Diaphragm Valve User Manual

The Diaphragm Valve User Manual provides essential information for the safe and proper use of the product. It includes details on Technical Data, Notes on Safety, Transport, Storage and Disposal, Installation, Operation, Malfunctions, Maintenance, Drawings, and Declarations of Conformity. Each section is designed to guide the user through correct handling, installation, operation, and maintenance procedures. It is important that this manual is read carefully and in full before using the product to ensure safe operation and to avoid damage or hazards. The complete manual can be downloaded by clicking the button provided or viewed online below.

Download Diaphragm Valve User Manual

Precision Manufacturing Meets Transfer Molding

Installation and Operating Manual

Diaphragm Valve

PFA Lined Diaphragm Valve

Membron9

Please review the following instructions carefully before transport, installation, operation, and maintenance.

1 Technical Data

1.1 Manufacturer Information

Advanced Fluoropolymer Devices GmbH
Hooghe Weg 16, 47906 Kempen, Germany
Email: sales@gft9.shop
Web: http://gft9.shop
Phone: +49 2152 9148591

1.2 Product Overview

Parameter	Value
Name	Membron9
Design Norm	DIN/ISO \| ANSI
Size	DN15-150 \| NPS ½-6
Flange Dimensions	DIN 2501 (PN 16) \| ASME B16.10 (Class 150-RF LP)
Face-Face Dimensions	PN (EN 558-1), Series 1 \| ANSI-B-16.5
Lining Options	PFA, PFA/AS, PVDF
Body Materials	WCB/PFA, CF8/ SS 304 , 1.4401
Pressure Range	Depending on Size (see P-T Diagram below)
Custom Options	Various Actuation Types, Coatings
Certificates	EU Pressure Equipment Directive 2014/68/EU

1.3 Type plate, conformity and body markings

Type Plate
The stainless steel name plate is undetachably riveted to the body. If the operator attaches his identification, it must be ensured that the valve matches the application inquestion.

Exemplary_Nameplate_PFA_Lined_Valve_Size_Pressure_Temperature_Valve_Type_Order_No._Identification_Number

Body identification:
The following are visible on the body according to DIN EN 19 and AD 2000 A4:

Nominal size
Rated pressure
Body material
Manufacturer's identification
Melt number/Foundry identification
Foundry date

1.4 Weight DIN | ANSI

Size DIN
DN 15
DN 20
DN 25
DN 40
DN 50
DN 65
DN 80
DN 100
DN 125
DN 150

Size ANSI
NPS ½"
NPS ¾"
NPS 1"
NPS 1½"
NPS 2"
NPS 2½"
NPS 3"
NPS 4"
NPS 6"

1.5 Tightening Torque

All screws greased, tighten in diametrically opposite sequence!
The tightening torques for pipe screws and body screws mentioned must not be exceeded. For an exception, see Section 8, Flange connection valve/pipe is leaking.The following tightening torques are recommended.

1.5.1 Pipe Screws DIN | ANSI

Flange Size DIN	Tighetening Torque [Nm]	Pipe Screws
DN 15	6	4 x M12
DN 20	8	4 x M12
DN 25	10	4 x M12
DN 40	20	4 x M16
DN 50	26	4 x M16
DN 65	26	4 x M16
DN 80	25	8 x M16
DN 100	35	8 x M16
DN 125	55	8 x M20
DN 150	65	8 x M20

Flange Size ANSI	Tighetening Torque [lbs]/[Nm]	Pipe Screws
NPS ½"	45/5	4 x ½“
NPS ¾"	55/6	4 x ½“
NPS 1"	70/8	4 x ½“
NPS 1½"	135/15	4 x ½“
NPS 2"	220/15	4 x ⅝“
NPS 2½"	400/45	4 x ⅝“
NPS 3"	400/45	4 x ⅝“
NPS 4"	310/35	8 x ⅝“
NPS 6"

1.5.2 Body screws DIN | ANSI

Flange Size DIN	Tighetening Torque [Nm]/[lbs]	Body Screws
DN 15	35/310	4 x M12
DN 20	35/310	4 x M12
DN 25	35/310	4 x M12
DN 40	45/398	4 x M16
DN 50	45/398	4 x M16
DN 65	45/398	4 x M16
DN 80	50/442	8 x M16
DN 100	60/531	8 x M16
DN 125	150/1330	8 x M20
DN 150	150/1330	8 x M20

Flange Size ANSI	Tighetening Torque [lbs]/[Nm]	Body Screws
NPS ½"	310/35	4 x M12
NPS ¾"	310/35	4 x M12
NPS 1"	310/35	4 x M12
NPS 1½"	398/45	4 x M16
NPS 2"	398/45	4 x M16
NPS 2½"	398/45	8 x M16
NPS 3"	442/50	8 x M20
NPS 4"	531 /80	12 x M24
NPS 6"

1.6 Flow Rate DIN | ANSI

Actuating Torque

Size DIN	Actuating Torque [Nm]
DN 15	80
DN 20	85
DN 25	115
DN 40	155
DN 50	155
DN 65	190
DN 80	200
DN 100	245
DN 125	300
DN 150	360

Size ANSI	Actuating Torque [Nm]
NPS ½"	80
NPS ¾"	85
NPS 1"	115
NPS 1½"	155
NPS 2"	155
NPS 2½"	190
NPS 3"	200
NPS 4"	245
NPS 6"	360

1.7 Pressure Temperature Diagram

P-T Diagram for the Diphragm Valve

2. Notes on safety

This operating manual contains fundamental information which is to be observed during installation, operation and maintenance.It must be read before installation and commissioning!
This operating manual must always be available at the place of use of the valve.
For valves which are used in potentially explosive areas, see section 3.
Installation, operation and maintenance are to be performed by qualified staff.
The area of responsibility, authority and supervision of the staff must be regulated by the customer.

It is imperative to observe warnings and signs attached directly to the ball valve and they are to be kept fully legible.
Non-observance of the notes on safety may resulting the loss of any and all claims for damages.

For example, non-observance may involve the following hazards:

Failure of important functions of the valve/plant.
Risk to people from electric, mechanical and chemical effects.
Risk to the environment through leaks of hazardous substances.

General hazard symbol!
People may be put at risk.

Safety symbol!
The ball valve and its function may be put at risk if this safety symbol is not observed

2.1 Intended use

GFT9 diaphragm valves are pressure containing components in accordance with the Pressure Equipment Directive (PED) for the passage and shutoff of fluids at a specified differential pressure.
They are used as shut-off, control and throttling valves for corrosive, pure and high-purity liquids, gases and vapours. They are hermetically tight. The wetted materials are FDA-compliant. They are soft-sealing and gas-tight.

The valves are suitable for non-boiling liquids of group 1 in acc. with the Pressure Equipment Directive (PED). Solids can lead to increased wear, damage to sealing surfaces or to a reduction in the service life of the valve.

In case of the valve is intended for operating data other than those intended, the customer must carefully examine whether the design of the valve, accessories and materials are suitable for the new application. (Please consult the manufacturer)

2.2 For the customer / operator

If a valve is used, the operator must ensure that

hot or cold valve parts are protected by the customer against being touched
the valve has been properly installed in the pipe system
the usual flow rates are not exceeded in continuous operation.
an appropriate collection system is used to contain drip leaks/leaks locally and harmlessly.

This is not the manufacturer's responsibility.

Loads caused by earthquakes were not allowed for in the design.

Fire protection to DIN EN ISO 10497 is not possible (plastic lining and plastic components).

2.3 Improper operation

The operational reliability of the valve supplied is only guaranteed if it is used properly in accordance with Section 2.1 of this operating manual.

The valve is supplied with flange caps. Do not remove them until just before installation. They protect the plastic surfaces against dirt and mechanical damage.

3. Safety notes for applications in potentially explosive areas based on the Directive 2014/34/ EC (ATEX)

The valves are intended for use in a potentially explosive area and are therefore subject to the conformity assessment procedure of the directive 2014/34/EC (ATEX).

As part of this conformity assessment, an ignition hazard analysis to EN 13463-1 to satisfy the fundamental safety and health requirements was conducted with the following result:

The valves do not have any ignition source of their own and can be operated both manually as well as mechanically/electrically.
The valves are not covered by the scope of application of the ATEX directive and therefore do not need to be identified accordingly.
The valves may be used in a potentially explosive area.

Supplementary notes:

Electric/mechanical actuators must be subjected to their own conformity assessment to ATEX.

It is imperative to observe the individual points of intended use for application in a potentially explosive are

3.1 Intended use

Improper operation, even for brief periods, may result in serious damage to the valve. In connection with explosion protection, potential sources of ignition (overheating, electrostatic and induced charges, mechanical and electric sparks) may result from improper operation. Their occurrence can only be prevented by adhering to the intended use. Furthermore, reference is made to Directive 95/C332/06 (ATEX 118a), which contains the minimum regulations for improving the occupational health and safety of workers who may be at risk from an explosive atmosphere.
A distinction is made between two cases for the use of chargeable liquids (conductivity < 10⁻⁸ S/m):

3.1.1 Chargeable liquid and non-conductive lining

Charges can occur on the lining surface, which may produce discharges inside and outside the valve.

Discharges inside the valve:
These discharges cannot cause ignitions if the valve is completely filled with medium. If the valve is not completely filled, such as during evacuation and filling, the formation of an explosive atmosphere must be prevented, e.g., by superimposing a layer of nitrogen. It is recommended to wait one hour before removing the valve from the plant to allow for the elimination of static peak charges. To safely prevent ignitions, the valve must always be completely filled with medium, or an inert gas layer must be used to exclude a potentially explosive atmosphere.
Discharges outside the valve:
Where the non-conductive lining protrudes on the sealing surfaces to the outside or comes into contact with the atmosphere, discharges may occur to nearby valves or attachments. To safely avoid explosion hazards and accidents, the atmosphere surrounding the valve must not be explosive.

3.1.2 Chargeable liquid and conductive lining

No hazardous charges can occur because charges are discharged directly via the lining and shell (surface resistance < 10⁹ Ohm, leakage resistance < 10⁶ Ohm). However, if non-conductive versions of individual components are installed in the valve, they may restrict the permitted ATEX zone and explosion subgroup despite the conductive lining of the armor plating. In such cases, it is necessary to consult the manufacturer. According to the “Technical Rules for Hazardous Substances: Avoidance of Ignition Hazards Due to Electrostatic Charges” (TRGS 727), static discharges of non-conductive linings occur only through interaction with a non-conductive medium and are therefore the responsibility of the plant operator. Static discharges are not sources of ignition stemming from the valves themselves.
Additional safety measures include:

The temperature of the medium must not exceed the temperature of the corresponding temperature class or the maximum permissible medium temperature as per the operating manual.
If the valve is heated (e.g., heating jacket), the prescribed temperature classes in the Annex must be observed.
To ensure safe and reliable operation, regular inspections must verify that the valve is properly maintained and kept in technically perfect condition.
Increased wear to the valve can be expected when conveying liquids containing abrasive constituents, requiring shorter inspection intervals than usual.
Actuators and electric peripherals, such as temperature, pressure, and flow sensors, must comply with valid safety requirements and explosion protection provisions.
The valve must be grounded, which can be achieved using pipe screws with tooth lock washers. Otherwise, grounding must be ensured by other means, such as a cable link.
Attachments such as actuators, position controllers, and limit switches must comply with relevant safety regulations concerning explosion protection and, if required, be designed in accordance with ATEX.
Special attention must be paid to the appropriate safety and explosion protection notes in the respective operating manuals.
Plastic-lined valves must not be operated with carbon disulfide.

4. Safety note for valves, certified to Clean Air Act (TA Luft)

The validity of the Certificate/Manufacturer Declaration depends on the operating instructions being read and observed.

Carry out regular maintenance intervals and check the tightness of the screw connections, tightening them as necessary.

5. Transport, storage and disposal

Handle the goods being transported with care. During transport protect the valve against impacts and collisions.

Directly after receipt of the goods, check the consignment for completeness and any in-transit damage.

Do not damage paint protection.

For all transport work, observe generally accepted engineering practice and the accident prevention regulations

The valve is supplied with flange caps. Do not remove them until just before installation. They protect the plastic surfaces against dirt and mechanical damage.

5.1 Storage

If the valve is not installed immediately after delivery, store them properly.
The valves be stored in a dry, vibration-free and well ventilated room at as constant a temperature as possible.
Protect elastomers against UV light.
In general, a storage period of 10 years should not be exceeded.

5.2 Return consignments

It is imperative to enclose a safety information sheet / general safety certificate on the field of application with the return consignment.
Contact the Manufacturer for more Information in that regard.
Safety precautions and decontamination measures are to be mentioned.

Valves which have conveyed aggressive or toxic media rinse
and clean before being returned to the manufacturer's works

5.3 Disposal

Parts of the valve may be contaminated with medium which is detrimental to health and the environment and therefore cleaning is not sufficient.

Risk of personal injury or damage to the environment due to the medium!

Wear protective clothing when work is performed on the valve.
Prior to the disposal of the valve:

Collect any medium, etc. which has escaped and dispose of it in accordance with the local regulations.
Neutralise any medium residues in the valve.
Separate valve materials (plastics, metals, etc.) and dispose of them in accordance with the local regulations.

6.Installation

Examine valve for in-transit damage, damaged sample valves must not be installed.

Before installation the valve and the connecting pipe must be carefully cleaned to remove any dirt, especially hard foreign matter.
During installation, pay attention to the correct tightening torque, aligned pipes and tension-free assembly.
The lever must move freely (deadman's position).

6.1 Flange caps and gaskets

Leave protective caps on the flanges until just prior to installation.

Where there is a particularly high risk of damage to the plastic sealing surfaces, e.g. if the mating flanges are made of metal or enamel, PTFE-lined gaskets with a metal inlay should be used. Contact the Manufacturer for further discussion.

6.2 Direction of flow and installation position

Installation is independent of the direction of flow.
The installation position of hand-actuated diaphragm valves can be freely selected.
In the case of diaphragm valves with an actuator, inclined positions of the actuator are only permitted after consultation with the manufacturer. In this case a support structure may have to be provided for the actuator.

6.3 Grounding

The valve must be grounded. This can be achieved in the simplest way via the pipe screws using tooth lock washers. One pipe screw per flange is underlaid with toothed disks.

Upon customer request a set screw M6 is attached to each flange with a hex nut and washer as an additional earthing connection.

Otherwise grounding must be ensured by different measures e.g. a cable link.

6.4 Test pressure

The test pressure PT of a valve must not exceed the value of 1.5 x PS(PN) as per the identification of the valve.

6.5 Angular position for drainability

Both manual and remote actuated MV diaphragm valves can be installed in vertical or horizontal pipes. When installed in vertical pipes, they are self-draining in the opened state. To achieve optimum self-draining in horizontal pipes, the valves must be installed in an inclined position. Contact the Manufacturer for further Information.

7. Operation

7.1 Initial commissioning

Normally, the valves have been tested for leaks with air or water. Prior to initial operation check cover screws. For tightening torques, see Section 1.6!

To prevent leaks, all connection screws should be retightened after the initial loading of the valve with operating pressure and operating temperature. For tightening torques, see Section 1.6.

Unless otherwise agreed there could be residual amounts of water in the flow section of the valve. This could result in a possible reaction with the medium.

7.2 Improper operation and their consequences

Crystallisation must be prevented, e.g. by heating. In extreme cases a leak may occur.
Increased wear occurs in operation with solids contents.
When used in the minus temperature range, the regulations applicable in the country in question must be observed.
Non-observance of the pressure-temperature diagram can lead to damage.
Operation during cavitation leads to increased wear.
Do not subject the handwheel to heavy loads to prevent damaging it.
Do only use a handwheel without lever extension as otherwise there is a risk of damage.
If no monitoring is provided by the warning connection, do not tighten safety stuffing box. Otherwise any leak cannot be seen.

7.3 Shutdown

The local regulations are to be observed when dismantling the valve!

After dismantling, immediately protect the valve flanges against mechanical damage by using flange caps. See also Section 6.1.
Make sure that a remote-controlled actuator cannot be switched on by accident.

Prior to undoing the flange connection ensure, that the plant is depressurised and emptied!

Prior to starting any repair work, make sure that
1. the valve is to be thoroughly cleaned. Medium residue may be in the valve even if it has been properly drained and flushed.
2. a remote-controlled actuator cannot be switched on by accident.

8. Malfunctions

Flange connection valve/pipe is leaking

Retighten the flange screws to a tightening torque according to Section 1.2.
If this does not remedy the leak, the recommended torques may be exceeded by 10%.
If this also fails to stop the leak, dismantle and inspect the valve.

Flange connection body/bonnet is leaking

Retighten the cover screws to a tightening torque according to Section 1.3. If this does not remedy the leak, the recommended torques may be exceeded by 10%.

Safety stuffing box (option) leaks

Tighten packing nut until the leak has been eliminated.
Then dismount the valve as quickly as possible and repair

Diaphragm valve does not switch

Is the actuator supplied with power?
Is there any foreign matter in the diaphragm valve? Leak between stem/bonnet and handwheel?
Diaphragm is defective. For replacement see Section 9.1.

In the case of valves which were opened, the diaphragm must always be replaced with a new one.

9. Maintenance

All repair work is to be performed by qualified personnel using the appropriate tools.
For the arrangement, designation and item numbers of all parts of the valve, see Section 10.
Spare parts are to be ordered with all the details in acc. with the valve identification.
Only original spare parts may be installed.
To prevent leaks, a regular check of the connection screws should be made in line with the operating requirements.
For tightening torques, see Section 1.2

Make sure that when working on the diaphragm valve it is drained and the plant is depressurised See also Section 7.4. The valve can remain installed during the maintenance work.

9.1 Replacing the diaphragm

9.1.1 Dismantling diaphragm valve with handwheel

Step 1:
Undo hex. nuts of the bonnet and remove (the handwheel can remain installed for replacing the diaphragm).
Step 2:
Remove bonnet. Then, unscrew stem off the bonnet.
Step 3:
Unscrew the compressor out of the diaphragm / diaphragm support out of the tube nut.
Step 4:
Remove diaphragm / diaphragm support.

9.1.2 Dismantling diaphragm valve with actuator

Compact actuator: Observe separate instructions.
Dismantling column-style/bracket-style actuator:

Step 1:
Remove actuator and coupling. Then remove bracket or yoke with protective
bellows and travel stop.
Step 2:
The entire actuator with bonnet can also be removed to replace the diaphragm.
Step 3:
Further dismantling is performed as described in Section 9.1.1.

9.2 Assembly

Prior to assembly all parts are to be cleaned and the plastic-lined parts checked for damage.
The entire valve is always assembled in the open position.

9.2.1 Assembly diaphragm valve with handwheel

Step 1:
Screw diaphragm/diaphragm support into the tube nut in the compressor up to the stop and turn into the correct position.
Step 2:
Screw diaphragm/diaphragm support into the tube nut in the compressor up to the stop and turn into the correct position.
Step 3:
The thread of the stem and the nut thread in the bonnet must be clean and free from solvents. Grease the thread with the lubricant.
Step 4:
Turn the stem into the bonnet. Then, insert the plain bearing into the bearing disc and grease with the lubricant. Mount the bearing disc onto the stem.
Step 5:
Connect compressor with stem. Push compressor guide onto the stem from the side.
Step 6:
Screw stem in the open position right up to the travel stop. Now you can mount bonnet onto the body and bolt together. For tightening torques, see Section 1.3.
Step 7:
Check for leaks. (Only by specialists on the test stand).

Step 8:
Turn the stem in until the valve closes (bubble-tight).
Step 9:
Screw on hex. nut 920/2 with a space of 1 mm between the bonnet and the hex. nut. The hex. nut serves as a travel stop so that the diaphragm is
not damaged.
Step 10:
Mount handwheel.
Step 11:
Apply screw securing agent Loctite to the thread of the hex. screw. Secure handwheel with hex. screw.

9.2 2 Assembly diaphragm valve with actuator

Compact actuator: Observe separate instructions.
Dismantling column-style/bracket-style actuator:

Step 1:
For assembly of bracket or yoke, see drawing in Section 10.
Step 2 Option:
Mount travel stop with protective bellows.
Step 3:
Mount coupling and actuator. Observe securing position, see operating instructions for the actuator.
Step 4:
Further assembly as described in Section 9.2.1

9.2.3 Diaphragm valve with safety stuffing box

A modified bonnet is used when installing a safety stuffing box.

Step 1:
Insert 2 packing ring offset against each other
Step 2:
Insert thrust ring.
Step 3:
Screw on packing nut. Only tighten further in the event of a leak.

In order to ensure leak monitoring, GFT9 recommends the combination of the safety stuffing box with a warning connection.
If only the safety stuffing box is present, do not tighten it so that any leak becomes visible. Otherwise the valve may be destroyed by an unnoticed internal leak!

10. Dimensional Drawings

10.1 Dimensional Measurements DIN

Size	L	ød	øk	øD	Bolting
DN 15	130 mm	45 mm	65 mm	95 mm	4 x 14 (M12)
DN 20	150 mm	58 mm	75 mm	105 mm	4 x 14 (M12)
DN 25	160 mm	68 mm	85 mm	115 mm	4 x 14 (M12)
DN 40	200 mm	88 mm	110 mm	150 mm	4 x 18 (M16)
DN 50	230 mm	102 mm	125 mm	165 mm	4 x 18 (M16)
DN 65	290 mm	122 mm	145 mm	185 mm	4 x 18 (M16)
DN 80	310 mm	138 mm	160 mm	200 mm	8 x 18 (M16)
DN 100	350 mm	158 mm	180 mm	220 mm	8 x 18 (M16)
DN 125	400 mm	188 mm	210 mm	250 mm	8 x 18 (M16)
DN 150	480 mm	212 mm	240 mm	285 mm	8 x 22 (M20)

10.2 Dimensional Measurements ANSI

Size	L	ød	øk	øD	Bolting
NPS ½"	108 mm	34,9 mm	60,3 mm	88,9 mm	4 x 15.9
NPS ¾"	117 mm	42,9 mm	69,8 mm	98,4 mm	4 x 15.9
NPS 1"	127 mm	50,8 mm	79,4 mm	108 mm	4 x 15.9
NPS 1½"	165 mm	73 mm	98,4 mm	127 mm	4 x 15.9
NPS 2"	178 mm	92,1 mm	121 mm	152,4 mm	4 x 19
NPS 2½"	190 mm	104,8 mm	139,7 mm	177,8 mm	4 x 19
NPS 3"	203 mm	127 mm	152,4 mm	190,5 mm	4 x 19
NPS 4"	229 mm	157,2 mm	190 mm	228,6 mm	8 x 19
NPS 6"	394 mm	216 mm	241 mm	279 mm	8 x 22.2

11. Sectional Drawing

Pos.	Item	Material
1	Lined Body	WCB, CF8 - PFA Lined
2	Bonnet	WCB, CF8
3	Spindle	SS316
4	Compressor Pin Type	WCB, CF8
5	Handwheel	CF8
6	Opening Indicator Sleeve	HDPE
7	Diaphragm (pin Type)	PTFE Backed with EPDM
8	Compression Spring	Stainless Steel
9	Dowell Pin Spring	Steel
10	Stud	Stainless Steel
11	Nut	Stainless Steel
12	Plain Washer	Stainless Steel

12. Declaration of Conformity

Konformitätserklärung 2014/68/EU
Declaration of Conformity 2014/68/EU

Product Diaphragm Valve
Design Diaphragm Valve
Serial number
Size DN 25 - DN 150 | NPS 1½" - NPS 10"
EU-Directive 2014/68/EU
Applied Technical Specification DIN EN IS0 12100 AD 2000
Surveillance Procedure 2014/68/EU, TÜV Rheinland Industrie Service GmbH
Notified Body for Pressure ID-No. 0035
Equipment
Conformity assessment. 2014/68/EU / 2014/68/EU
Procedure
Marking 2014/68/EU¹⁾ ≥ DN 25, ≥ 1“

Advanced Fluoropolymer Devices GmbH confirms that the basic requirements of the above specified directives and standards have been fullied
¹⁾ For sizes not listed a marking is not permissible.

Kempen, 17.12.2024

K. Schalm

Land/Region

Sprache