Operation and Maintenance Instructions

VAG EKN® Butterfly Valve Type AWWA

KAT 1321-B Edition2 10-12

Table of Content
VAG reserves the right to make technical changes and
1 General 3 use materials of similar or better quality without express
notice. The pictures are non-binding.
1.1 Safety 3
1.2 Warning levels 3
1.3 Proper use 3
1.4 Identification 3

2 Transport and Storage 4

2.1 Transport 4
2.2 Storage 5
3 Product features 5
3.1 Features and function description 5
3.2 Applications 5
3.3 Performance limits 5
3.3.1 Cavitation 5
3.3.2 Maximum permissible flow velocity 6
3.4 Permissible and impermissible modes of
operation  6

4 Installation into the pipeline 6

4.1 Conditions required on site 6
4.2 Installation location 6
4.2.1 Installations in the pipeline upstream and down-
stream of the valve  7
4.2.2 Gear positions 9
4.3 Installation position 10
4.4 Assembly instructions and fittings 11

5 Set-up and operation of the valve 11

5.1 Visual inspection and preparation 11
5.2 Function check and pressure test 11
5.3 Putting electric actuators into operation 11

6 Actuators 11
6.1 General 11
6.2 Operating torques 12
6.3 Emergency manual operation (handwheel) 12
6.4 Assembly of the electric actuator 12

7 Maintenance and repair 13

7.1 General safety instructions 13
7.2 Inspection and operation intervals 13
7.3 Maintenance work and replacement of parts 13
7.3.4 Replacement of the profile seal 14
7.3.1 Design 13
7.3.5 Replacement of the O-rings in the bearing  14
7.3.2 Recommendations for the replacement of
parts 14
8 Trouble-shooting 15

7.3.3 Cleaning and lubrication 14 9 How to contact us 15

 1 General • Caution: Used for personal injury
Possible consequences if the safety instructions are not followed:
1.1 Safety Light or minor injuries

Warning/Caution: These Operation and Maintenance

Instructions must be observed and applied at all times
• Caution: Used for proberty damage
along with the general “VAG Installation and Operation
Instructions for Valves” (see www.vag-group.com / Ca-
tegory: Installation and Operation Instructions). Possible consequences if the safety instructions are not followed:
Material damage to the unit or its surroundings
Arbitrary alterations of this product and the parts supplied with it
are not allowed. VAG will not assume any liability for consequen-
tial damage due to non-compliance with these instructions.When
using this valve, the generally acknowledged rules of technology 1.3 Proper use
have to be observed (e.g. national standards, ASME/AWWA etc.).
The installation must only be carried out by qualified staff (see The VAG EKN® Butterfly Valve type AWWA is a shut-off valve de-
also Section 7.1 General safety instructions). For further technical signed for installation in pipelines.
information such as dimensions, materials or applications, please
refer to the respective documentation (KAT 1321-A). The VAG EKN® Butterfly Valve type AWWA is intended to shut
off the medium. Its use as a control valve is only possible within
VAG valves are designed and manufactured to the highest stan- certain limits.
dards and their safety of operation is generally ensured. However,
valves may be potentially dangerous if they are operated impro- VAG EKN AWWA Butterfly Valves are designed acc. AWWA 504
perly or are not installed for their intended use. standard with maximum working pressure of 150 psig and a ma-
ximum full open velocity of 16 ft / sec. Temperature range acc.
Everyone dealing with the assembly, disassembly, operation, AWWA 33° - 125° F.
maintenance and repair of the valves must have read and under-
stood the complete Operating and Maintenance Instructions (Ac- For any deviating operating conditions and applications, the
cident Prevention Regulations and ANSI Z535). manufacturer’s written approval must be obtained!

Before removing any protective devices and/or performing any These Operation and Maintenance Operation Instructions contain
work on the valve, depressurise the pipeline section and ensure important information on the safe and reliable operation of the
it is free of hazards. Unauthorised, unintentional and unexpected VAG EKN® Butterfly Valve type AWWA.
actuation as well as any hazardous movements caused by stored
energy (pressurised air, water under pressure) must be prevented. Observing these Operation and Maintenance Instructions helps
you to:
In case of equipment that must be monitored and inspected, all
relevant laws and regulations, such as the Industrial Code, the • Prevent hazards
Accident Prevention Regulations, the Ordinance of Steam Boilers
and instructional pamphlets issued by the Pressure Vessels Study • Reduce repair costs and down-time of the valve and/or the en-
Group must be complied with. In addition, the local accident pre- tire equipment
vention regulations must be observed.
• Improve the operational safety and useful life of the equipment.
If a valve serving as an end-of-line valve is to be opened in a pres-
surised pipeline, this should be done with the utmost care to pre-
vent the emerging fluid from causing damage. Care must also be
taken when closing the valve to avoid crushing or trapping. 1.4 Identification
When a valve needs to be dismantled from a pipeline, fluid may According to AWWA C 504 / section 6.1 all valves bear an identi-
emerge from the pipeline or the valve. The pipeline must be emp- fication label specifying the valves size, class, body material and
tied completely before the valve is dismantled. Special care needs the manufacturer’s logo.
to be taken in case of residue which may continue flowing.
A rating plate is attached to the body and contains at least the
1.2 Warning levels following information:
VAG Manufacturer’s name
The following warning levels are used in this manual
Valve size Size of the of the valve in inch
• Danger: Used for personal injury (immediate danger).
Class Nominal pressure of the valve in psi
Possible consequences if the safety instructions are not follo-
Body material
wed: Death or serious injuries
Date of manufacture

• Warning: Used for personal injury (possibly dangerous

situation).

Possible consequences if the safety instructions are not followed:

Death or serious injuries

VAG Operation and Maintenance Instructions • 3

 ters do not have their centre of gravity in the middle and therefore
2 Transport and Storage may swing sideways when lifted if the stop device is improperly
fixed.

2.1 Transport Avoid jerks and jolts when lifting or lowering the load, as the
forces generated in the process may damage both the valve and
Caution: For transportation to its installation site, the valve must the lifting devices.
be packed in stable packaging material suitable for the size of
the valve. It must be ensured that the valve is protected against For transport purposes and also to support assembly, lifting de-
atmospheric influences and external damage. When the valve is vices such as cables and belts must only be attached to the valve
shipped under specific climatic conditions (e.g. overseas trans- body, bearing lugs or the lifting devices provided for that purpose.
port), it must be specially protected and wrapped in plastic film The actuator or the gearbox are unsuitable for this purpose. The
and a desiccant must be added. length and positioning of the cables/belts must ensure that the
valve is in a horizontal position during the entire lifting procedure.
The factory-applied corrosion protection and any assemblies
must be protected against damage by external influences during
transport and storage.

The VAG EKN® Butterfly Valve type AWWA must be transported

with its disk slightly open. For transport, place the valve onto its
inlet-side flange or on the flange flat base with the bearing lugs
facing upwards.

Picture 1: Transport position - on inlet-side flange

Picture 3: Suspension bores of the VAG EKN® Butterfly Valve

The general regulations relating to the use of lifting devices must

be complied with.

The VAG EKN® Butterfly Valves type AWWA are provided with
suspension bores located above the flange. As shown in Picture 3,
they can be used to lift the VAG EKN® Butterfly Valve type AWWA.

For valves that have been factory-packed in transport crates

(wooden crates), the centre of gravity of the entire unit must be
taken into account. The centre of gravity is marked on each side
of the crate at our factory and must be considered for all lifting
operations.
Picture 2: Transport position – on flat base • Warning: Suspended Load!

The valve can tilt and can be damaged while being lowered! Dan-
If the valve is equipped with actuation assemblies, make sure the ger of injury during lifting and transport.
actuators are safely stored to prevent transverse loads from af- -- Avoid valve’s tilting by always moving it cautiously during lif-
fecting the connections. ting and transport.
-- Wear protective equipment (safety helmet, safety gloves and
When selecting and using stop devices, take the weight and the safety shoes).
stop type into account. For the respective weights of the VAG
EKN® Butterfly Valve type AWWA, please refer to KAT 1321-A. -- Make sure that no attachments can be jammed.
The way the stop devices are used should comply with the rele- • Danger: The valve can fall down during lifting!
vant regulations.
Death or serious injury can result if body parts are hit and/or crus-
VAG EKN® Butterfly Valves type AWWA of large nominal diame- hed!

VAG Operation and Maintenance Instructions • 4

 -- Never stand under a suspended load! tion. If required, the profile seal ring can be disassembled without
-- Only use hoists and slinging tackles which are safe to sup- having to dismantle the valve.
port the load!
-- Lift the valve carefully until it is freely suspended. In case of epoxy-coated VAG EKN® Butterfly Valves type AWWA,
the sealing seat is made corrosion-resistant by high-alloy weld
-- Balance the valve carefully. Consider the center of mass! overlay and is also resistant to mechanical damage. In the steel-
-- The valve can now be hoisted and cautiously transported to welded type of the body, the sealing seat is made of stainless
the installation site. steel.

2.2 Storage 3.2 Applications

In its standard version, the VAG EKN® Butterfly Valve type AWWA
Caution: The VAG EKN® Butterfly Valve type AWWA type should
is equipped with EPDM seals.
be stored with its disk slightly open.
The VAG EKN® Butterfly Valve should only be used in media in
which there is no risk of clogging.
The butterfly valve can be used for the following media:
• Water,
• Raw and cooling water (with appropriate corrosion protection)
• Weak acids and alkaline solutions (with according corrosion
protection)

Caution: The use of the valve with media containing gas or oil
may result in the destruction of the EPDM seals (rubber lining) and
O-rings and is therefore not permissible.

Picture 4: Storage of the VAG EKN® Butterfly Valve type AWWA

VAG EKN AWWA Butterfly Valves are designed acc. AWWA 504
standard with maximum working pressure of 150 psi g and a ma-
ximum full open velocity of 16 ft / sec. Temperature range acc.
The elastomeric parts (seals) must be protected against direct
AWWA is 33° - 125° F.
sunlight and/or UV light as otherwise their long-term sealing
function cannot be guaranteed. Store the valve in a dry and well In case of differing operating conditions, the manufacturer needs
aerated place and avoid direct heat. Protect any assembly units to be consulted. If in doubt, consult the manufacturer to inquire
important for proper function such as the disk and the body seal about the appropriate sealing materials for your application.
against dust and other dirt by adequate covering.

Do not remove the protective caps of the connections / flanges 3.3 Performance limits
and the packaging materials until immediately prior to assembly
into the pipeline.
The valve can be stored in ambient temperatures ranging from
3.3.1 Cavitation
-4° F to 122°F (-20 °C to +50 °C) (protected by adequate covers).
If the valve is stored at temperatures below 32° F (0 °C), it should Caution: VAG EKN® Butterfly Valves are mainly used to shut off
be warmed up to at least 41° F (+5° C) before installation and be- flow. If a VAG EKN® Butterfly Valve is used to control flow, the
fore it is put into operation. operational limits of the maximum flow velocity as well as the ca-
vitation limits must be observed. However, in this case VAG will
void any warranty issues, unless VAG authorized the operating
3 Product features mode in writing.

3.1 Features and function description The operational limits can be calculated either using the VAG
UseCAD® or the following calculation rules:
The VAG EKN® Butterfly Valve type AWWA is a fully flanged but-
terfly valve and can therefore be used both between two flanges Cavitation limits
and as an end-of-line valve without counter-flange and at full ope-
rating pressure. After the upstream and downstream pressures of the valve as well
as the flow rate have been determined, the cavitation value is cal-
The design of the VAG EKN® Butterfly Valve is that of an offset culated as follows:
valve with a double offset bearing of the disk. In closed position,
the disk is perpendicular to the direction of flow. To close or open Calculation of the σ-Value acc. AWWA M49:
the valve, the disk must be turned by 90°.

The body is sealed with an endless profile seal ring which in the
standard version is fixed by a retaining ring.

In closed position, the elastic profile sealing ring is pressed to the σ = cavitation index [dimensionless]
conical seat surface inside the body and safely seals in both flow
directions. Due to the double offset bearing of the disk, the profile Pd = downstream pressure [psig (kPa)]
seal ring is completely unstressed when the valve is in open posi-

VAG Operation and Maintenance Instructions • 5

Pv = vapor pressure adjusted for temperature and Permanent operation of the valve in throttle position will result in
atmospheric pressure,psig (kPa) = - 14.2 psig its increased wear and tear. The throttling operational limits ac-
(-97.5 kPa) for water at 60°F (16°C), measured cording to Section 3.3.1 need to be established.
at sea level

Pu = upstream pressure [psig (kPa)] 4 Installation into the pipeline

The VAG EKN® Butterfly Valve has the correct dimensions when • Danger: Danger of bruise between valve body and
the computed σ-value lies above the limit curve of σk. The recom- pipeline (-flanges) during installation!
mended control range lies between 10-100% opening degree.
Below that no reasonable control can be guaranteed. If cracking Death or serious injury can result if persons remain between valve
noises or vibrations occur while the valve is being put into opera- and pipeline!
tion, the actual operation conditions should be checked. In case -- Never stand under a suspended load!
of changed operation conditions, the equipment may have to be
recalculated. If the computed σ-value lies below the limit curves -- Lift the valve carefully until it is freely suspended.
of σk cavitation will occur. -- Avoid valve’s tilting by always moving it cautiously during lif-
ting and transport.
To remedy the problems, we recommend: -- Make sure that no person stays in hazardous area.
• Changing the downstream pressure
• Choosing a different place of installation
4.1 Conditions required on site
If the σ-value lies above the limit curves of σk the noise is caused
by other criteria and the pipeline will have to be checked. When installing the valve between two pipeline flanges, these
must be coplanar and in alignment. If the pipes are not in align-
ment, they must be aligned before installation of the valve, as
otherwise this may result in impermissibly high loads acting on
3.3.2 Maximum permissible flow velocity the valve body during operation, which may eventually even lead
to fracture.
While the medium flows through or against the valve disk, the
disk is exposed to forces of flow whose impact is determined by Caution: When installing the valve into the pipeline, make sure it
the flow velocity of the medium in the pipeline. Similar to a wing is as stress-free as possible. In plant piping, install so as to mini-
profile, a greater lift (or buoyancy) is generated at higher flow ve- mize bending of valve connection with pipe loading. It is recom-
locity and a changed angle of incidence. The same is true for the mended that valves be installed into piping system in accordance
disk inside the valve. The buoyancy generated is perceived as with AWWA M-44 in order to prevent any undue piping stress,
torque at the drive shaft. deflection or bending that may affect the performance of the val-
ve. Make sure valve disc, when opened, will not contact pipe port.
Caution: VAG EKN® Butterfly Valves type AWWA are designed/ This is especially necessary on pipe with linings and when wafer
sized for the following velocities in liquid media: valves are used. Check manufacturer for minimum pipe I.D. requi-
red for clearance.

• Pressure rating class 150 A: 8 ft/s (2,4 m/s) Prepare pipe ends and install valves in accordance with the pipe
manufacturer’s instructions for the joint used. Do no deflect pipe/
• Pressure rating class 150 B: 16 ft/s (4,9 m/s)
valve joint. Do not use valve as jack to pull pipe into alignment.

In case of works around the valve causing dirt (e.g. painting, ma-
3.4 Permissible and impermissible modes of sonry or working with concrete), the valve must be protected by
operation / Caution adequate covering.

VAG EKN AWWA Butterfly Valves are designed acc. AWWA 504 For assembly in drinking water pipelines, suitable sealing mate-
standard with maximum working pressure of 150 psi g and a ma- rials, lubricants and process materials must be used which are
ximum full open velocity of 16 ft / sec. Temperature range acc. approved for use in drinking water pipelines.
AWWA is 33° - 125° F.
Before putting the valve into operation, clean and purge the corre-
The VAG EKN® Butterfly Valve has its limit stop in the gearbox. sponding pipeline sections.
This stop limits both the open and the closed position. Due to the
automatic lock of the gear, it suffices to touch the end position.
Do not tighten it as this will not improve the tightness of the valve.
4.2 Installation location
Do not permit operation of any valve at pressure above the ra-
ted pressure of the valve. Do not exceed 300 ft.-lb. input torque The installation location of the valve must be selected to provide
on actuators with wrench nuts, 200 lb. rim pull input torque for sufficient space for function checks and maintenance works (e.g.
handwheels and chainwheels. If portable auxiliary actuators are dismantling and cleaning of the valve).
used, size the actuator or use a torque limiting device to prevent
application of torque exceeding 300ft. lbs. If an oversize actuator If the valve is installed in the open, it must be protected against
with no means of limiting torque is used, stop the actuator before extreme atmospheric influences (e.g. formation of ice) by adequa-
valve is fully opened or closed against stops and complete the te covers.
operation manually. Be sure to check actuator directional switch
against direction indicated on wrench nut, handwheel or records If the VAG EKN® Butterfly Valve is installed underground, the gear
before applying opening and closing torque. must be equipped with a cover for buried installation.

VAG Operation and Maintenance Instructions • 6

In case of submerged installation, increased actuation forces and
increased wear and tear (sometimes also accompanied by cor-
rosion) of the relatively moving parts are to be expected. This
must be taken into account when determining the maintenance
interals.

If the valve is installed as an end-of-line valve, it must be ensu-

red that its free outlet side is not accessible to interference from
any source.

Caution: Installing the valve in the wrong location may cause

excessive dynamic torque and damage the valve.

4.2.1 Installations in the pipeline upstream and

downstream of the valve / Caution
• If the valve is used in contaminated media, a filter with a suita-
ble mesh size must be provided upstream of the valve in order
to prevent malfunction.
• Directly upstream of (3 x Valve size) ) and downstream of (3 x
Valve size) the VAG EKN® Butterfly Valve an inspection valve,
an elbow, T-pieces and Y-filters should be provided as other-
wise irregular flow may disturb the proper function of the VAG
EKN® Butterfly Valve.
• A damping zone between the branch/elbow and the valve is
ideal.

EKN® EKN®
unfavourable favourable

3X
Valve
size

EKN®
ideal

Picture 5: Installation of the VAG EKN® Butterfly Valve at elbows and branches

VAG Operation and Maintenance Instructions • 7

• When installing a butterfly valve downstream of a
control valve or a plunger valve, make sure that
there is enough space between them (minimum
10 x Valve size).

min. 10 X
Valve size

Picture 6: Installation of the VAG EKN® Butterfly Valve with control valves installed upstream.

• Butterfly valves of a nominal diameter of up to 42“ can be in-

stalled vertically (with gear facing upwards or downwards) in
pipelines.
• In case of valves with larger nominal diameters, a special design
of the valve must be ordered due to the load of the disk.

vertically installation

Picture 7: Vertical installation of the VAG EKN® Butterfly Valve

VAG Operation and Maintenance Instructions • 8

4.2.2 Gear positions
The gear can be turned by 90° around the drive shaft.
• A: Flow on shaft side, seat surface on the outlet side, gear on the right
• B: Flow on the side away from the shaft, seat surface on the inlet side, gear on the left
• C: Flow on the side away from the shaft, seat surface on the inlet side, gear on the right
• D: Flow on shaft side, seat surface on the outlet side, gear on the left

Picture 8: Possible gear positions

VAG Operation and Maintenance Instructions • 9

4.3 Installation position
Caution: VAG EKN® Butterfly Valves type AWWA of all nominal
widths can be installed in horizontal position (with the gear facing
up or down).

Up to a valve size of 42“, EKN® Butterfly Valves type AWWA may

be installed in vertical position without restrictions (with the gear
facing up or down) in the pipelines. In case of valves with larger
nominal diameters, a special design of the valve must be selected
due to the load of the disk. Please consult VAG before placing
your order.

permissible

horizontal
installation position

vertical
installation position
• Permissible up
to valve size 42“
without restrictions.
• Valves with nominal
diameters exceeding
valve size 42“ requi-
re a special design
of the valve disk.
Please contact the
manufacturer before
placing your order.

impermissible
> valve size 42“

Picture 9: Installation positions

VAG Operation and Maintenance Instructions • 10

4.4 Assembly instructions and fittings bolted connections have been properly fastened.

Caution: Check the valve for possible damage that it may have
suffered during transport and storage. Protect the valve against 5.2 Function check and pressure test
dirt caused on the construction site by adequate covering until
Prior to installation, the function parts of the valve have to be ope-
installation. Prior to installation all components essential for pro-
ned and closed completely at least once and should be checked
per function, such as the seat and the sealing ring of the disk
for trouble-free operation.
must be thoroughly cleaned to remove all dirt particles. VAG does
not assume any liability for consequential damage caused by dirt, Caution: When a pressure test is performed in the pipeline with a
shot-blasting gravel residues etc. test pressure exceeding the admissible nominal pressure in clo-
sing direction, the pressure must be compensated by way of a
The sealing and operational parts should be checked for proper
bypass.
operation prior to installation.
If the VAG EKN® Butterfly Valve type AWWA is operated in dry
Should the valves be repainted later on, You should ensure that
state, higher actuation torques may be expected.
no paint is applied to the sealing and operational parts . The iden-
tification plates must not be painted over either. If the equipment Newly installed pipeline systems should first be thoroughly purged
is sand-blasted for cleaning prior to installation, these parts must to remove all foreign particles. Residue or dirt particles present
be adequately covered. If solvents are used for cleaning, You in the pipeline may impair the function of the valve .or prevent its
should ensure that the solvents do not destroy the seals of the free movement.
pipeline or the valve.
In particular after repair work or upon the commissioning of new
For the assembly of the VAG EKN® Butterfly Valve type AWWA it equipment, the pipeline system should be purged again with the
must be ensured that proper load suspension devices as well as valve being fully open position. If detergents or disinfectants are
means of transport and lifting devices are available. used it must be ensured they do not attack the valve materials. As
a standard, the valve is closed by turning clockwise at the gear.
In open position, the disk of the VAG EKN® Butterfly Valve type
AWWA protrudes beyond the overall length. It needs to be made The dimensions of the stems and actuators allow operation of the
sure that there is sufficient space between the disk and other ins- valve by one person via the handwheel. Extensions for operation
tallations in the pipeline. are not permissible as they may damage the valve due to exces-
sive force. The 90° turn is limited by a limit stop located at the
Suspending the valve by its disk may lead to damage to or de-
gear. If it is turned further using excessive force, this may cause
struction of the disk or valve.
damage. Proper function is to be checked by opening and closing
When connecting the valve with the pipeline flanges, hexagon the valve several times.
bolts and nuts with washers from flange to flange must be used
in the through holes. Fasten the bolts evenly and crosswise to
prevent unnecessary tension and the resulting cracks or breaks. 5.3 Putting electric actuators into operation
The pipeline must not be pulled towards the valve. Should the gap Turn the valve into medium intermediate position by hand. Check
between valve and flange be too wide, this should be compen- the rotary motion at the gear and thus the direction of rotation of
sated by thicker seals. the motor by shortly starting the actuator electrically. If the direc-
The material of the seal needs to be selected according to the tion of rotation is wrong, reverse the polarity of the motor con-
operation conditions. nection.

The operator needs to select bolts and nuts suitable for the res- By short electrical start-up, check the direction of rotation again
pective operation pressure, temperature, the flange material, the by checking the direction of motion.
operational loads and the seal. As depending on the seal materials Check the switch-off function of the torque and limit switches in
used and whether they are used in main friction connections or both directions by manually operating the switches in intermedia-
secondary friction connections, very different tightening torques te position. Reverse the polarity, if necessary. The valve must not
of the flange bolts result, the operator must choose the tightening be operated over its entire travel until the direction of rotation and
torque of the flange bolts according to the above parameters. the switch-off function are correct.
Do not over-tighten the bolts of the flanges as this may result in
the flanges cracking. Caution: If the direction of rotation is wrong, the limit and torque
switches have no effect at all!
While the valve is being installed, it must be ensured that the
flanges of the pipeline it is connected to are aligned and level with
each other. Welding works on the pipeline must be performed be-
fore the valves are installed to prevent damage to the seals and 6 Actuators
the corrosion protection. Welding residue must be removed befo-
re the equipment is put into operation. Warning: Non compliance of these directives may cause
The pipeline must be laid in a way that prevents harmful pipeline danger to life and limb and/or cause damage
forces from being transmitted to the valve body. Should construc- to material or pipeline system.
tion works near or above the valve not be completed yet, the valve
must be covered to protect it from dirt. 6.1 General
Actuators (gears, pneumatic, hydraulic and electric actuators)
are designed for flow velocities according to AWWA Class 150 B
(valves used for water supply; requirements relating to fitness for
use). Any deviating operating conditions need to be specified. The
adjustment of the limit stops (OPEN, CLOSE) must not be chan-
5 Set-up and operation of the valve
ged without the manufacturer’s consent.
5.1 Visual inspection and preparation Caution: Danger of damages to the VAG Butterfly Valve!. False
Before putting the valve and the equipment into operation, per- settings of limit stops may cause mechanical risk of injury of the
form a visual inspection of all functional parts. Check whether all valve and gearbox.

VAG Operation and Maintenance Instructions • 11

 Operation via the emergency handwheel is intended for short peri-
If valves are installed without gear units it must be ensured that ods only, for commissioning and for exceptional situations.
the valve is not pressurised.
The emergency handwheel is not suitable for continuous opera-
• Warning: Uncontrolled rotation of the valve shaft!. tion.
Danger of damage to the VAG Butterfly Valve / Pipeline
system! Death or serious injury can result if body parts or If, in intermediate position, a foreign body gets jammed in the
pieces of clothing get caught up in rotating shaft. valve, this may result in higher operating forces – especially with
heavily geared down actuators – which in turn may damage the
-- Never operate the butterfly valve without gearbox in a pres- actuation components. Therefore:
surised pipeline!
-- Make sure that no pressure is in the pipeline when you dis- If you meet any resistance while operating the valve with the emer-
mantle the gearbox from the valve! gency handwheel, turn the handwheel in the opposite direction for
some turns and then turn it in the direction again in which the
For detailed information on gears and actuators, please refer to disturbance was found (washing out of the foreign body). Conti-
the operation manuals issued by the manufacturers of these com- nue operation very carefully, never use excessive force and repeat
ponents (e.g. AUMA, Rotork). washing, if necessary.
The VAG EKN® Butterfly Valve has an adjustment angle of 90°.
The valve itself is not equipped with position limiters.
6.4 Assembly of the electric actuator
The actuator must be equipped with limit stops. The actuator
must be designed so that it turns counter-clockwise in relation to The electric actuator is mounted to the input flange of the gear
the valve shaft! unit. The actuator size is selected according to the maximum ac-
tuation elements.
The limit position adjustment is to be done in compliance with
the operating manuals issued by the respective gear manufactu- The valve is switched off:
rers, such as AUMA, Rotork etc. In case a gear is retrofitted, its • position-dependent in Open position
nominal torque and the adjustment of the limit stops “OPEN” and
“CLOSE” must be adapted to the valve. • position-dependent in Closed position

Non-compliance with these regulations may endanger life and The switch settings are factory-adjusted. The torque switches
limb and/or cause damage to the pipeline system. If actuators serve as overload protection in the intermediate positions. If the
powered by external sources of energy (electric, pneumatic or hy- valve is retrofitted with an electric actuator, the position switches
draulic) have to be disassembled from the valve, the safety inst- have to be adjusted after the actuator has been mounted. For the
ructions under Section 1.1 needs to be observed and the external adjustment procedure, please refer to the operating manual issu-
source of energy must be switched off and isolated. ed by the manufacturer of the electric actuator.

The relevant safety regulations and the instructions of the manu-

6.2 Operating torques facturer of the electric actuator must be observed.

Operating torques are the maximum required torques acting on When the items are delivered, the adjustment screws and the
the actuator stem at full differential pressure including a safety connection bolts of the gear and the electric actuator are sealed
factor of 1.5. If required, you can contact us for information about with labels and/or identified by colour markings. The removal
the respective torques and/or controlling torques for electric ac- or breaking of these identifications will result in the loss of the
tuators. manufacturer’s warranty.

6.3 Emergency manual operation (handwheel) • Caution: Non-observance of the warnings and notes may
result in serious injuries or damage. Qualified personnel must be
• Caution: If the valve is operated via the handwheel of the thoroughly familiar with all warnings and notes in these opera-
electric multiturn actuator, the torque switches do not have any tion instructions.
safety function.

Picture 10: Gearbox markings

VAG Operation and Maintenance Instructions • 12
 Death or serious injury can result if persons remain between valve
7 Maintenance and repair and pipeline!
-- Never stand under a suspended load!
7.1 General safety instructions
-- Lift the valve carefully until it is freely suspended.
Caution: Prior to the performance of inspection and maintenance -- Avoid valve’s tilting by always moving it cautiously during lif-
work on the valve or its assemblies, shut-off the pressurised pipe- ting and transport.
line, depressurise it and secure it against inadvertent activation. -- Make sure that no person stays in hazardous area.
Depending on the type and risk of the fluid conveyed, comply
with all required safety regulations! After completing the mainte- • Danger: Dangers from electrical current!
nance works and before resuming operation, check all connec- Death or serious injury can result when coming into
tions for tightness. Perform the steps described for initial set- contact with energised parts.
up as described under Section 5 “Set-up and operation”. A VAG
EKN® Butterfly Valve type AWWA not equipped with a gear unit is • Warning: Suspended Load! All parts of the valve can tilt
not self-locking. The actuator/the gear unit may not be disassem- and can be damaged while being lowered!
bled as long as the valve is pressurised. This also applies in case Danger of injury during lifting and transport.
the valve is completely dismantled. Statutory and local provisions
as well as the safety and accident prevention regulations must be
observed and complied with at all times. Couplings and connec-
tions must never be disassembled when they are under pressure. 7.2 Inspection and operation intervals
Servicing, maintenance and inspection work as well as the repla-
cement of spare parts must only be done qualified staff. The plant The valve should be checked for tightness, proper operation and
operator is responsible for determining the suitability of the staff corrosion protection “at least once per year” .
or for ensuring the relevant qualifications.
In case of extreme operating conditions inspection should be per-
In case the operator’s employees do not have the qualifications formed more frequently.
required, they need to attend a training course. This training
course can e.g. be held by VAG Service employees. In addition to
this, the plant operator needs to ensure that all employees have
understood these Operation and Maintenance Instructions as well 7.3 Maintenance work and replacement of
as all further instructions referred to in them. Protective equip- parts
ment such as safety boots, safety helmets, goggles, protective
gloves etc. must be worn during all work requiring such protective
equipment or for which such protective equipment is prescribed.
Improper or wrong use of the valve should be avoided. Prior to the 7.3.1 Design
performance of any work on the valve and equipment it must be
ensured that the relevant pipeline section has been depressurised The design view in Picture 11 serves as a partial overview for the
and/or de-energised. descriptions of the working steps below.
• Danger: Danger of bruise between valve body and
pipeline (-flanges) during removing the valve!

14 10 13 20 7 1 8 12 11 15 5.3 5.1 3 4.1 2

No. Designation Material

ASTM A536,
1 Body Grade 65- 17 16

45-12 No. Designation Material

ASTM A536, 11 Bearing cover A383C-A
2 Disk Grade 65-
45-12 12 Bearing bush C90800
3 Profile seal EPDM
13 Spacer bush AISI 304
4.1 Retaining ring SA 105
5.1 Hexagonal screw SA 193 B8M 14 Hexagonal screw A383C-A
5.3 Washer AISI 316 15 Threaded pin A383C-A
A276 Grade 16 O-Ring EPDM
7 Shaft, driven end
304
A276 Grade 17 O-Ring EPDM
8 Shaft, free end
304
10 Bearing flange A383C-A A276 Grade
20 Tapper pin
431

Picture 11: Design and sub-assemblies

VAG Operation and Maintenance Instructions • 13
7.3.2 Recommendations for the replacement unfastened and the bearing flange (10) as well as the bearing
cover (11) are pulled off. Slightly grease the O-rings (17 / 16)
of parts with KLÜBERSYNTH VR 69-252 before installation.
Profile seals and O-rings must be replaced whenever necessary.
The replacement intervals depend on the operating conditions.

7.3.3 Cleaning and lubrication

When being replaced, the profile seal and the O-rings should al-
ways be lightly greased. Use lubricants with approval for applica-
tion with foodstuffs or drinking water.
Recommended lubricants:
• For the profile seal and the O-rings: KLÜBERSYNTH VR 69-252
(NFS61-approved)
Manufacturer: Klüber Lubrication München AG, Germany.

7.3.4 Replacement of the profile seal

Due to the double-offset bearing, the profile seal can be replaced
without disassembly of the disk. Valves of up to valve size 36“
must either be completely dismantled from the pipeline or at least
Picture 13: Replacement of O-ring - Step 2
disconnected from the pipeline on one side to replace the profile
seal. In the same way as for the installation of the disk, all safety
precautions need to be taken.
Disassembly of the sealing ring: • Reassembly is done in reverse order
• Open the disk (2) until the profile seal (3) emerges from the body • Tighten the hexagonal screws (14) only slightly to prevent ten-
sioning the bearing bush (12) on the disk (2). Secure the flange
• Unfasten the retaining ring screws (5.1)
position using the threaded pins (15).
• Remove body (1) and sealing ring (3)
• Clean the disk (2) in the sealing zone
• Check the seat ring in the body for damage or deposits
• Insert the new sealing ring into the groove of the disk and slight-
ly grease it with KLÜBERSYNTH VR 69-252 (NFS61-approved)
• Insert the hexagonal screws (5.1) and fasten them.

7.3.5 Replacement of the O-rings in the

bearing
For this kind of maintenance work, the valve must be depressu-
rised.
• Turn the butterfly valve (2) into closed position
• Unfasten the hexagonal nuts at the gear flange and pull the gear Picture 14: eplacement of O-ring - Step 3
off the shaft (7)
• Loosen the threaded pin and pull off the coupling. Pull the ad- • Assemble the adjustment spring (20) and the coupling
justment spring (20) off the shaft
• Before mounting the gear, check whether the disk position and
• In the depressurised pipeline, the hexagonal screws (14) are the gear position match

Picture 12: Replacement of O-ring - Step 1 Picture 15: Replacement of O-ring - Step 4

VAG Operation and Maintenance Instructions • 14

• Fasten the gear fixing screws
9 How to contact us

Head office

VAG-Armaturen GmbH

Carl-Reuther-Str. 1

68305 Mannheim

Germany

Phone: +49 (621) 749-0

Fax: +49 (621) 749-2153

info@vag-group.com

http://www.vag-group.com
Picture 16: Replacement of O-ring – Step 5
Service
• If necessary, readjust the limit stop of the gear. The limit stop
Our service hotline can be reached 24/7 world-wide. In case of
must only be adjusted when the valve is in closed position.
emergency, please contact us by phone.
AUMA worm gear units are adjusted as specified in the AUMA
90° Gear Operation Manual.
Service hotline: +49 621 - 749 2222

Service per email: service@vag-group.com

8 Trouble-shooting
Caution: For all repair and maintenance work, please observe the
general safety instructions described in Section 7.1!

Problem Cause Remedial action

Unfavourable installation position

causing unfavourable flow around Change installation position
or inside the valve (e.g. installed too
Valve makes noise
closely downstream of an elbow etc.)

Check design and/or operation data, change flow resistance

Valve operating beyond its design limits
in the valve, if required, by using different internals

Foreign matter jammed in the seat area Flush valve, dismantle, if necessary, and remove foreign matter

Gear blocked Undo block

Valve cannot be operated No electrical connection of electric actuator Establish electrical connection

Unfavourable flow and im-

Change installation position
pairment of movement

Valve not completely closed yet Close valve completely

Leaks in the body seat
Valve seal damaged or worn Replace seal

Valve operating beyond its design limits Butterfly valve not suitable for use as control valve. Re-
Cavitation in valve
Operational data changed place valve by a more suitable valve type.

Leaks at the body Deterioration of seals Replace seals

Seat of the valve polluted by deposits Flush valve, dismantle, if necessary, and clean seat area

High operating forces

Valve is dry in pipeline, no medium present Valve can be operated more easily when wet

VAG Operation and Maintenance Instructions • 15

 Edition2 -10/2012

www.vag-group.com
info@vag-group.com