SPSPRVGLT-VCP375DC
Ground Level Test Device for Silo Pressure Relief Valves
Installation and Operation Manual
ISSUE
DATE
AUTHOR
1
21.11.11
RJH
2
17.02.12
LC
3
04.07.12
LC
4
23.07.12
LC
5
25.01.13
LC
6
05.03.15
MS
1. DESCRIPTION. ..........................................................................................1
2. INSTALLATION. .........................................................................................1
Mechanical..................................................................................................1
WAM .......................................................................................................3
PORTASILO............................................................................................4
Important note.............................................................................................4
Pneumatic ...................................................................................................4
Electrical .....................................................................................................5
3. OPERATION ...............................................................................................6
4. TROUBLESHOOTING ...............................................................................7
5. SPECIFICATIONS ......................................................................................8
Materials of construction:…….....................................................................8
Technical specifications: .............................................................................8
6. WIRING DIAGRAM ....................................................................................9
7. CONTENTS OF INSTALLATION KIT.......................................................10
1. DESCRIPTION
The two most common suppliers of silo pressure relief valves in the UK are PORTASILO and
WAM. This manual deals with applying the Hycontrol Ground Level Test feature to their
products.
The Ground Level Test Device is designed to fit between the metal upstand welded to the top
of the silo and the pressure relief valve that bolts to it.
The purpose of fitting the device is to allow the pressure relief valve to be tested without
pressurising the silo.
By piping air from the dust filters air supply to the GLT device, it is possible to open the relief
valve and confirm its operation both locally and more importantly, remotely at ground level.
The GLT device can be easily retrofitted to an existing PRV or installed with a new one.
2. INSTALLATION
Mechanical
The SPSPRVGLT-VCP375DC is pre-assembled to reduce installation time.
Above: A standard base
Right: A Hycontrol POD installation
If the PRV is already installed on the silo roof it will be necessary to remove it from its upstand.
First remove the cover by undoing the three knobs or ring nuts and then remove the eight or
nine nuts and bolts securing the PRV to the upstand.
Drill two holes in the upstand, one above the other if the Hycontrol Pod is not being used. The
lower hole should be 25mm to 35mm up from the bottom and 13mm to 14mm diameter. The
top hole should be 70mm to 80mm from the bottom and 15mm to 16 mm diameter.
If there is not a PRV present then a Hycontrol POD (above right) can be fitted directly onto the
silo roof and the holes do not have to be drilled.
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Mechanical (continued)
Fit the bulkhead connectors provided in the holes. The larger of the two should have its 8mm
push fit connector to the outside. The smaller one has 6mm push fits at both ends, so
orientation is not important.
Fix the cylinder to the underside of the inner circle of the plate with four bolts. Push the small
filter into the 8mm push fit connector of the top bulkhead fitting and then place one of the foam
gaskets on the upstand before placing the SPSPRVGLT-VCP375DC on top of that. Roughly
align the holes and cut outs of the three items.
At this stage the upstand should look like this:
Now connect the flexible piping inside the upstand between the lower connector on the air
cylinder and the lower connector on the upstand, followed by the upper connection between
the air cylinder and the exhaust filter. These connections provide the air in and out of the
actuating cylinder.
Affix the junction box using two bolts on the side bracket (see photos overleaf).
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Mechanical (continued)
Place the second foam gasket on top of the SPSPRVGLT-VCP375DC aligning all holes and
cut outs before replacing the PRV. Insert three or four bolts initially to help alignment before
replacing all nuts and bolts and securing the PRV back in place.
Every SPSPRVGLT-VCP375DC is supplied with an M18 proximity switch pre-wired, that
needs to be fitted to the moving part of the PRV. The installation of this sensor is slightly
different for the two manufacturers' products, but both will need to have their covers removed
to allow access.
WAM
This PRV already has a mounting hole for the sensor located near one of the springs. The
sensor has two locknuts. Remove one and turn the other all the way to the cable end. Insert
the sensor through the top of the hole with cable pointing upwards and screw on the locknut
to secure the sensor in position.
The target for the sensor needs to be fitted underneath the detecting face of the proximity
sensor and secured by the nearest PRV fixing bolt.
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PORTASILO
As this PRV does not have an integral mounting for an M18 sensor, a fitting is provided with
the installation kit. The fitting clamps onto the edge of the moving part and provides a
mounting hole for the sensor. As with the WAM PRV, the sensor should be fitted in the same
way with cable facing up. The SPSPRVGLT-VCP375DC main plate should provide an
adequate target. We recommend setting the distance between the sensor and the target at
around 1 mm by adjusting the height of the sensor using the lock nuts.
Proximity switch
mounting plate for
PORTASILO PRV
Proximity switch
Target plate for
WAM PRV
The mechanical installation is now complete.
Important note
Please note that the Hycontrol POD unit is only supplied as part of a complete Hycontrol
Advanced Silo Protection System. For full information and installation directions for the SPS,
please refer to separate documentation.
Pneumatic
The SPSPRVGLT-VCP375DC requires an air supply capable of providing at least 5 bar
pressure but no more than 10 bars. On a silo top this can usually be found cleaning the dust
filters. Tapping into the dust filter supply is the easiest way to provide the air required, to test
the PRV and FLEX500 pressure sensor.
On the small panel attached to the SPSPRVGLT-VCP375DC there are two 6mm push fit
connectors. One connected to an air regulator with gauge and one to a solenoid valve. The
top one connected to the regulator is where the inlet for the air supply should be connected.
The lower one from the solenoid valve is the outlet and should be connected to the upstand
bulkhead connector fitted earlier, using 6 mm tubing provided.
With air supply turned on the regulator pressure should be set at 4.0 bar. The pneumatic
installation is now complete.
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Electrical
The solenoid valve and the proximity switch are pre-wired to the SPSPRVGLT-VCP375DC
so the only other connections to be made are with the silo protection panel at the base of the
silo.
This DC version is designed to work with the Hycontrol HYCDPS250-2, HYCDPS250-3,
HYCDPS250-3F silo protection systems or SPSPRVGLT-CONDC.
Only 4 cores are required between the PRV and the HYCDPS250-2, HYCDPS250-3,
HYCDPS250-3F or SPSPRVGLT-CONDC.
See wiring diagram on page 9 for further details.
The electrical installation is complete.
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3. OPERATION
Once installed, ensure that an adequate air supply is connected, 4.0 bar is
showing on the pressure gauge and that there is a 24 volt DC supply across
terminals 1 and 3.
To operate the pressure relief valve, press the small YELLOW button on the
junction box. The pressure relief valve will open immediately and stay open
while the button is held in.
**WARNING**
PLEASE EXERCISE CAUTION WHEN OPERATING THE PRV FROM THE
TANK TOP TEST BUTTON. THE VALVE WILL SLAM SHUT WHEN BUTTON
IS RELEASED.
If the SPSPRVGLT-VCP375DC is connected to Hycontrol’s HYCDPS250-2 or
HYCDPS250-3 at ground level then the PRV will be tested at the same time that
the pressure sensor and high level probe are tested during normal Ground
Level Test.
If the proximity sensor does not detect movement of the PRV, it will be indicated
at ground level and the cause should be investigated.
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4. TROUBLESHOOTING
PRV fails to operate when YELLOW button pressed.
- Check there are no obstructions preventing PRV from opening.
- Check air supply is on.
- Check pressure indicated on gauge is not less than 60psi.
- Check solenoid is operating.
- Check voltage is more than 21 volts DC.
- If all of the above are ok, remove 6mm tubing from upstand fitting, hold and
direct the end of the tube away and into space. Press the yellow button briefly. If
the tube blows out high pressure it would suggest that there is a problem with
the air cylinder inside the upstand or the air supply tubing to it, which will require
removal of the PRV for further investigation.
PRV gets stuck open
- Refer to Manufacturers operating and maintenance instructions.
PRV is leaking
- Refer to Manufacturers operating and maintenance instructions.
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5. SPECIFICATIONS
SPSPRVGLT-VCP375 and SPSPRVGLT-VCP375DC
Materials of construction:
Main GLT module:
6mm tubing:
6mm fittings:
Electrical enclosure:
Regulator:
Solenoid valve:
Air cylinder:
Proximity sensor:
Powder coated mild steel
Polyurethane
Nickel plated brass
Polystyrene
Technopolymer
Aluminium
Aluminium, anodised
Nickel plated brass
Technical specifications:
Regulator:
Solenoid valve:
Air cylinder:
Proximity sensor:
Inlet 0-13 bar, outlet 0-8 bar
1/8” G ports
50 Deg C max operating temp
3-way NC / exhaust return
1/8” G ports
Max pressure 6.5 bar
24 V dc operating voltage
Single acting/spring return
50 mm stroke
-10 to +80 Deg C operating temp
M18 Inductive Normally Open
10-30V dc switching PNP
5mm sensing range
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6. WIRING DIAGRAM
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7. CONTENTS OF INSTALLATION KIT
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1.5 metre length of 6 mm polyurethane tubing
x1 Bulkhead fitting 6mm x 6mm push fit
x1 Bulkhead fitting 6mm x 8 mm push fit
x1 Silencer 8mm push fit

x2 EPDM sponge flange gaskets


x1 Proximity switch target plate
x1 Proximity switch mounting plate

x9 Extended length M10 x 40mm bolts
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
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
x4 M6x100 bolts
x2 M6x16 bolts
x2 M6 locknuts
x9 M10 nuts
x8 M8 x 40 bolts
x8 M8 nuts
x18 M10 plain washers
x16 M8 plain washers

x1 Pre-assembled SPSPRVGLT_VCP375DC assembly
(c) 2015 Hycontrol Ltd. All rights reserved.
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