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 is normally horizontal with the bottle connection pointing vertically downwards (deviations from this position require a special bottle connection). Contact the Manufacturer if not discussed prior.

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 Star knob

The stroke and thus the pressure reduction and medium flow can be influenced with the star knob.

Moreover, the star knob can be used to close the valve like a manual valve.

It also served to enforce tightness in case of damaged seat sealing surfaces or seized particles.

6.6 High-viscosity media / Low operating pressure

With the version "design for high-viscosity media" the changed operating limits acc. to the name plate must be observed and the travel must be set according to the setting instructions in Section 6.7

6.7 Setting instructions

• Press the sampling lever in the direction of the
  valve.
• Slowly turn the star knob counterclockwise until the flow into the sampling bottle corresponds to the intensity you want.
• Release lever and lock the star knob in this position.

This procedure guarantees that with each further sampling process (with the same internal pressure) the flow of the sample into the bottle remains within the desired
range without any risk to the person taking the sample.

If the operating pressures vary, we recommend you for safety's sake to turn the star knob after every sampling operation clockwise again until it reaches zero point
(lever cannot execute any travel).

7.1 Initial commissioning

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.

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. Damage to the seat or cone would be inevitable.In extreme cases a leak may occur.
• Increased wear occurs in operation with solids contents.
• Violent opening or rapid filling may cause the bottle to burst.
• Non-observance of the pressure-temperature diagram can lead to damage.
• Do not transport the valve using the lever.
• Do not use a lever extension as otherwise there is a risk of damage.
• At the customer's request, the middle hole in the lever is drilled through. If the lever is then locked in the lower hole to take samples and if, in addition, a pin is inserted into the middle hole, it must be ensured that sampling does not take place accidentally

7.3 Sampling (Standard)

Screw bottle into the bottle connection 226.

• Check travel set on the star knob 963/1.
• Lever 203 is in the dead man's position.
• For sampling, lock lever in the top groove.
• If it is requested that the lever is firmly locked, drill through the middle hole and insert an additional pin into the middle hole.
  CAUTION! Sampling may also take place acci-
  dentally.
• Press in direction of valve.
• Sampling can take place.

A lock is available from GFT9 as an option.

A device, screw fitting 917 for example, for the riskfree discharge of the medium must be connected to the venting connection. Sealing plugs are not allowed because this results in overpressure in the bottle.

7.4 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.

Step 1:
Undo clip 937 and unscrew bottle connection 226.
Undo groove nut 509. Star grip 963 can remain screwed in.

Step 2:
Undo spring bonnet 513

Step 3:
Pull pressure spring 952 from stem 855

Step 4:
Loosen setscrew 904 in spring bush 514.

Step 5:
Undo spring bush 514.

Step 6:
Undo hex nut 920 with tooth lock washer 936, and
remove seat 205.

Step 7:
Remove cover 106 and the stud screws 902.

Step 8:
Pull out bellows 206 with stem 855 downwards.

Step 9:
Remove actuation 515 from cover 106.

Step 10:
Undo both hex nuts 920 of packing gland follower
503

Step 11:
Remove stud screws 902.
Remove packing gland follower 503.
Remove thrust ring 405 from cover 106.

Step 12:
Remove packing rings 402.

Step 13:
Turn cover 106 around and remove guide ring 302

Step 14:
Turn cover 106 around and remove guide ring 302.

Step 1:
Unscrew cap nut 927, remove disc 550 and bottle connection 226.
Undo groove nut 509. Star grip 963 can remain screwed in.

Step 2:
Undo spring bonnet 513

Step 3:
Pull pressure spring 952 from stem 855

Step 4:
Loosen setscrew 904 in spring bush 514.

Step 5:
Undo spring bush 514.

Step 6: Undo hex nut 920 of cover 106.

Step 7:
Remove cover 106 and the stud screws 902.

Step 8:
Pull out bellows 206 with stem 855 downwards.
Remove actuation 515 from cover 106

Step 9:
Undo both hex nuts 920 of packing gland follower 503.

Step 10:
Remove stud screws 902.
Remove packing gland follower 503

Step 11:
Remove thrust ring 405 from cover 106.

Step 12:
Remove packing rings 402.

Step 13:
Turn cover 106 around and remove guide ring 302

Step 1:
Mount seat 205 and tighten with hex nut 920 and tooth lock washer 936.
Screw stem 855 into bellows 206



Step 2:
Insert guide ring 302 from the bottom into cover 106, and push the ring into the groove.

Step 3:
Turn cover 106 around, and insert two packing rings 402.
ATTENTION: Offset overlapping from ring to ring by 60° to 90°

Step 4:
Insert thrust ring 405

Step 5:
Place packing gland follower 503.
Insert two stud screws 902, and loosely fasten them with hex nuts 920. Do not yet tighten the hex nuts!

Step 6:
Insert actuation 515 into cover 106.

Step 7:
Insert stem 855 and bellows 206 into cover 106.

Step 8:
Place cover 106 on body 100. Make sure that actuation 515 is located on the same side as the name plate.

Step 9:
Undo both hex nuts 920 of packing gland follower 503.

Step 10:
Attach cover 106 with stud screws 902 and hex nuts 920 to body 100. See Section 1.6 for the tightening torques of the body screws.

Step 11:
Move actuation 515 into dead man´s position.

Step 12:
Screw on spring bush 514. Note: Use your right hand to push actuation 515 up, and at the same time use your left hand to tighten spring bush 514 until the stop

Step 13:
Insert spring pressure 952.
Mount spring bonnet 513 with groove nut 509. Note: The thread of spring bonnet 513 must be just visible at the bottom

Step 14:
Use a hook wrench to tighten groove nut 509.

Step 15:
Tighten both stud screws 920 of packing gland follower 503

Step 16:
Tighten setscrew 904 in spring bush 514.

Step 17:
Standard: Screw in bottle connection 226 and secure with clip 937.
Set stroke with star knob. See Section 6.7.

Step 1:
Screw stem 855 into bellows 206

Step 2:
Insert guide ring 302 from the bottom into cover 106,
and push the ring into the groove.

Step 3:
Turn cover 106 around, and insert two packing rings 402.
ATTENTION: Offset overlapping from ring to ring by 60° to 90°.

Step 4:
Insert thrust ring 405.

Step 5:
Place packing gland follower 503.
Insert two stud screws 902, and loosely fasten them with hex nuts 920. Do not yet tighten the hex nuts!

Step 6:
Attach actuation 515 to cover 106.

Step 7:
Insert stem 855 and bellows 206 into cover 106.

Step 8:
Mount spring bonnet 513 with groove nut 509. Note: The thread of spring bonnet 513 must be just visible at the bottom

Step 9:
Place cover 106 on body 100. Make sure that actuation 515 is located on the same side as the name plate

Step 10:
Attach cover 106 with stud screws 902 and hex nuts 920 to body 100. See Section 1.6 for the tightening torques of the body screws.

Step 11:
Move actuation 515 into dead man´s position

Step 12:
Screw on spring bush 514. Note: Use your right hand to push actuation 515 up, and at the same time use your left hand to tighten spring bush 514 until the stop

Step 13:
Insert spring pressure 952.

Step 14:
Use a hook wrench to tighten groove nut 509

Step 15:
Tighten both stud screws 920 of packing gland follower 503

Step 16:
Tighten setscrew 904 in spring bush 514.

Step 17:
Standard: Secure bottle connection 226 with threaded rod 918 and cap nut 927.
Set stroke with star knob. See Section 6.7