Installation and Operating Manual

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

2.1 Intended use

2.2 For the customer / operator

2.3 Improper operation

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.

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.

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.

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.
  

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.

7.1 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.

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.

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.

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!