A.R.I. D-060 Owner's manual

D060.IOM.ENG03 SH
Installation, Operation & Maintenance
COMBINATION AIR VALVE
MODEL D-060 D-060-C D-062 D-065 D-060L
The following is a step-by-step narrated description of the A.R.I. D-060 combination air valve installation,
operation and maintenance processes.
The D-060 air valve has the features of both an Automatic 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.

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TABLE OFCONTENTS
1. SAFETY INSTRUCTIONS ............................................................................................................................... 3
Safety Instructions - General................................................................................................................................... 3
Safety Instructions - Handling ................................................................................................................................ 3
Safety Instructions - Installation ............................................................................................................................. 3
Safety Instructions - Commissioning and Operation ............................................................................................ 4
Safety Instructions - Maintenance.......................................................................................................................... 4
Safety Instructions - Before returning to regular operation.................................................................................. 4
2. INSTALLATION............................................................................................................................................ 5
2.1
.
Installation Recommendations ......................................................................................................................... 5
2.2. Conventions and Measurements.................................................................................................................. 6
2.3. Installation Instructions ............................................................................................................................... 7
2.4. Directions for Discharge Outlet..................................................................................................................... 7
3. OPERATION ................................................................................................................................................ 8
4. PERIODIC MAINTENANCE ........................................................................................................................... 9
4.1. Preparation ................................................................................................................................................... 9
4.2. Maintaining the Automatic Air Release valve –S-050 ............................................................................. 10
4.3. Maintaining the Automatic Air Release valve - S-050C / S-052 .............................................................. 12
4.4. Maintaining the Automatic Air Release valve - S-050L ........................................................................... 14
4.5. Maintaining the Automatic Air Release valve - S-015 ............................................................................. 16
4.6 Maintaining the Air & Vacuum valve ....................................................................................................... 18
5. TROUBLESHOOTING ..................................................................................................................................20
6. A.R.I. LIMITED WARRANTY ........................................................................................................................21
Disclaimer
ThisdocumentisanInstallation,OperationandMaintenance(IOM)manualforA.R.I.FlowControlAccessoriesLtd.(A.R.I.)products.Theinformationenclosedherein
containsrestricted,privileged,proprietary andconfidentialinformation,intendedonlyforusagebyauthorizedA.R.I.technicians.Ifyouarenotaqualifiedtechnician, you
must not take any action in reliance upon this document, unless otherwisepermitted in writingby A.R.I.
A.R.I. has made every effort to ensure that this document is accurate; A.R.I. 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,
removedor changedwithoutA.R.I.'spriorwrittenapproval.A.R.I. makesnocommitmentto updateorkeepthe informationin thisdocumentcurrentand/orup-to-
date, and reserves therighttomake improvements, alterations and/or modifications tothis document and/or totheproducts described in this document, at any time
without providing any notice with respectthereto. Nothing in this Disclaimerderogates in any way whatsoever fromthe confidentialnatureof any document enclosed
hereto, including for avoidanceof doubt, any mistake orclericalerrororother error. None oftheprocedures 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 A.R.I. If you received this Disclaimer and/or in any document
enclosed heretoin error or by mistakeorif this Disclaimer and/or in anydocumentenclosed heretois notintendedforyou, please notify A.R.I. in writing immediately.
A.R.I. assumes that all users understand the risks involved within this Disclaimer and/or in any document enclosed hereto.
A.R.I. accepts/assumes noliability whatsoever, whethercaused by: accessing and/or relying upon this Disclaimer and/or in any document enclosed hereto including
withoutlimitationanylinks,proceduresormaterials.
A.R.I. shallNOT assume any liability for any costs, directorindirect, including loss of income, loss ofprofits and/or goodwill, legalactions and/or damages ofany kind
whatsoever including any, damages accidents, equipmentdamage or bodily injury resulting fromand/or related toany of thefollowing:
• producthasnotbeendulyinstalledandthereaftermaintained in strict compliance with its designated Maintenance Instructions and/or any other installation and
operationmanualsprovidedby A.R.I.fortheproduct and/orapplicableordinancesand/orcodes;
• Repairs madein and to the products by personnelnotauthorizedby A.R.I.
• Maintenanceor repairs using parts orcomponents otherthan thosespecified byA.R.I. andin their originalcondition.
• Operating theproducts in ways other thantheoperating procedures described in themanuals provided by A.R.I., orresulting from notfollowing the
cautionary remarks and warnings intheproductmanual.
• Improper storage, workplace conditions and environmental conditions which do not conform to those stated in the Product manual.
• Fires,earthquakes,floods,lightning,naturaldisasters,oractsofGod.
A.R.I. does notwarrant and hereby disclaims any express or impliedwarranties that theproductwill work properly in environments and applications other thanits original
designpurpose,andmakesnowarrantyandrepresentation,eitherimpliedorexpressed,withrespecttothequality,performance,merchantability,orfitness foranyother
particularpurpose.
Exceptas provided hereinandto the fullextentpermitted by law,A.R.I.shallnot be responsibleand/orliablefor direct, special, incidental orconsequentialdamages or
loss resulting from any breach oftheabove or under any other legaltheory.
Thisdocument doesnotreplaceanycertifieddrawing,procedureor informationprovided by A.R.I.inreferenceto aspecificcustomer,siteor project. All
rights reserved.

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1. SAFETY INSTRUCTIONS
Safety Instructions - General
1. A.R.I.productsalwaysoperate ascomponentsinalargersystem.Itisessentialforthesystemdesigners,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 to 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 theproduct.
6. Priortoinstallation, operation, maintenanceor any othertypeofactioncarriedoutontheproduct, readcarefully the safety,
installation and operationinstructionsoftheproduct.
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 isnot 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 tonoise.
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 A.R.I. Any misuse of the product may lead to undesired damages and
may affect your warranty coverage. Please consult with A.R.I. prior to any non-regular use of this product and make no change
ormodificationtotheproduct without aprior written consent tobeprovidedbyA.R.I.atA.R.I.'ssolediscretion.
11. Please note that A.R.I. 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 A.R.I. for the product
and/or applicableordinancesand/or codes.
Safety Instructions - 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. Storage should be in the original delivery crates or cases. Storage should be off the ground in a clean, dry indoor area.
3. For lifting and positioning the product, use only approved lifting equipment operated by authorized employees and
contractors.
4. Prior to the installation visually verify that the product was not damaged during shipment to the installation site.
Safety Instructions - Installation
1. Install the product according to the detailed Installation Instructions provided with it by A.R.I. 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 onhazardous
environment sites.
4. Check and re-tighten the bolts connecting the product to the pipeline during commissioning and before operating the
productforthefirsttime.

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Safety Instructions - Commissioning and Operation
1. Read carefully theoperation instructions prior toany attempt tooperate theproduct.
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 asdescribed in this manual.
4. In cases where formal commissioning procedure is required, it should be done by an authorized A.R.I. technician prior to the
firstoperation oftheproduct.
Safety Instructions - 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 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;
- removeanyprotectioncover;
- open any service port.
4. Beforeanymaintenanceornon-regularoperation,shutofftheIsolation valveandreleasetheresidual pressure:
A. Forair valves with a 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 a significant
volume of compressed gas with accumulated energy!
B. Forair valves without a pressure release outlet, slowly unscrew the flange bolts until all the pressure isreleased 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. Inspectthe product’ssafety stickers and replace anydamaged orfaded 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 thevicinity
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.
Safety Instructions - Before returning to regular operation
1. Re-assemble any protection covers orprotection mechanisms removed during service or maintenance operations.
2. Make sure thatall the tools, ladders, lifting devices, etc. used during the maintenance procedures are takenaway from the
productareaandstored.
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 asdetailed in your user
manual.

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2. 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.
2.1. Installation Recommendations
Single Air Valve on an Isolating Valve at 45° to Air Valve outlet
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
Two Air Valves on a shared Isolating Valve. Air Valves outlets face
outward and the Isolating Valve 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.

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2.2. 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).
D
Isolation
Valve
Air Trap
Raiser
H
d
D

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2.3. Installation Instructions
1. Flush the system before installing the air valve to avoid any debris or sharp objects getting into the air
valve.
2. Carefullyremovetheairvalvefromtheshippingpackage.Unloadall airvalvescarefullytoa sturdylevel
surface taking care not to dropthem.
3. Air valves fitted with hoist rings should only be lifted and conveyed using these hoist rings.
4. Install an isolating valve below the air valve, connected by a Riser to the crown of the pipe.
5. Mount the air valve carefully on the rubber gaskets of the isolating valve.
6. Place washers on each of the bolts & nuts that connect the air valve flange to the isolating valve flange.
7. Tighten all the bolts and nuts using the crossover method.
8. The closure tightness of the bolts and nuts shall be according to the standard torque for their specific
size.
9. Use ring wrench keys for the closing and opening of all bolts of the air valve (including the flange bolts).
2.4. Directions for Discharge Outlet
1. Recommended to leave the discharge outlet completely open andunhindered:
2. Avoid directing the discharge outlet opening in the direction of workers, bystanders or animals.
3. Avoid directing the discharge outlet opening in the direction of vulnerable equipment that can be
damaged, such as electrical equipment, unstable structures, etc.

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3. OPERATION
The Air & Vacuum component, with the large orifice, discharges air at high flow rates during the filling of the
system, and admits air into the system, at high flow rates, during system’s drainage and at water column
separation. High velocity air does not blow the float shut. Water lifts the float which seals the valve.
At any time during system operation, if the internal pressure of the system falls below the atmospheric
pressure, air enters the system.
The smooth discharge of air reduces pressure surges and other destructive phenomena.
The intake of air in response to negative pressure protects the system from destructive vacuum conditions,
and prevents damage caused by water column separation. Air entry is essential to efficiently drain the system.
The automatic air release component releases entrapped air in pressurized systems.
As the system starts to fill, the valve functions according to the following stages:
1. Air in the pipeline is discharged by the valve.
2. Liquid enters the valve, lifting the float which pushes the sealing mechanism to its sealing position.
3. Entrapped air, which accumulates at peaks and along the system, rises to the top of the valve, which
in turn displaces the liquid in the valve’s body.
4. The float descends, unsealing the rolling seal. The air release orifice opens and the accumulated air is
released.
5. Liquid enters the valve and the float rises, pushing the rolling seal back to its sealing position.
When the internal pressure falls below the atmospheric pressure (negative pressure):
1. The floats drop down, immediately opening the Air & Vacuum and the air release orifices.
2. Air enters the system.

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4. 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 as appear chapter of this document and with all the relevant local and general safety
instructions, standards and work regulations.
4.1. Preparation
Releasing Pressure
Shut the isolating valve located on the riser under the air valve.
Option A:
Using two combination spanners, partially unscrew the bolts connecting the air valve to the riser in order
to release the pressure. Wait till the pressure is released.
Option B. –for air valves with Plug:
Use a ratchet box wrench to gradually release the Plug of the pressure release port, wait till the pressure
is released and then unscrew the Plug completely, remove it and drain the air valve.
The maintenance procedure of the D-060 air valve is divided into the following two separate processes:
Automatic valve
Air & Vacuum valve.

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4.2. Maintaining the Automatic Air Release valve –S-050
Refer to the drawing on the next page.
1. Shut the isolating valve below the air valve.
2. Unscrew the Body of the Automatic air release valve from the Base, making sure that the valve Base does
not rotate.
3. Remove the Clamping Stem and the Float from the automatic component
4. Wash the inside of the Body including the Strainer, the Clamping Stem, the Float and the Rolling Seal
under clean running water.
5. Check to make sure that the Rolling Seal is not damaged (torn or cracked) and is located precisely in the
middle of its groove in the Float.
6. Replace the Rolling Seal if it is damaged or has been removed from the float.
7. Reassemble the air valve in the reverse order:
8. First insert half the length of the Rolling Seal into the groove in the Body, and then push it the rest of the
way in the groove with the aid of the Clamping Stem.
9. Make sure that the Rolling Seal is set and held in place.

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S-050 - AUTOMATIC VALVE –ASSEMBLY BOM TABLE AND DRAWING
1
Body
2
Discharge Outlet Elbow
3
Rolling Seal
4
Float
5
Clamping Stem
6
O-ring
7
Base
8
Strainer

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4.3. Maintaining the Automatic Air Release valve - S-050C / S-052
Refer to the drawing on the next page.
1. Shut the isolating valve below the air valve.
2. Unscrew the Body of the Automatic air release valve from the Base, making sure that the valve Base does
not rotate.
3. Remove the Clamping Stem and the Float from the automatic component
4. Wash the inside of the Body including the Strainer, the Clamping Stem, the Float and the Rolling Seal
under clean running water.
5. Check to make sure that the Rolling Seal is not damaged (torn or cracked) and is located precisely in the
middle of its groove in the Float.
6. Replace the Rolling Seal if it is damaged or has been removed from the float.
7. Reassemble the air valve in the reverse order:
8. First insert half the length of the Rolling Seal into the groove in the Body, and then push it the rest of the
way in the groove with the aid of the Clamping Stem.
9. Make sure that the Rolling Seal is set and held in place.

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S-050C / S-052 - AUTOMATIC VALVE –ASSEMBLY BOM TABLE AND DRAWING
1
Shell
2
O-ring
3
Discharge Outlet
4
Body
5
Rolling Seal
6
Float
7
Clamping Stem
8
O-ring
9
Base
10
Strainer
9
10

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4.4. Maintaining the Automatic Air Release valve - S-050L
Refer to the drawing on the next page.
1. Shut the isolating valve below the air valve.
2. Unscrew the Body of the Automatic air release valve from the body extension, making sure that the valve
Base does not rotate.
3. Rinse the O-ring and verify its integrity.
4. Remove the Clamping Stem and the Float from the automatic component
5. Wash the inside of the Body including the Strainer, the Clamping Stem, the Float and the Rolling Seal
under clean running water.
6. Check to make sure that the Rolling Seal is not damaged (torn or cracked) and is located precisely in the
middle of its groove in the Float.
7. Replace the Rolling Seal if it is damaged or has been removed from the float.
8. Reassemble the air valve in the reverse order:
9. First insert half the length of the Rolling Seal into the groove in the Body, and then push it the rest of the
way in the groove with the aid of the Clamping Stem.
10. Make sure that the Rolling Seal is set and held in place.
11. Unscrew the Body extension from the base.
12. Rinse the O-ring and verify its integrity.
13. Return the O-ring and reassemble the body extension and the base.

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S-050L - AUTOMATIC VALVE –ASSEMBLY BOM TABLE AND DRAWING
1
Body
2
Discharge Outlet
3
Rolling Seal
4
Clamping Stem
5
Float
6
O-ring
7
Body Extension
8
Plug
9
Base
10
Strainer
9
10

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4.5. Maintaining the Automatic Air Release valve - S-015
Refer to the drawing on the next page.
Basic, Periodic Maintenance:
1. Shut the isolating valve below the air valve.
2. Unscrew the Cover Bolts of the automatic air release valve slowly, to release accumulated pressure.
3. Remove the Cover of the automatic valve, clean the Orifice with flowing water or a burst of pressurized
air.
4. Wash the inside of the Body, the Float, and the Rolling Seal with clean water.
5. Check to make sure the Rolling Seal is unharmed (not torn or cracked). If it needs to be replaced, see
below, Instructions for Replacing the Rolling Seal.
6. Reinstall in reverse order and fasten and tighten all bolts. Make sure to re-assemble all the components
correctly.
7. Open the shutoff valve beneath the air valve.
Replacing the Rolling Seal:
1. Perform steps 1-3 of the Basic, Periodic Maintenance (found above).
2. Unscrew and remove the Discharge Outlet.
3. Remove the Roll-pin with the aid of a hand punch, small hammer and pliers.
4. Press down on the threaded end of the Orifice and Float Assembly that extends out from the top the
Cover, remove and place it on a flat surface for the next step.
5. Remove the damaged Rolling Seal by extracting it from both ends of the Lever.
6. Replace with a new Rolling Seal by inserting each end of the seal into each slot in the Lever.
7. Reinsert the Orifice and Float Assembly into the Cover by pushing the threaded end of the assembly up
through the bottom hole in the Cover.
8. Aligned the holes in the threaded end with the slots in the Cover.
9. Insert the Roll-pin into the hole with the aid of a hand punch and small hammer.
10. Make sure the ends of the Roll-pin sit inside the slots of the Cover.
11. Place the Cover with the attached assembly onto the Body.
12. Insert the 4 Bolts and Washers into the Cover holes and tighten the Nuts.

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S-015 - AUTOMATIC VALVE –ASSEMBLY BOM TABLE AND DRAWING
1
Air Release Outlet
2
Circlip
3
Cover
4
O-Ring
5
Orifice seat
6
Rolling Seal
7
Lever
8
Roll-Pin
9
Float
10
O-Ring
11
Bolts, Nuts & Washers
12
Body
13
Adaptor
10
9
13
12
11

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4.6 Maintaining the Air & Vacuum valve
Refer to the drawing on the next page.
1. Shut the isolating valve below the air valve.
2. Unscrew the Bolts that connect the valve Cover to the valve Body.
3. Remove the Cover assembly from the valve Body
4. Wash and clean the following parts: Body including the groove of the O-ring, Screen, Float, and Cover
including the Orifice Seat and Orifice Seal under clean running water in order to remove coarse grime
and/or accumulated scale.
5. Check that the Orifice Seal is not damaged (torn and/or cracked).
6. In case the Orifice Seal is damaged, consult your dealer.
7. Reassemble the air valve in the reverse order:
8. First insert the Float, and then place the O-ring in the groove.
9. Place the Cover on the Body, insert the Bolts and Washers and tighten the Nuts.
10. Tighten all the Bolts and Nuts using the crossover method.
11. The closure tightness of the Bolts and Nuts shall be according to the standard torque for their specific
size.
12. Use ring wrench keys (Hand force only) for the closing and opening of all Bolts of the air valve (including
the flange bolts).

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AIR & VACUUM VALVE - ASSEMBLY BOM TABLE AND DRAWING
1
Cover Assembly
2
Float
3
O-ring
4
Bolts & Nuts
5
Body

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5. TROUBLESHOOTING
Symptom
Possible Causes
Remedy
Leakage from the Small Orifice
A. Debris or scale buildup on the Rolling Seal.
B. TornRollingSeal.
Shut the isolating valve, wait a minute, and
open it again, very fast. If leaking
continues, follow instructions for:
4.2 Maintenance - Automatic Air Release
Component
Leakage from the Large Orifice
Dirt particles stuck on the Orifice Seal, Orifice
Seat, or on the Float
Shut the isolating valve, wait a minute,
and open it again, very fast.
If leaking continues, follow steps for:
4.3 Maintenance - Air & Vacuum Valve
Component