Vag GA Industries FIGURE 200 Manual de usuario

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

FIGURE 200

RUBBER FLAPPER CHECK VALVE

TABLE OF CONTENTS

Introduction ….………………………… 2

Receiving & Storage .....……………… 2

Description of Operation .....………… 2

Valve Construction ......………………. 2

Installation ......…………………………. 3

Preventive Maintenance ....………….. 3

Trouble Shooting ...…………………… 3

Disassembly ....………………………… 3

Reassembly ....…………………………. 4

Visual Position Indicator …..………….. 4

Limit Switch Installation/Adjustment …. 4

Backflow Actuator Installation ….….…. 5

Parts & Service ………………..…….…. 6

Repair Kits ……………………………… 6

Warranty .……………………………….. 6

234 Clay Avenue • Mars, PA 16046 USA

Telephone (724) 776-1020 • Fax (724) 776-1254

E-mail: info-ga@vag-group.com

Manual Number 200-IOM-110520

Figure 200 Rubber Flapper Check Valve

INTRODUCTION

This manual will provide the information to

properly install, operate and maintain the valve

to ensure a long service life. The GA Industries

Figure 200 Rubber Flapper Check Valve is

designed to provide years of dependable

operation. This manual will provide you with the

information needed to properly install and

maintain the valve and to ensure a long service

life.

The valve is of the swing check type utilizing an

angled seat and fully encapsulated, resilient

disc. It opens to allow fluid flow in the forward

direction and closes automatically to prevent

flow in the reverse direction.

The Figure 200 can handle a wide range of

fluids including those containing suspended

solids. The valve’s size, flow direction,

maximum working pressure, and series number

are cast on the valve body or stamped on the

nameplate.

CAUTION

Do not use valve for line testing at pressures

higher than nameplate rating or damage to valve

may occur.

The “Maximum Working Pressure” is the non-

shock pressure rating of the valve at 150˚ F. The

valve is not intended as an isolation valve for

line testing at pressures higher than the valve

rating.

RECEIVING AND STORAGE

Inspect valves upon receipt for damage in

shipment. Unload all valves carefully to the

ground without dropping. Do not allow lifting

slings or chains to contact the backflow actuator

or visual position indicator (if provided). Use

eye bolts or rods through flange bolt holes to lift

large valves.

Valves should remain crated, clean and dry until

installed to avoid weather related damage. For

storage longer than six months, apply a thin coat

of approved lubricant to the flexible disc.

Do not remove flange protectors until ready to

install or expose flexible disc to sunlight or

ozone for an extended period.

DESCRIPTION OF OPERATION

The valve is designed to automatically prevent

reverse flow. During forward flow conditions, the

movement of the fluid forces the disc to the open

position allowing 100% unrestricted flow area

through the valve. Upon flow reversal, the disc

automatically returns to the closed position to

prevent reverse flow.

Figure 1

VALVE CONSTRUCTION

The standard GA Industries Figure 200 Rubber

Flapper Check Valve is constructed of rugged

ductile iron with a reinforced rubber flexible disc.

See the specific Materials List submitted for the

order if other than standard construction. The

disc is the only moving part assuring long life

with minimal maintenance. The body (1) is

flanged for connection to the pipeline with an

Item

Description

Standard Material

Body

Ductile Iron

Cover

Ductile Iron

Flexible Disc

Buna-N Rubber Encapsulated Steel

Gasket

Buna-N

Cover Bolt

Stainless Steel

open top sealed with a cast cover (2). The

flexible disc (3) is retained by the cover.

An optional valve mounted position indicator,

with or without limit switch, is available to

provide local and remote position indication.

These also can be field installed (see Page 4).

An optional backflow actuator is available to

manually open the valve to allow reverse flow.

The backflow device can be easily installed in

the field (see Page 5).

INSTALLATION

The Figure 200 Rubber Flapper Check

Valve must be properly installed for proper

operation. It may be installed in either horizontal

or vertical (flow-up) applications. However,

when horizontal, the valve must be installed with

the nameplate facing up. In all installations, the

arrow cast in the valve cover must be pointed in

the direction of forward flow.

Do not remove flange protectors until ready to

install and ensure there is no debris inside the

valve before installation.

Flanged valves should only be mated with flat-

faced pipe flanges equipped with full-face

gaskets.

CAUTION

The use of ring gaskets or mating flanges with a

raised face may damage valve flanges.

The valve and adjacent piping must be

supported and aligned to prevent imposing

stress on the valve. Once the flange bolts or

studs are lubricated and inserted around the

flange, uniformly hand tighten. Then tighten the

bolts to the recommended torque in graduated

steps using the cross-over tightening method. If

leakage occurs, allow gaskets to absorb fluid

and check torque and leakage after 24 hours.

Do not exceed bolt rating or extrude gasket.

PREVENTIVE MAINTENANCE

The Figure 200 Rubber Flapper Check Valve

requires no scheduled lubrication or

maintenance. The valve can be inspected or

serviced without removal from the line.

Valve Inspection: If internal inspection of the

valve is required, follow the disassembly

instructions provided below.

TROUBLESHOOTING

Common problems and solutions are presented

below to assist you in troubleshooting the valve

assembly in an efficient manner.

• Leakage at flanges

Tighten bolts, replace gasket.

• Valve leaks backwards when closed

Inspect disc for damage and replace. Inspect

metal seating surface; clean if necessary.

• Valve does not open

Check for obstruction in valve; see Disassembly

procedure below. Operating pressure may

be insufficient to open valve. If less than 0.5

PSIG review application with factory

• Leakage at Backflow Actuator

Remove line pressure and exercise actuator. If

leak persists, replace seals in actuator; see the

Backflow Actuator Seal Replacement Procedure

on Page 6.

DISASSEMBLY

The valve can be disassembled for inspection or

repair while in the line or when removed if more

convenient. All work on the valve should be

performed by a skilled mechanic with proper

tools. A power hoist should be employed when

disassembling large valves.

WARNING

Lock out any associated pumps. Isolate the

valve and relieve pressure before removing it

from the line or disassembling while in the line or

pressure may be released causing bodily harm.

Relieve pressure and drain the pipeline. Refer

to figure 2 on page 2. Remove the cover bolts

(4), pry cover (2) loose and lift off valve body.

Remove flexible disc (3) and inspect for cracks,

tears or damage in rubber sealing surface.

Inspect seating surface in body for damage.

Clean and inspect parts. Replace worn parts as

necessary.

REASSEMBLY

Clean gasket surfaces on body and cover with a

stiff wire brush in the direction of the serrations

or machine marks. Clean seating surface in

body with emery cloth. Lay disc (3) over seat

with beaded seating surface directed down

toward machined seat. Lay cover gasket (5)

and cover (2) over bolt holes and disc hinge.

Insert lubricated bolts (4) noting that the bolts

in the hinge area are longer than the other

cover bolts. Incrementally and uniformly tighten

cover bolts in a cross over pattern.

VISUAL POSITION INDICATOR OPERATION

The optional visual position indicator (Figure 2)

provides a local indication of the flexible disc’s

position.

The counterweight (11) rests against the back of

the flexible disc and pivots as the disc swings

from closed to open. The word CLOSED is

exposed when the valve is closed and OPEN

when the valve is fully open.

VISUAL POSITION INDICATOR FIELD

INSTALLATION

WARNING

Lock out any associated pumps. Isolate the

valve and relieve pressure before removing it

from the line or disassembling while in the line or

pressure may be released causing bodily harm.

WARNING

Do not field install the visual position indicator

unless the valve is in the horizontal position or

damage to the indicator assembly may result.

Once the indicator is installed, the valve may be

installed in a vertical (flow up) pipe

•Remove pipe plug from the port in the

cover

•Apply sealant to threads on the lower

bushing (10)

•Insert counterweighted end of assembly

(9) through the port and tighten,

ensuring the indicator flag (23) and

channel bracket (25) are parallel to the

valve’s centerline.

•Proper action can be verified by lifting

the counterweight. Do not attempt to

move the indicator flag by hand.

•Re-pressurize and check for leaks. If

further tightening is needed, ensure

indicator remains parallel to valve

centerline.

Figure 2

Item

Description

Material

Position Indicator Assembly

See Figure 3

Counterweight Arm

Stainless Steel

Counterweight

Stainless Steel

LIMIT SWITCH INSTALLATION AND

ADJUSTMENT

An optional single pole double throw (SPDT)

limit switch can be provided for remote indication

of valve position. The limit switch can be

supplied with the visual position indicator

assembly or added later. Refer to Figure 3.

To install the limit switch on the visual position

indicator assembly:

•Attach the limit switch mounting bracket

(29) to the channel bracket (25) using

the limit switch bracket mounting screws

(30).

•Mount the limit switch (28) on the

bracket using the limit switch mounting

screws (31) so that the switch’s

“whisker”is on the left side of the flag

(23) when looking at the flag.

Typically, the limit switch contacts close when

the valve is closed. Adjust the switch position so

that the indicator flag (23) actuates the switch

when the valve is fully closed. DO NOT

ADJUST THE FLAG POSITION.

Figure 3

Item

Description

Material

Lower Bushing

Brass

Roller

Stainless Steel

Roller O-Ring

Buna-N Rubber

Retaining Ring

Stainless Steel

Indicator Flag

Stainless Steel

Indicator Flag Screw & Washer

Stainless Steel

Channel Bracket

Aluminum

Upper Bushing w/Flush Port

Stainless Steel

Upper Bushing O-Ring

Buna-N Rubber

SPDT Limit Switch

See Switch for

Model Number

Switch Mounting Bracket

Aluminum

Bracket Mounting Screw & Nut

Stainless Steel

Switch Mounting Screw

Stainless Steel

BACKFLOW ACTUATOR OPERATION

The actuator is not designed to open the valve

with pressure at its outlet. Therefore, prior to

using the actuator, close the pump isolation

valve and relieve line pressure between the

check valve and isolation valve. To open the

valve, loosen the jam nut (15) turn the T-handle

clockwise. The handle should turn easily.

When resistance is felt, the disc has reached its

body stop and is in the fully open position. Then

open the isolating valve to allow backflow

through the valve.

WARNING

Relieve line pressure before using back flow

actuator or damage may occur.

Upon completion of the backflushing operation,

turn the T-handle fully counterclockwise to allow

the valve disc to return to the closed position.

Lock the backflow actuator in the closed position

with the jam nut (15). The system is again ready

for normal operation.

BACKFLOW ACTUATOR FIELD

INSTALLATION

•Isolate the rubber flapper check valve,

depressurize and drain pipeline.

WARNING

Removal of the bottom plug while under

pressure may cause bodily harm.

•Remove the pipe plug in the bottom

boss of the valve.

•Inspect the backflow rod (16) and

ensure the T-handle has been turned

fully counterclockwise. The rod should

extend about 1” past the end of the

brass backflow tube (14). Apply thread

sealant to brass threads.

•Insert the threaded end of the assembly

into the valve boss. Slowly turn the

assembly into the boss. Continue

turning the assembly into the valve for a

tight fit.

•Introduce pressure and check for leaks.

Tighten if needed.

Figure 4

Item

Description

Material

Rod Wiper

Urethane

Rod Seal

Buna-N Rubber

Backflow Tube

Brass

Jam Nut

Stainless Steel

Backflow Rod

Stainless Steel

T-Handle

Stainless Steel

Setscrew

Stainless Steel

Backflow Actuator Seal Replacement:

There are two parts (12 & 13) on the

backflow actuator that are subject to wear.

Before replacing the seals, the pipeline must

first be depressurized and drained. Next,

remove the backflow assembly from the

valve by turning the Backflow tube (14)

counterclockwise. Disassemble the actuator

as follows:

•Remove the Set Screw (18) with an

Allen wrench.

•Loosen the jam nut (15) and spin it back

until it’s just under the T-Handle (17).

Turn the T-Handle fully clockwise (17),

then remove the Setscrew (18), T-

handle (17) and jam nut (15) from the

Backflow rod (16).

•Remove the rod (16) from the tube (14)

by hand turning it counterclockwise. Do

not use tools that would score or

damage the smooth sealing surface.

•Using a pick remove the rod wiper (12)

and rod seal (13) from the end of the

backflow tube (14).

•Inspect and if needed clean the inside of

the backflow tube.

•Lubricate rod wiper and rod seal with

approved grease and install in the

grooves in the backflow tube.

•If necessary, clean the backflow rod with

fine emery cloth. Lubricate the non-

threaded portion with approved grease

and thread into the backflow tube being

careful not to damage the rod seal or

wiper.

•Install jam nut, T- handle and setscrew.

•Turn T-handle fully counterclockwise.

•Apply thread sealant to bushing and

carefully thread into valve taking care

not to cross-thread the bushing.

•Introduce pressure and check for leaks.

Tighten if necessary.

PARTS AND SERVICE

Parts and service are available from your local

representative or the factory. Make note of the

Valve Size, Series No., and Serial No. located

on the valve nameplate and contact:

VAG USA, LLC

234 Clay Avenue

Mars, PA 16046 USA

Telephone: 724-776-1020

Fax: 724-776-1254

E-mail: [email protected]

REPAIR KITS

Repair Kit includes Buna-N flexible disc (3) and

cover gasket (4).

Size

Kit Number

Part Number

2”

RF2

2-80-16000-005

2½”

RF2.5

2-80-16000-062

3”

RF3

2-80-16000-008

4”

RF4

2-80-16000-009

6”

RF6

2-80-16000-010

8”

RF8

2-80-16000-011

10”

RF10

2-80-16000-000

12”

RF12

2-80-16000-001

14”

RF14

2-80-16000-002

16”

RF16

2-80-16000-003

18”

RF18

2-80-16000-004

20”

RF20

2-80-16000-006

24”

RF24

2-80-16000-007

WARRANTY

The Warranty for GA Industries valves is

included in our Terms and Conditions which can

be found here: https://gaindustries.com/terms

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