is shut.

6) Once completed, reset the valve flap for operation.

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7) Close the valve lid.

Figure 6.1 – Cleaning the Internal Areas of the Valve

Figure 6.2 – Cleaning the Internal Areas of the Valve to Make Sure the Valve Closes Properly
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For all flap valves, apply Mogul LV 2-3 lubricant (or equivalent) to the internal area of the locking
mechanism. For the valves of size DN 710 and DN 800, a lever is added to ensure better unlocking of the
valve. Be sure to lubricate the second locking system of these valve sizes. In addition, it is recommended
to lubricate the dowel screw for better run of the lever mechanism.

Figures 6.3 and 6.4 – Locking mechanism of back flaps for all sizes up to DN630

Figures 6.5 and 6.6 – Locking mechanism of back flaps for DN 710 and DN 800

Apply Mogul LV 2-3 lubricant to the indicator pin and spring as well.

NOTE: Recommended annual maintenance or as needed.

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Servicing of the Position Indicator:

1.) Verify the wiring of the inductive sensor and the power supply
2.) Set the inductive sensor to the correct position (flap must be shut) until the signal comes on
3.) Secure the inductive sensor in the correct position with the screw
4.) Test – if the flap is open, the “Open” output signal is active
5.) Test – if the flap is closed, the “Closed” output signal is active

1 – Inductive Sensor
2 – Inductive Sensor Holder
3 – Position Indicator Device
4 – Terminal Box

Figure 6.7 – Mechanism of the Position Indicator

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Revision History
REV. ECO Date
1 2418 10/11/17