AZ F-2-STD-A Manual

ARMATUREN
totraumfrei & wartungslos
1
Storage, operating and
maintenance instructions
for AZ plug valves and
Standard valves
Plug - Valves metallic
with PTFE Sleeve 2 - 7 way
Plug - Valves FEP/PFA - lined,
2 - 3 way
Buttery - Valves
FEP/PFA - lined
Ball - Valves
FEP/PFA - lined
Ballcheck - Valves metallic
with FEP/PFA - lined
Sampling - Systems for
liquid, liquid gas and gas
Special - Valves
and customized

2
Content :
1. General information
2. Marking
3. Safety instructions
4. Transport and storage
5. Installation and start-up
a) Mounting Instruction
b) Statement on Directives 2014/68/EU and 2006/42/EG
c) Installation in explosive areas (directive 2014/34EU, ATEX)
6. Handling and operating mode
7. Maintenance instructions
8. Trouble shooting of malfunctions and defects
9. Valve readjustment
10. Pressure tests

ARMATUREN
totraumfrei & wartungslos
3
1. General information
These storage, operating and maintenance instructions apply for all AZ
plug valves and other AZ products based on the plug valve design. AZ
valves are high performance valves which can also be used under extreme
conditions. Due to this, the valves should be handled carefully in order
to avoid damages which could be hazardous to human health and/or the
environment. Please consider the relevant remarks in this manual.
Please check the valves immediately after receipt for any defects or
transport damages. Claims for transport damages can only be accepted
if the forwarder is informed immediately in writing. For return shipments
(transport damage or valve repair) please issue a damage report immedi-
ately and return the components back to the manufacturer, if possible in
the original packaging. Returning shall be sent free of charge for AZ. Other
returning terms have to be agreed with the AZ sales department.
Please provide the following information as a minimum for the returned valves:
• Name and address of the consignee
• Order number or AZ reference number
• Type of valve
• Description of the defect
The valve guarantee period must be agreed and conrmed by AZ at
the order conrmation stage. If no agreement has been reached be-
tween the buyer and the seller, the standard guarantee period as per
our general sales terms and conditions must be applied. In any case,
the general warranty terms of AZ Armaturen GmbH always apply. We
assume no liability if our storage, operating and maintenance instruc-
tions have been ignored and /or used for inappropriate installation
or maintenance work. The end user is responsible for the materials
selection regarding media consistency. AZ Armaturen can provide ad-
ditional technical information such as material recommendations from
steel suppliers and references. However, AZ Armaturen doesn’t give
any warranty regarding material adequacy and resistance.

4
4408
12345
DN32
PN 40
0035
www.az-armaturen.co.za
2. Marking
According to EN 19 every valve is marked with the following data:
A Charge number
B Tag plate
C Part number
D Nominal pressure [PN]
E Manufacturer’s sign
F Material number
G Nominal diameter [DN]
Valves which are covered by the pressure equipment directive
2014/68/EU (> DN 25 / 1”) are additionally marked with a non-
removable CE-identification tag plate. This tag plate also includes
the test centre identification number, the fitting serial number
along with its coded year of manufacture (the first two digits stand
for the year of manufacture) and the permissible operating condi-
tions (Tmin, Tmax, Pmax):

ARMATUREN
totraumfrei & wartungslos
5
3. Safety instructions
AZ valves are high quality products manufactured according
to the latest applicable technical regulations, and have left
the manufacturer´s workshop in perfect condition. Installation,
adjustment, maintenance and repair work of valves, pneumatic
accessories and electrical equipment shall only be executed
by correctly trained and authorized personnel. AZ Armaturen
GMBH accepts no liability for damage caused by unauthorized
modification of any item and/or the use of non-genuine AZ
spare parts.
National legislation for accident prevention and/or
the site specic advice of the end user must always
be considered. This manual is in no way intended to
replace these regulations.
Before starting any repair or maintenance work, actuators and
electrical parts have to be de-energized. Please consider a safe
distance to open mounted and moving parts in order to avoid in-
jury. Ensure that the valves are utilized only within the permitted
limits (especially pressure and temperature). Information about
these limits can be found in the technical information leaflet of
the valves or on the valve tag plate. Operation of valves beyond
the permitted temperature and pressure limits can cause dam-
age to the valve, especially on gaskets and components.
Valves may only be used for the purpose that they have been
designed for.

6
IMPORTANT NOTE:
Never carry out any maintenance or repair work if
the valve is under pressure. Please consider that
some valves can trap pressurized medium (e.g. in
the plug of the plug valve).
IMPORTANT NOTE:
The piping system where the valve is installed
has to be pressure-free and any media over
pressure has to be released before dismounting.
Check potential risks which can be caused by
media residues. Please consider that media can
be released from the valve or piping during
dismounting.
In case of toxic / dangerous / harmful media, the pipe has to
be emptied completely before dismantling the valve. Hot valves
must be cooled down to ambient temperature before work
starts.
For your own safety, please always use the correct protective
clothing or special equipment which is required for work with a
particular media.
4. Transport and storage
AZ valves must be stored in fully open position. In certain cases
(actuated valves with fail safe position “closed”), the valves can
be stored in closed position, but storage in a half open position
has to be avoided at all times. AZ valves are delivered with the
end connections covered by protection caps. These caps protect

ARMATUREN
totraumfrei & wartungslos
7
the valve ends from mechanical damage and the internals from
environmental influences (e. g. dust, dirt etc.). The protective
caps shall only be removed when the valve is to be installed. The
valves shall be stored indoors in order to protect them from de-
structive influences like dirt, moisture and frost. The valves shall
be transported in solid and stable packaging to the place of instal-
lation. Lifting accessories (ropes, belts) shall only be attached to
the valve bodies. Never use the levers, gear boxes or actuators to
lift the valves.
IMPORTANT NOTE: Valves which have been in-
stalled in toxic or aggressive media applications
must be flushed and cleaned before returning
them to the supplier for repair or disposal. Media
may be located underneath the plug so the valve
must be disassembled, the plug removed and all
individual parts must be provided fully cleaned. A
certificate of non-objection and a material safety
data sheet must be attached to the shipping
documents and shall be included in the delivery.
5. Mounting Instruction and start-up
a) Mounting Instruction
Important Note: This does not apply for check valves, control
valves and sight glasses. These valves are marked with an arrow
indicating the flow direction. Valves which are
equipped with a plug with relief hole or a “T4”-
plug, a notch on the plug stem indicates the
orientation of the overpressure relief side.
Obey Flow direction
(Sight glasses a.s.o.)

8
In order to avoid valve damage caused by line impurities (swarf-, dirt,
welding residues) the pipeline must be emptied and cleaned before
installation of the valves. Prior to installation, ensure that the valve is in
open position and the valve end protection caps are removed. Check
the sealing surface of anged valves for damage. In case the valve has
been stored without protection caps, please make sure that the valve is
clean inside. If necessary ush the valve with clean and dry air.
The valves must be installed stress-free in the pipeline. For example,
stress can occur due to misaligned pipelines. Place the valve in the
piping, if needed, by using lifting accessories. Flanges shall be bolted
constantly crosswise. Please consider the stipulated fastening torque of
the gasket manufacturer. Flanges and bolting should be clean. A ange
gasket which is suitable for the application shall be used. Please en-
sure that the valves are properly supported during installation. Normally
the valves can be installed in any position. However, please consider
a support / bearing for heavy actuators if the valve is mounted in a
vertical pipe or the actuator orientation is not on top of the valve / piping
(sideways).
In order to protect the valve’s internal sealing from
overheating, please make sure that there is suffi-
cient cooling if the valve is welded into the pipe-
line (butt weld / socket weld end valves).
Please check the whole valve for proper operation by repeated
opening and closing before commissioning (<2 strokes per min-
ute). In case of prolonged storage of the valve the breakaway
torque during the first stroke may be higher than usual, after fre-
quent operation the torque will reduce to the normal level.
Please check if the hand lever or the actuator is installed in such
a manner that the valve closes clockwise. When installing multi
way valves (three-way, four-way etc.) please check the port form
and the switching positions in order to avoid incorrect connection
to the piping. The switching positions are shown on the position

ARMATUREN
totraumfrei & wartungslos
9
indicator (hand operated valves) or by red marks on the coupling
(actuated valves). Please finish all installation work before putting
the valves into operation. RECOMMENDATION: If the operat-
ing temperature exceeds 120°C the plug may be adjusted once
operating temperature has been reached (1/2 to 1/1 turn of the
adjustment bolt).
b) Statement on Directives 2014/68/EU and 2006/42/EG
AZ valves are pressurised equipment components according to
the Pressure Equipment Directive 2014/68/EU. The design, manu-
facture, and testing of the valves comply with the requirements of
this directive. On the basis of its prescribed use with its installed
pneumatic, electric, or hydraulic drive, AZ-Armaturen are classi-
fied as “incomplete machinery” within the meaning of Machinery
Directive 2006/42/EG.On the basis of their intended use, AZ
valves, with installed pneumatic, electric or hydraulic drives, are
considered “incomplete machinery” according to the Machinery
Directive 2006/42/EG. The valves must be used exclusively in the
same way that their specifications are described in this operating
manual. The automated valve may only be commissioned after
the pipeline has fully been installed.
c) Installation in explosive areas (directive 2014/34/EU (ATEX)
AZ valves has undergone a hazard analysis according to directive
2014/34/EU (ATEX). Result:
• According to DIN EN 13463-1:2000 AZ-valves don’t have an
own potential ignition source and therefore they are not cov-
ered by the scope of application of code 2014/34/EU (ATEX).
• There’s no marking according to ATEX.
• All valves can be used in explosive areas ( zone 0,1,2 and
20,21,22).

10
IMPORTANT NOTE:
• Fully lined valves which are installed in zone 0 and 20 have to
be lined with conductive PFA material. A static eliminator device
has to be assembled in order to connect the plug with the body
(grounding).
• AZ valves can be operated manually (e.g. hand lever, gear box)
as well as mechanical or electrical (e.g. pneumatic, hydraulic or
electric actuator).
• For electrical and mechanical actuators and accessories an own
declaration of conformity according to code 2014/34/EU may
have to be considered.
• Whenever fully lined valves with non-conductive lining are in-
stalled in explosive areas, AZ-Armaturen GmbH strongly rec-
ommends the use of an anti-static band/earth cable in order to
ensure grounding of the plug.
6. Operation and functionality
Ball and plug valves are installed in pipeline systems by
flanging, screwing or welding and are designed to conduct,
block or control media flow. On/off valves have the open and
closed position indicated by the lever position (lever longitu-
dinal to the valve = open, lever perpendicular to the valve =
closed) or by a position indicator on top of the gear box. Flow
directions of multiport valves are indicated by a notch on the
plug stem or by a position indicator assembled on top of the
plug or the gear box. Flow directions of actuated valves are
indicated by red markings on the coupling between valve and
actuator.
Jacketed valves are used for particular media in order to
maintain the process capability or the flow.

ARMATUREN
totraumfrei & wartungslos
11
Control valves are used for the adjustment and the relocation
of a certain process factor (mass flow, pressure, temperature).
With sampling valves and sample systems representative
samples are taken during the ongoing process out of chemi-
cal, petrochemical and pharmaceutical systems in order to
monitor and control the media quality.
Asight glass with optical transparent glass can be used
for observing process flow. A strainer protects dirt sensitive
installations as measurement devices or pumps from line im-
purities
7. Maintenance instructions
Under normal conditions and in the case of the use according
to the regulations, frequent maintenance work on AZ valves is
not necessary. After an extended period of operation, AZ recom-
mends checking the function of the valve by repeated open-close
strokes. Tightness of the valve/pipe connection and valve cover
area may also be visually checked for leakage. The functionality
of valves which remain constantly in the same position should be
checked frequently, e. g. by performing a “partial-stroke-test”.
After a certain operating time, leakage can occur due to wear-
ing of the sealing parts, small leakages (depending on type of
sealing) can be stopped by tightness adjustment (please refer to
pages 7 + 8).
After finishing maintenance or repair work please check the
proper function of the valve (particularly the closing position of
actuated valves) and the tightness of the connection between
valve and piping.

12
8. Malfunction / defects and fault clearance
Malfunc-
tion Possible reason Fault clearance
Leakage
in the pas-
sageway
• The allowed valve operating
limits (pressure / tempera-
ture) have been exceeded.
• Damage of the sleeve or
plug resp. ball surface
caused by foreign particles.
• Wearing of the sleeve.
• Damage of the valve due to
chemical corrosion, caused
by wrong material selection
regarding media suitability.
• Check if the valve
closes completely.
• Adjustment of the
plug according to the
guideline (please refer
to pages 13 + 14).
• If the leakage cannot
be stopped the valve
has to be repaired.
External
leakage
(cover or
stem seal)
• The allowed valve operating
limits (pressure / tempera-
ture) have been exceeded.
• Wearing of the sleeve.
• Damage of the valve due to
chemical corrosion, caused
by wrong material selection
regarding media suitability.
• Cover bolting became loose
(e.g. caused by heavy vibra-
tions in the pipeline)
• Wearing resp. damage of the
cover seal.
• Adjustment of the
plug according to the
guideline (please refer
to pages 13 + 14).
• Check if the cover
bolting is fastened
properly.
• If the leakage cannot
be stopped the valve
has to be repaired.
High torque/
valve
blocks
• Possible change of the me-
dia aggregate state.
• Deposit of media on plug
resp. ball surface.
• Solid media or forgotten
installation devices in the
valve
• Remove deposits and
solid media.
Malfunction
of actuator
or acces-
sories
See corresponding
guidelines / manuals
of the manufacturer.

ARMATUREN
totraumfrei & wartungslos
13
9. Adjusting instructions
Adjusting instructions in case of leakage for AZ plug valves type:
ISO-STANDARD DN15-100 NPS ½“-4“ / ISO-EXTRA DN15-80 NPS ½“-3“
1. Plug should be in an open position
2. Both adjusting bolts shall be turned ¼ to ½ rotations clock-
wise one after another.
3. Afterwards move the plug 10-15 degrees and back.
4. If the valve is still leaking please repeat step 2) and 3).
Please do not over tighten the adjustment bolts as the breakaway
torque may increase beyond the normal limits.
Adjusting screws
(plug)
Thrust collar
Stainless
diaphragm
PTFE
V-diaphragm
with delta
thrust collar
PTFE
sealing ring
PTFE sleeve
Plug

14
Adjusting instructions in case of leakage for AZ plug valves type:
STANDARD DN125-600 NPS 5“-24“ / EXTRA DN100-600 NPS 4“-24“
1. Plug should be in an open position
2. All adjusting bolts shall be turned ½ to 1/1 rotations clockwise one
after another.
3. Move the plug 10-15 degrees and back.
4. If the valve is still leaking please repeat step 2) and 3).
NOTE: Please do not over tighten the adjustment bolts as the
breakaway torque may increase beyond the normal limits.
Plug Adjust-
ing screws
Thrust collar
PTFE-delta
thrust collar
Diaphragm
sealing
Plug
PTFE sleeve
NOTE: Special cover sealing designs (e. g. type “FS-N”) may vary.
Stainless
diaphragm

ARMATUREN
totraumfrei & wartungslos
15
PN 10 ISO 5208
EN 12266
15 11 611
PN 16 24 17,6 617,6
PN 25 37,5 27,5 627,5
PN 40 60 44 644
PN 64 96 70,4 670,4
PN 100 150 110 6110
PN 160 240 176 6176
ANSI 150 API 6D /
API 598
30 22 622
ANSI 300 75 55 655
ANSI 400 99 72,6 672,6
ANSI 600 150 110 6110
ANSI 900 225 165 6165
10. Pressure tests
In accordance with ISO 5208 / EN 12266 and API 6D / API 598 hydros-
tatic strength tests using 1.5 times the nominal pressure (housing) are
carried out at the factory. The complete valves are either tested hydrosta-
tically using the indicated valve nominal pressure or an air tightness test
using 6 bar is carried out.
For system specic pressure tests carried out by the operator the nomi-
nal pressure must not exceed 1.1 times of the value specied on the type
plate (also refer to section 2 “Marking”). For test pressures higher than
“1.1 x PN” there is the risk of damage to the PTFE (polytetrauorethyle-
ne) seal. Higher pressure tests only after authorisation by AZ.
*) Tightness test of the valve at closure
**) Tightness test of the outward valve
Pressure
rating
Strength test
(housing) with water
Tightness test,
complete valve *)
AZ valves
test pressure**)
Standard PN x 1,5
[bar]
Water
[bar]
Air
[bar]
PN x 1,1
[max. bar]

16
ARMATUREN
totraumfrei & wartungslos
Print 01/2018 - Rev3 - GB - Subject to technical change without notice
AZ-Armaturen GmbH
Waldstraße 7
D-78087 Mönchweiler
Telefon: [phone]
Telefax: [phone]
[email protected]
www.az-armaturen.de