Irrigationglobal D-040 Combination Air Valve Instruction Manual

Irrigationglobal D-040 Combination Air Valve

Product Specifications

• Model: A.R.I. D-040 Combination Air Valve
• Features: Combination of air release valve and air & vacuum valve

Product Usage Instructions

Safety Instructions:
It is essential to follow all safety instructions provided in the manual to ensure safe installation, operation, and maintenance of the A.R.I. D-040 Combination Air Valve. Always comply with relevant safety standards and use qualified personnel for handling the product.

Installation:
Follow the step-by-step installation guide provided in the manual. Ensure that installation is carried out by qualified workers using good engineering practices. Properly connect the valve to the pipeline or piping system.

Operation:
The air release component of the valve automatically releases small pockets of air to the atmosphere as they accumulate in the pipeline under pressure. Ensure that the valve is operating effectively by monitoring its performance regularly.

Troubleshooting:
If any issues arise with the operation of the A.R.I. D-040 Combination Air Valve, refer to the troubleshooting section in the manual for guidance on identifying and resolving common problems.

Periodic Maintenance:
Regular maintenance is essential to ensure the proper functioning of the valve. Follow the maintenance procedures outlined in the manual, including preparation steps and first and second stage maintenance tasks.

FAQ

Can the A.R.I. D-040 Combination Air Valve be used with hazardous liquids?
The product is designed for hazardous liquids systems. Consult Aquestia for specific pressure and temperature specifications and for other products suitable for hazardous environments.

INTRODUCTION

• The following is a step by step narrated description of the A.R.I. D-040 Combination Air Valve installation, operation and maintenance processes.
• A.R.I. D-040 series Combination Air Valve has the features of both an air release valve and an air & vacuum valve. The air release component is designed to automatically release small pockets of air to the atmosphere as they accumulate along a pipeline or piping system when it is full and operating under pressure.
• Please consult Aquestia for the pressure and temperature framework of this model specifications table and for other products designed for hazardous liquids systems.

Disclaimer

• This document is an Installation, Operation and Maintenance (IOM) manual for Aquestia Ltd. The information enclosed herein contains restricted, privileged, proprietary and confidential information, intended only for usage by authorized Aquestia technicians. If you are not a qualified technician, you must not take any action in reliance upon this document, unless otherwise permitted in writing by Aquestia
• Aquestia has made every effort to ensure that this document is accurate; Aquestia disclaims liability for any inaccuracies or omissions that may have occurred.
• All the procedures, drawings, pictures and/or any other information provided in this document are presented as general information only; they can be altered, removed or changed without Aquestia’s prior written approval.
• Aquestia makes no commitment to update or keep the information in this document current and/or up-to- date, and reserves the right to make improvements, alterations and/or modifications to this document and/or to the products described in this document, at any time without providing any notice with respect thereto. Nothing in this Disclaimer derogates in any way whatsoever from the confidential nature of any document enclosed hereto, including for avoidance of doubt, any mistake or clerical error or other error. None of the procedures provided in this Disclaimer and/or in any document enclosed hereto may be used in any form or by any means without the prior written consent from Aquestia If you received this Disclaimer and/or in any document enclosed hereto in error or by mistake or if this Disclaimer and/or in any document enclosed hereto is not intended for you, please notify Aquestia in writing immediately.
• Aquestia assumes that all users understand the risks involved within this Disclaimer and/or in any document enclosed hereto. Aquestia accepts/assumes no liability whatsoever, whether caused by: accessing and/or relying upon this Disclaimer and/or in any document enclosed hereto including without limitation any links, procedures or materials.
• shall NOT assume any liability for any costs, direct or indirect, including loss of income, loss of profits and/or goodwill, legal actions and/or damages of any kind whatsoever including any, damages accidents, equipment damage or bodily injury resulting from and/or related to any of the following:
  • product has not been duly installed and thereafter maintained in strict compliance with its designated Maintenance Instructions and/or any other installation and operation manuals provided by Aquestia for the product and/or applicable ordinances and/or codes;
  • Repairs made in and to the products by personnel not authorized by Aquestia
  • Maintenance or repairs using parts or components other than those specified by Aquestia and in their original condition.
  • Operating the products in ways other than the operating procedures described in the manuals provided by Aquestia, or resulting from not following the cautionary remarks and warnings in the product manual.
  • Improper storage, workplace conditions and environmental conditions which do not conform to those stated in the Product manual.
  • Fires, earthquakes, floods, lightning, natural disasters, or acts of God.
• Aquestia does not warrant and hereby disclaims any express or implied warranties that the product will work properly in environments and applications other than its original design purpose, and makes no warranty and representation, either implied or expressed, with respect to the quality, performance, merchantability, or fitness for any other particular purpose. Except as provided herein and to the full extent permitted by law, Aquestia shall not be responsible and/or liable for direct, special, incidental or consequential damages or loss resulting from any breach of the above or under any other legal theory. This document does not replace any certified drawing, procedure or information provided by Aquestia in reference to a specific customer, site or project. All rights reserved.

Safety Instructions

General

1. Aquestia products always operate as components in a larger system. It is essential for the system designers, installers, operators and maintenance personnel to comply with all the relevant safety standards.
2. Installation, operation or maintenance of the product should be done only by qualified workers, technicians and/or contractors using only good engineering practices, complying with and observing all conventional safety instructions in order to minimize risk and/or danger and/or hazard to workers, the public or to property in the vicinity in accordance with all relevant local standards.
3. Extra safety considerations should be taken with hot and hazardous liquids or in hazardous environments’ applications to avoid bodily/physical harm and damage to public or private property.
4. All individuals installing operating and/or handling the products including all workers should at all times adhere with the occupational safety and health (OSH) instructions and wear safety helmets, goggles, gloves, and any other personal safety equipment required by the local standards and regulations.
5. Use only appropriate standard tools and equipment operated by qualified operators when installing, operating and maintaining the product.
6. Prior to installation, operation, maintenance or any other type of action carried out on the product, read carefully the safety, installation and operation instructions of the product.
7. Please note:
   • Pressurized fluid and/or gas may be discharged from the product without prior warning. Make sure that the product’s outlet port is not directed toward electrical elements (pumps) or people.
   • The pressurized fluid and/or gas that can be discharged from the product may create high noise levels. Take this into consideration when installing the product in areas sensitive to noise.
8. Always open and close valves slowly and gradually.
9. Please note that the maximum working pressure indicated at the product’s specifications table doesn’t include pressure changes caused by water hammer and pressure surge effects. Use the product only according to its designated pressure rate specifications.
10. Use the product only for its intended use as designed by Aquestia Any misuse of the product may lead to undesired damages and may affect your warranty coverage. Please consult with Aquestia prior to any non regular use of this product and make no change or modification to the product without a prior written consent to be provided by Aquestia at Aquestia’s sole discretion.
11. Please note that Aquestia shall NOT assume any liability with respect to any damage losses and/or expenses caused to any person and/or property whatsoever unless the product has been duly installed and thereafter maintained in strict compliance with its designated maintenance Instructions and/or any other installation and operation manuals provided by Aquestia for the product and/or applicable ordinances and/or codes.

Handling

1. Shipping and handling the product must be done in a safe and stable manner and in accordance with the relevant standards and regulations.
2. For lifting and positioning the product, use only approved lifting equipment operated by authorized employees and contractors.
3. Prior to the installation visually verify that the product was not damaged during shipment to the installation site.

Installation

1. Install the product according to the detailed Installation Instructions provided with it by Aquestia and according to the description given in this manual.
2. The user should install a manual Isolation Valve under the product’s inlet port.
3. In all installation sites the user should enable good visibility and verify that the work and auxiliary equipment used are done in accordance with the relevant local authorized standards. Extra safety considerations should be taken on hazardous environment sites.
4. Check and re-tighten the bolts connecting the product to the pipeline during commissioning and before operating the product for the first time.

Commissioning and operation

1. Read carefully the operation instructions prior to any attempt to operate the product.
2. Observe the safety stickers on the product and never perform any operation contradicting the instructions given.
3. In order to achieve maximum performance and smooth operation of the product it is crucial to perform the startup and first operation procedures exactly as described in this manual.
4. In cases where formal commissioning procedure is required it should be done by an authorized Aquestia technician prior to the first operation of the product.

Maintenance
Before any maintenance or non regular operation please read the following:

1. Servicing the product should be done only by qualified technicians for this type of work.
2. Make sure that you know the exact type of the system’s fluid. Act accordingly and comply with all the relevant standards and regulations set for handling this type of fluid.
3. Before disconnecting the product from the system and before releasing the residual pressure do NOT:
   • loosen or unscrew the product bolts;
   • remove any protection cover;
   • open any service port.
4. Before any maintenance or non regular operation shut off the Isolation valve and release the residual pressure:
   • For air valves with pressure release outlet, slowly open the pressure release plug or the ball valve and make sure that all pressure is released. Please note that some air release valves, especially the waste water models, may contain significant volume of compressed gas with accumulated energy!
   • For air valves without a pressure release outlet, slowly unscrew the flange bolts until all the pressure is released from the valve.
5. Make sure the air valve is empty of all liquid prior to commencing maintenance.
6. Remove the product from the line only after ensuring that internal pressure has been released.
7. Place warning signs around the work area as required by the local standards and procedures.
8. Inspect the product’s safety stickers and replace any damaged or faded sticker.
9. Manual cleaning of the product and/or its components using high water pressure or steam should be performed in accordance with its specific cleaning instructions, the local standards and regulations and without endangering the operator or the vicinity
10. Manual cleaning of product and/or its components using acid or other chemical agents should be performed in accordance with the specific cleaning instructions, the relevant safety instructions for using that chemical as given by its supplier, the local standards and regulations and without endangering the operator or his vicinity.
11. For products used in potable water systems if it is required to disinfect the product, do so according to the local water authority standards and regulations before putting the product into service.

Before returning to regular operation

1. Re-assemble any protection covers or protection mechanisms removed during service or maintenance operations.
2. Make sure that all the tools, ladders, lifting devices, etc. used during the maintenance procedures are taken away from the product area and stored.
3. Remove grease and fat material residues in order to avoid slipping.
4. In order to return the product to regular operation, follow the First Start-up Operation instructions as detailed in your user manual.

Installation

Important: Before performing any work on the air valve make sure that all workers on site are familiar with the safety instructions and the relevant local and general safety instructions and work regulations.

Installation Recommendations

• Single Air Valve on an Isolating Valve at 45° to Air Valve outlet

• Two Air Valves on a shared Isolating Valve. Air Valves outlets face outward and the Isolating Valve at 45° to Air Valve outlets

• Two Air Valves on an Air Trap with separate Isolating Valves. Air Valve outlets face outward and the Isolating Valves at 45° to Air Valve outlets

• Underground Installations

  • Underground installations require a venting pipe from the manhole
  • Use an angular installation to bypass an obstacle directly above the pipeline.

Conventions and Measurements

• This paragraph presents and explains the terms and measurements used for the Installation process.

  • D = Diameter of pipeline
  • d = diameter of riser
  • H = Height of riser on the pipeline (Measured from crown of pipeline)

• For pipelines up to 12″ (300mm) in diameter (D), the Air Trap diameter (d) should be the same as the pipeline diameter.

• For larger pipelines of up to 60″ (1500mm) in diameter (D), the Air Trap diameter (d) should be 60% of the pipeline diameter.

• For larger than 60″ (1500mm) pipelines (D), the Air Trap diameter (d) should be 35% of the pipeline diameter.

• The Air Trap length (H) should allow easy access to the air valve from below and should be at least 6″ (150mm).

Installation Instructions

1. Flush the system before installing the air valve to avoid any debris or sharp objects getting into the air valve.
2. Carefully remove the air valve from the shipping package. Unload all air valves carefully to a sturdy level surface taking care not to drop them.
3. Install an isolating valve below the air valve, connected by a riser to the crown of the pipe.
4. The D-040 combination air valve should be installed vertically on a riser on the crown of the pipeline.

Operation

The D-040 series Combination Air Valve has the features of both an air release valve and an air & vacuum valve. The air release component is designed to automatically release small pockets of air to the atmosphere as they accumulate along a pipeline or piping system when it is full and operating under pressure. The air & vacuum component is designed to automatically discharge or admit large volumes of air during the filling or draining of a pipeline or piping system. This valve will open to relieve negative pressures whenever water column separation occurs.

Troubleshooting

gently pry off the outlet with screwdriver Pressure insert the replacement part using a plastic hammer. Replacement part can be ordered from Aquestia.

Note: The part is not mandatory for the function of the valve.

Outlet thread size needed in order to attach a vent/ drain pipe| End user needs to connect a vent/drain pipe from the discharge outlet.| 1″ D-040 has 3/8” female thread. 2” D-040 has 1¼” female thread.

End of pipe must be left open in order for valve to

function.

Valve spits water.| This is normal at start up and during pressure test. Could be debris stuck to the

sealing mechanism.

| Perform steps for BASIC MAINTENANCE
Valve is continuously leaking.| Line pressure issues (inadequate pressure) or debris lodged in seal or O- rings.| Check line pressure. It needs at least 0.2bar (3 psi) to seal tight.

Is the valve on a booster pump? Can be an installation issue if the valve is level with the water level in a tank – there is no pressure to seal.

Perform steps for BASIC MAINTENANCE

Valve leaks from threads.| Damaged O-ring

Plastic threads stripped.

| Replace the Base O-ring

Check for cross-threading. Replace Base. Offer to replace with a metal Base.

Periodic Maintenance

• Please note that the periodic maintenance of the air valve is an integral part of the proper pipeline maintenance regime; it should be maintained at least once a year in accordance with the quality and composition of the fluid in the system.
• Important: Before performing any work on the air valve, make sure that all workers on site are familiar with the safety instructions section of this document and with all the relevant local and general safety instructions, standards and work regulations.

Preparation

Required tools and materials:

• Small bowl with kitchen type liquid soap
• 4.5mm roll pin punch

First Stage Maintenance

Perform when a small leak is detected from the Discharge Outlet Elbow and clogging or debris in the sealing mechanism is suspected

Releasing Pressure

• Shut the isolating valve located on the riser under the air valve
• Carefully release the pressure and drain the air valve
• Important: Discard liquid to comply with local regulations

Removal of the Valve’s Body

• Slowly turn the Body (1) counterclockwise, and remove it [2]
• Remove the Discharge Outlet Elbow [3], [4] (snap-on or thread)

Cleaning of the Air Valve

• Thoroughly wash and clean the air valve components under clean running water to remove all grime; Pay special attention to the internal parts.
• Thoroughly clean the O-ring (replace it if needed [1]. Make sure that the O-ring is correctly seated in its designated groove [2].

Assembly and Testing for Leaks

• Reassemble the air valve in reverse order of paragraphs 5.2.3 and 5.2.2.
• Slowly open the isolating valve located on the riser under the air valve.
• Look for leaks in the Outlet Discharge Elbow.
• If the air valve still leaks, proceed to Second Stage Maintenance

Second Stage Maintenance

Perform if the first stage doesn’t solve the leak, if one of the seals or inner parts need replacement or for periodic maintenance to thoroughly clean the valve.

Releasing Pressure

• Shut the isolating valve located on the riser under the air valve
• Carefully release the pressure and drain the air valve
• Important: Discard liquid to comply with local regulations

Removal of the Air Valve Body

• Slowly turn the Body (1) counterclockwise, and remove it [2]
• Remove the Discharge Outlet Elbow [3], [4] (snap-on or thread)

Disassembly of the Float
Hold the Body, turn it to the side [1] and remove the Clamping Stem [2] and the Float [3] (together with the Rolling Seal

Cleaning and inspecting the components

• Thoroughly but gently wash and clean all the components under clean running water. Pay attention to the sealing area inside the Body.

• Visually check the condition of the Rolling Seal [1] & [2]. If any cracks or tears are found remove it from the Float and replace it.

• If replacement is necessary, slide out and remove the Rolling Seal Assembly [3]

• Take a new Rolling Seal Assembly and dip the tail end into the liquid soap solution [4]

• Pay attention to the correct position and direction and insert the tail end of the Rolling Seal Assembly into the groove on the Float [5].

• Gently pull the Rolling Seal Assembly until it is partially inserted into the Float grove. Use the 4.5mm Roll Pin Punch to push the Rolling Seal Assembly to the middle of the Float [6] and align the middle of the Rolling Seal Assembly tail with the midline of the Float [7].

Reassembling the Operating Valve

• Dip the head end of the Rolling Seal into the liquid soap solution [1]

• Reassemble the Operating Valve by inserting the loose end of the Rolling Seal into its designated groove in the Body [2] & [3], making sure that the insertion direction of the seal’s end is as shown by the arrows.

• Insert the Float halfway into the Body [1], insert the Clamping Stem into the Rolling Seal groove of the Body; make sure that it is inserted in the direction of the arrow [2]. Push the Float and the Clamping Stem together downwards into the Body until they are locked [3].

Assembly and Testing for Leaks

• Reassemble the air valve in reverse order of chapter 5.2.
• Slowly open the isolating valve located on the riser under the air valve.
• Look for leaks in the Outlet Discharge Elbow.

Assembly Bom Table and Drawing

1. Body
2. Discharge Outlet Elbow
3. Clamping Stem
4. Float
5. Rolling Seal Assembly
6. O-ring
7. Base

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