Jafar 7010 User manual

OPERATION AND MAINTENANCE MANUAL 12-2015
Operation and maintenance
manual for
AIR VALVES
FOR WATER AND SEWAGE SYSTEMS
atalogue no.
7010, 7040, 7050
Approved for use by
President of Factory, JAFAR S.A.
User's failure to follow the instructions and guidelines included in this operation and
maintenance manual exempts the manufacturer of all obligations and warranty.
Due to continuous business development, we reserve the right to introduce
modifications and structural changes to the presented product.

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TABLE OF CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT NAME AND FEATURES......................................................................................................... 3
1.2 PURPOSE..................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 STRUCTURE...................................................................................................................................................... 4
2.1 FITTING STRUCTURE DESCRIPTION.................................................................................................... 4
2.2 MATERIALS................................................................................................................................................ 5
2.3 DIMENSIONS.............................................................................................................................................. 7
2.4 STANDARDS............................................................................................................................................. 10
2.5 ORDERING PRINCIPLES......................................................................................................................... 10
2.6 MANUFACTURE AND ACCEPTANCE.................................................................................................. 11
2.7 MARKING.................................................................................................................................................. 11
3 PROTECTION — STORAGE — TRANSPORTATION................................................................................. 11
3.1 PROTECTIVE COATINGS....................................................................................................................... 11
3.2 PACKAGING............................................................................................................................................. 11
3.3 STORAGE.................................................................................................................................................. 11
3.4 TRANSPORTATION................................................................................................................................. 12
4 ASSEMBLY AND INSTALLATION............................................................................................................... 12
4.1 INSTALLATION GUIDELINES............................................................................................................... 12
4.2 INSTALLATION INSTRUCTION............................................................................................................ 12
4.3 OPERATION.............................................................................................................................................. 14
4.4 H&S REGULATIONS................................................................................................................................ 14
5 WARRANTY CONDITIONS ........................................................................................................................... 15

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT NAME AND FEATURES
The purpose of this TED are air valves for water systems.
TYPE 7010
-single step cast iron air valve for water systems, flanged
- with a floating ball (closing device) vulcanised in 100% with an elastomer
- with an o-ring cover gasket
- with screws which connect the cover with the body.
TYPE 7040
-single step brass air valve for water systems, threaded
- stainless steel with a floating ball
- with an o-ring cover gasket
TYPE 7050
- two step air valve for water systems which comprises
valves 7010 and 7040.
1.2 PURPOSE
Flanged cast iron and brass threaded air valves are intended to deaerate the pipe system when
it is filled with water or to aerate the pipe system when it is emptied in potable water systems and
industrial systems. They can be used in above ground and underground systems, essentially in the
highest point of horizontally placed piping.
1.3 TECHNICAL SPECIFICATION
Cast iron air valves TYPE 7010 are intended for purposes of aerating and deaerating systems
for potable water and other liquids (obtain agreement from the producer):
- operation temperature ranges from -10°C to +70°C.
- range of used diameters (dimensions): - DN50 –DN200[mm];
- max flow speed of medium - liquid up to 4[m/s];
- gas up to 15[m/s];
- nominal pressure value: - PN: - 1,6 MPa;
- operational pressure range: - 0,02 – 1,6MPa;
Flanges at valves TYPE 7010 are made according to PN-EN 1092-2 1999 with dimensions
appropriate to the assumed nominal pressures.
Dimensions of flanged air valves TYPE 7010 comply with the technical documentation.
Choice of TYPE 7010 valves is carried out regarding the amount of supplied (returned) air,
which involves the pipeline diameter and the length of the deaerated section. When filling the
pipeline, maximum flow speed in an unobstructed cross-section should not exceed 20 m/s, so that
the ball is not carried away and the flow is not closed before the deaerating process is finished.
When filling the pipeline, the whole of deaerating cross-section of a valve is available.

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Zawór 7010 DN50, DN80, DN100
Przepływ maksymalny zaworu 7010
DN Q
max
, m
3
/h
50 1182
80 2498
100 5601
2 STRUCTURE
2.1 FITTING STRUCTURE DESCRIPTION
F.A. „JAFAR” S.A manufactures cast iron, flanged air valves TYPE 7010 for potable water
and industrial systems. They have a cast iron body which houses a loose ball, which is a closing
component (float). The ball is made of metal insert fully covered with a rubber layer. The ball is
able to float when the valve is filled with water because it has lower density than water. Ball
density is chosen so that during air release via the valve, the ball is positioned in the lower part of
the body, and during water filling raised together with the water level. After the chamber has been
filled with water, the ball is positioned in the valve nest in its upper part and closes the flow.
However, during the aerating the ball, as the water level in the valve chamber decreases,
initially assumes position at the ledges in the lower part, not closing the air flow to the pipeline.
The body chamber is covered with a cast iron cover, caulked with an o-ring gasket, connected
with the body with hex head screws screwed into the body. All the internal and external cast iron

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surfaces of the valve are covered with powder epoxy paint.
In the cover flange opening there is an access plug with a ¾” thread, which makes it possible to
twist the TYPE 7040 deaerating valve, which is intended to release small quantities of air.
TYPE 7040 valve is a single step valve for water systems, which is made of a brass body 1
and cover 2 connected with a thread by means of an o-ring gasket 10. A metal ball – a float 3 with
density lower than water is suspended from a stainless steel lever 6. The lever has a movable joint
7 with a bolt 8, which is a lever spin axis mounted to the lower cover surface. Ball density is
especially chosen so that during air release via the valve, the ball is positioned in the lower
position (descended lever) and during water filling raised together with the water level. Filling the
chamber with water causes a simultaneous movement of the lever according to spin axis until it
reaches the upper position, where gasket 4 closes the output hole of a nozzle 5.
However, during the aerating the ball, as the water level in the valve chamber decreases, the
nozzle output hole opens and assumes the lower position in the position of descended lever.
During work with a TYPE 7010 valve, the TYPE 7040 valve is a second stage of deaerating
when the ball performs repetitive up and down movements, releasing small amounts of air, which
builds up in the chamber through the half-open nozzle, with 7010 valve still closed and filled with
water (under pressure).
It is recommended to install the air valve in vertical position in the highest point of the
pipeline or in its inflection points.
2.2 MATERIALS
Tables below show a list of materials used in the production of air valves.
TYPE 7010
No. Part name Material Standard
1Body Ductile cast iron EN-GJS-400-15 PN-EN 1563: 2012
2Cover Ductile cast iron EN-GJS-400-15 PN-EN 1563: 2012
3Vulcanised ball Aluminium alloy
covered with rubber: EPDM (or NBR)
PN-EN 1706: 2011
PN-ISO 1629: 2005
4Caulk ring Rubber: EPDM (or NBR) PN-ISO 1629: 2005
5Caulk ring Rubber: EPDM (or NBR) PN-ISO 1629: 2005
6 Hex head screw M16x40 Acc. to subject matter standards PN-EN ISO 4017: 2011
7 Rootstock 17 Acc. to subject matter standards PN-EN ISO 7091: 2003
8 Plug ¾” Brass/chrome plated acc. to the producer's
Technological Guidelines

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TYPE 7040
TYPE 7050
No. Part name Material Standard
1Body Brass CuZn39Pb1Al-B PN-EN 1982: 2010
2Cover Brass CuZn39Pb1Al-B PN-EN 1982: 2010
3Float Stainless steel 1.4301 PN-EN 10088-1: 2014
4Gasket Rubber EPDM/NBR PN-ISO1629: 2005
5Nozzle Stainless steel 1.4301 PN-EN 10088-1: 2014
6 Lower lever Stainless steel 1.4021 PN-EN 10088-1: 2014
7 Top Lever Stainless steel 1.4021 PN-EN 10088-1: 2014
8 Bolt Stainless steel 1.4301 PN-EN 10088-1: 2014
9 Caulk ring Rubber EPDM/NBR PN-ISO1629: 2005
10 Screw Stainless steel PN-EN ISO 4017: 2011
No. Part name Material Standard
1 7010 valve Like in the table for 7010 Like in the table for 7010
2 7040 valve Like in the table for 7040 Like in the table for 7040

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2.3 DIMENSIONS
TYPE 7010
DN H L D K l x n G G
1
Masa
[kg]
50 / GW 2" 187 156 165 125 19x4 5/4" 7
80 242 195 200 160 19x8(4)* 2" 14
100 319 195 220 180 19x8 2" 18
150 350 265 285 240 23x8 3" 33
200 350 270 340 295 23x8(12)* 3" 34
[cal][mm]
3/4"

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TYPE 7040
G H L
Masa
[cal] [kg]
3/4" 1,6
1" 1,7
5/4" 1,7
6/4" 1,8
[mm]
135 85

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TYPE 7050
DN H L D K l xn G G
1
Masa
[kg]
50 / GW 2" 250 108 165 125 19x4 5/4" 8,5
80 280 128 200 160 19x8(4)* 2" 15,5
100 316 141 220 180 19x8 2" 19,5
150 355 173 285 240 23x8 2" 34,5
200 355 173 340 295 23x8(12)* 3" 35,6
[cal][mm]
3/4"

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2.4 STANDARDS
PN-ISO 1629: 2005 Rubbers latex Nomenclature.
PN-89/H-02650 Fittings and pipelines. Pressures and temperatures.
PN-EN ISO 228-1: 2005 Pipe threads where pressure-tight joints are not made on the threads
Dimensions, tolerances and designation.
PN-EN 10226-1: 2006 Pipe threads where pressure-tight joints are made on the threads.
Dimensions, tolerances and designation.
PN-EN ISO 6708: 1998 Definition and selection of DN /nominal size/
PN-EN 1092-2: 1999 Flanges and their joints circular flanges for pipes,
valves, fittings and accessories Cast iron flanges.
PN-EN 1561: 2012 Founding. Grey cast iron.
PN-EN 1563: 2012 Founding. Nodular cast iron
PN-EN 1074-1: 2002 Valves for water supply. Fitness for purpose requirements and
appropriate verification tests. General requirements.
PN-EN 1074-4: 2002 Valves for water supply. Fitness for purpose requirements and
appropriate verification tests. Part 4 Air valves.
PN-EN 1706: 2001 Aluminium and aluminium alloys. Castings. Chemical composition
and mechanical properties.
PN-EN 12266-1: 2003 Industrial valves Testing of valves.
PN-EN 10088-1: 2007 Stainless steels. List of stainless steels.
PN-EN ISO 12944-5: 2001 Paints and varnishes. Corrosion protection of steel structures by
protective paint systems. Protective paint systems
PN-EN 19: 2005 Industrial valves. Marking of metallic valves.
PN-EN ISO 4017: 2011 Hexagon head screws. Product grades A and B
2.5 ORDERING PRINCIPLES
Cast iron flange valves Type 7110, typ 7050 and threded Typ 7040 for special purposes, which
is why the following details should be provided in the order:
- catalogue no. (constitutes product type),
- intended use, e.g. potable water,
additionally
- nominal diameter acc. to PN-EN ISO 6708: 1998;
- nominal pressure acc. to PN-89/H – 02650;
- body material type – e.g. grey cast iron acc. to PN-EN 1561: 2012;
- max operational temperature acc. to PN-89/H – 02650;

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2.6 MANUFACTURE AND ACCEPTANCE
Cast iron flange valves Type 7110, typ 7050 and threded Typ 7040
are manufactured and
commissioned according to: PN-EN 1074-4: 2002 (Valves for water supply. Fitness for purpose
requirements and appropriate verification tests. Part 4 Air valves) and PN-EN 12266-1: 2003
(Industrial valves. Testing of valves). All valves (100%) are tested for sealability. Outer body
sealability is tested and closed sealability in low and high pressure.
2.7 MARKING
Valve marking is governed by standards: PN-EN-19: 2005, PN-EN-1074-1: 2002.
Valve bodies have markings placed on the front and back wall of the chamber body, which
include the following data:
- nominal diameter
- nominal pressure
- type of body material
- producer trade mark
and a ledge to include an identification mark (e.g. series no.)
3 PROTECTION — STORAGE — TRANSPORTATION
3.1 PROTECTIVE COATINGS
All internal and external cast iron surfaces are protected with epoxy paint, applied electrostatically. The
paint is approved for contact with food products.
The thickness of the anti-corrosion coating layer is min. 250 µm.
Mould surface is prepared for the application of the epoxy coating in accordance with the technical
documentation and PN-EN ISO 12944-5: 2009.
The screws connecting the body and the cover are manufactured as stainless, grade OH18N9 or Fe/Zn5
(galvanised steel).
3.2 PACKAGING
Cast iron flange valves TYPE 7010, TYPE 7050 and threaded TYPE 7040 are packaged on
EURO pallets (1200x800) and secured with a heat shrinked hood.
3.3 STORAGE
Cast iron flange valves TYPE 7010, TYPE 7050 and threaded TYPE 7040 should be stored
indoors.

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3.4 TRANSPORTATION
Cast iron flange valves TYPE 7010, TYPE 7050 and threaded TYPE 7040 should be
transported by covered means of transport.
The producer recommends using a lifting sling from DN100 to DN200.
TYPE 7010 TYPE 7050
4 ASSEMBLY AND INSTALLATION
4.1 INSTALLATION GUIDELINES
Cast iron flange valves TYPE 7010, TYPE 7050 and threaded TYPE 7040 can be built over in
underground pipelines and above ground vertical systems. Flange valves are adapted to be fitted
with pipeline stub pipe flanges with dimensions corresponding with the valve flanges. Valves
sized DN50 additionally have a terminal which enables a threaded connection. During fitting,
make sure that the installation in progress does not cause the fittings (valve) to be stressed with
bending or stretching force resulting from mass of an unsupported pipeline. It is recommended to
carry out installation works taking into account pipeline compensation for temperature and
pressure. Valves should be installed in easily accessible places which enable regular controls with
scheduled frequency. Correctly sized holes should be provided in the installation design to ensure
uninterrupted air flow in both sides. As small amounts of water may escape with the air, a method
of its drainage should be provided as well (e.g. sewage grate). Threaded G
1
output hole in the
cover enables the installation of a bend or a pipe which makes it possible to direct water spatter in
the direction of a sink. It is recommended to put a security net on the output end to prevent the
entry of contamination or small insects.
The valve, after assembly and delivery by the producer is ready to be installed in the system.
Works connected with disassembly of valve elements carried out without due care may cause it to
lose its sealability.
4.2 INSTALLATION INSTRUCTION
When attempting installation of fittings, one should check the technical and commercial
documentation, that is the compliance of installed valve with the order and its intended use for
media and the working parameters of the pipeline it is to be installed. Each change of operation
conditions requires consultation with the fittings' producer.

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Before attempting the installation, pipe stoppers should be removed from the main tunnel,
state of external surfaces should be checked and, if necessary, rinse them thoroughly with water.
Attention! In case of mechanical damage, the device should not be installed on the pipeline.
The picture below shows how to install the valve.
1.-valve, 2.-nut, 3.-gasket, 4.-pipeline flange, 5.-washer 6.-assembly screw
Type7010
Type
7050

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Recommended method of connecting the air valve is presented in the diagram below.
Terminal diameter (tower) should be large enough and correspond at least to the air valve size.
The terminal should be positioned vertically. The drain valve is used to manually aerate and
deaerate as well as to reduce pressure (by release) before the maintenance works begin. Shut-off
fittings make it possible to install and disassemble the air valve as well as the drain valve.
During the system pressure test, the shut-off fittings should remain closed.
Before installing the air valve, the system should be rinsed.
4.3 OPERATION
Cast iron flange valves TYPE 7010, TYPE 7050 and threaded TYPE 7040 should be operated
according to the requirements regarding the air fittings, i.e. oriented as shown in the diagram of
possible orientations. In order to provide full operational efficiency, rinsing valves with clean
water is recommended (once a year). In order to protect the ball (floater) from blocking inside
the body or damaging the ball rubber cover, it is recommended to separate hard solid particles
larger than 5mm from the medium.
4.4 H&S REGULATIONS
Guidelines and recommendation from the OHS regulations apply, regarding the pipeline
systems and devices installed in pipeline stations, heat power stations, water treatment plants,
sewage treatment plants, pumping stations and other objects, as well as the ordinance regarding
general OHS regulations (using hand protection, leg protection, head protection and protective
clothing), especially when working exposed to low or high temperatures.
Product operation out of their intended use is not allowed.
Air valve
Drain fittings
Shut-off fittings
Connector stub pipe
Pipeline

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5 WARRANTY CONDITIONS
The manufacturer grants warranty for the product being installed and operated according to this OMM. The
conditions and period of the warranty is specified in the warranty sheet.