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

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

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.

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.

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)

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).

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 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

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):

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

1. 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.
2. 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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

• 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.

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.

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

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%.

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

1. Is the actuator supplied with power?
2. 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.

9.1.1 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!

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