Orbinox RR User manual

SPAIN · UK · GERMANY · FRANCE · CANADA · USA · BRAZIL · CHILE · PERU · INDIA · CHINA · SOUTH EAST ASIA
www.orbinox.com
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
RR & RC MODELS
FLAP GATES

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-2/10
Reserves the right to change specifications without notice
www.orbinox.com
INDEX Page
0. Introduction .................................................................................................................................... 2
1. Handling and Storage…………………………………………………………………………………..……. 2
2. Installation ...................................................................................................................................... 3
2.1. Installation: Wall Mounted................................................................................................... 3
2.2. Installation: Standard Flange Mounted................................................................................... 5
2.3. Installation: Wall Thimble Mounted ………………………..……………………………..……….... 6
3. Operation......................................................................................................................................... 6
4. Maintenance..................................................................................................................................... 7
4.1. Cleaning and lubrication...................................................................................................... 7
4.2. RC Seal replacement ……………………………….………………...…….…………………..….... 8
4.3. RR Seal replacement ……………………………………………………………..…..…………..….. 9
5. Trouble shooting............................................................................................................................... 10
6. Environmental considerations............................................................................................................. 10
0. INTRODUCTION
•This manual describes the recommended procedures for installation, operation, maintenance and safety
precautions for ORBINOX RR and RC model flap gates
•Please read thoroughly all the instructions in the manual prior to installation, and contact an ORBINOX
representative in case of any questions
•The manual makes reference to the “General Arrangement Drawing” (GAD). The GAD is the drawing that is
sent to and approved by the customer prior to the production of the weir gate
•ORBINOX assumes no responsibility or liability if the RR or RC Flap Gate is not installed, operated and main-
tained in strict accordance to the procedures described in this manual
1.HANDLING AND STORAGE
Standard safety procedures should be followed to prevent personal injury or equipment damage. Additionally, the
following instructions shall be followed during handling and storage to prevent any damage of the product:
•Special care shall be taken on any machined surface when lifting the gate
•Equipment shall be stored in a dry, clean and even area on a raised even wood surface to prevent distortion
of the frame. Do not stack slide gates

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-3/10
Reserves the right to change specifications without notice
www.orbinox.com
2. INSTALLATION
This section describes the different installation methods
2.1. Installation: Wall Mounted
▶ Required Materials:
•RR and RC flap gates are installed by means of mechanical anchor bolts (Hilti Kwilt 3 or equivalent) and
construction sealant (Sikabond/Sikaflex 11FC or equivalent). Note that as standard, anchor bolts and
construction sealant are not supplied with the flap gate
•For detailed information about the type, size and quantity of the required anchor bolts, or any other specific
installation notes or materials, please refer to the notes on the “General Arrangement Drawing”
▶ Installation procedure:
Step 1: Concrete construction inspection
•The concrete construction shall be flat, level and plumb, and shall be in accordance to DIN 18202 or ACI
117-06 standard. If necessary, use non-shrink grout in order to meet the specified standard. The minimum
concrete strength shall be 25 MPa (3,625 PSI)
•The wall surface shall be dry
Step 2: Pre-installation of the flap gate
•Position the flap gate against the wall and line up with the opening
•Drill and install an anchor bolt on each side of the flap gate. After installing the first anchor bolt, and prior to
drilling the hole on the other side, make sure the frame is perfectly leveled (see Figure 1)
Figure 1

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-4/10
Reserves the right to change specifications without notice
www.orbinox.com
Step 3: Construction sealant application (Sikabond/Sikaflex 11FC or equivalent)
•In order to avoid leakage between the frame and the wall, construction sealant shall be applied on the frame:
oRemove the weir gate from the wall (first remove the nuts of the anchor bolts)
oApply construction sealant all around the perimeter of the frame, where it will be in contact with the wall.
Sikabond (200 ml/m = 206 oz/ft) or equivalent construction sealant shall be used (See Figure 2 and 3). Be
sure not to get sealant on the gate’s seals or guides as this may cause leakage or damage
Step 4: Final installation
•Drill and install the rest of the anchor bolts (see Figure 4)
CAUTION!: If the flap gate is not completely in contact with the wall, do not over-tighten the anchor bolts. Over
tightening may bend or distort the frame. If the wall flatness and levelness is according to the specified standards,
the construction sealant will fill in the remaining void (see Figure 5)
•Apply construction sealant around the frame in order to fill in any existing gap between the wall and the frame
(this step is only for esthetics). Wipe away the excess sealant to leave a smooth finish
Figure 2
Figure 3
Back Side of the Frame
(Side in contact with
the Wall)
Construction Sealant
(Sikabond (200ml/m)
or equivalent

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-5/10
Reserves the right to change specifications without notice
www.orbinox.com
Figure 4 Figure 5
2.2. Installation: Standard Flange Mounted
▶ Required Materials:
ORBINOX Standard Flange Mounted RR Flap Gates are installed by means of Hex Bolts and a flange gasket. For
detailed information about the size and quantity of the required bolts, or any other specific installation notes or
materials, please refer to the notes on the „General Arrangement Drawing‟.
▶ Installation:
•Partially tighten the four corner bolts, and check that the flap gate is perfectly lined up with the flange
•Install the rest of the bolts, and evenly tighten all of them

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-6/10
Reserves the right to change specifications without notice
www.orbinox.com
2.3. Installation: Wall Thimble Mounted
▶ Required Materials:
ORBINOX Wall Thimble Mounted RR and RC Flap Gates are installed by means of Hex Bolts. In order to avoid
leakage between the wall thimble and the frame, construction sealant shall be used. (Sikabond/Sikaflex 11FC
Construction Sealant or equivalent, 200ml/m or 206oz/ft of opening perimeter). For de-tailed information about
the size and quantity of the required bolts, or any other specific installation notes or materials, please refer to the
notes on the „General Arrangement Drawing‟. Note that as standard, bolts and construction sealant are not
supplied with the slide gate.
▶ Installation:
•The concrete construction shall be flat, level and plumb, and shall be in accordance to DIN 18202 or ACI
117-06 standard. If necessary, use non-shrink grout in order to meet the specified standard
•Apply construction sealant all around the perimeter of the frame. Sikabond/Sikaflex 11FC (200 ml/m) or
equivalent construction sealant shall be used
•Partially tighten the four corner bolts, and check that the flap gate is perfectly lined up with the wall
thimble opening
•Install the rest of the bolts, and evenly tighten all of them
3. OPERATION
Initial Operation:
•Before operating the flap gate, make sure there are no foreign deposits or materials on the seals, guides or
sealing area. Gate seals could be damaged if the area is not cleaned and coated with a light grease. Please
refer to section “Materials needed for maintenance and seal replacement” on page 7 for detailed
information about the required grease type
Operation:
•The RR and RC Flap Gate is operated (opened) automatically, when the seating water head is higher than
the unseating water head

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-7/10
Reserves the right to change specifications without notice
www.orbinox.com
4. MAINTENANCE
4.1. Cleaning and lubrication
ORBINOX model RR and RC Flap Gates need practically no maintenance. In order to assure maxi-mum
performance of the flap gate, the following maintenance inspections shall be carried out peri-odically every 6
months:
•Clean the gate with clear water and remove any deposits, especially on the seals and in the guides
•Check the seals and make sure they are not damaged. Seals shall be replaced if damaged. See section
„ Maintenance: Seal Replacement ‟for detailed procedures about seal replacement
•Seals shall be wet. If the flap gate has not been used for a long period of time under dry conditions, the seals
shall be wetted with clear water
Spare parts:
ORBINOX does not recommend stocking any spare parts by the owner of the equipment as the flap gates are
designed for a very long life cycle. If a repair part is required, please contact an ORBINOX representative and
provide the following information:
oORBINOX S/O number
o“ORBINOX General Arrangement Drawing” number
oProject name (if applicable)
oVendor’s company name
Materials needed for maintenance and seal replacement:
Material
Type
Recommended or equivalent
Grease
Silica-Gel Silicone Grease
Verkosil G-2
Glue
Instant adhesive
Loctite 495

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-8/10
Reserves the right to change specifications without notice
www.orbinox.com
4.2. RC Seal Replacement
The following procedure describes how to replace the RC Flap Gate’s seal. The flap shall be secured by lifting it to
the open position with a crane. In case it cannot be secured in the open position, the flap should be first removed
prior to the seal replacement.
Un-install flap (Figure 6)
•Step 1: Remove spring pins, washers and hinge pins (items 1, 2 and 3) with caution, as the flap (item 4) is
no longer secured
Seal replacement (Figure 7)
•Step 1: Remove bolts and nuts (items 2 and 3) and remove the lateral and horizontal retainers (item 4 and 5)
•Step 2: Remove seal (item 6) and replace it with the new seal
Reassembly
•Follow Steps 2 to 1
Figure 6 Figure 7

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-9/10
Reserves the right to change specifications without notice
www.orbinox.com
4.3. RR Seal Replacement
The following procedure describes how to replace the RR Flap Gate’s seal. The flap shall be secured by lifting it to
the open position with a crane. In case it cannot be secured in the open position, the flap should be first removed
prior to the seal replacement.
Un-install flap
•Step 1: Remove spring pins, washers and hinge pins (items 1, 2 and 3) with caution, as the flap (item 4) is
no longer secured
Seal replacement
•Step 1: Remove bolts and nuts (items 5 and 8) and remove the retainers (items 6)
•Step 2: Remove seal (item 7) and replace it with the new seal
Reassembly
•Follow Steps 2 to 1
Figure 8

MODEL
RR & RC FLAP GATES
EDITION 09-2020
RR & RC-10/10
Reserves the right to change specifications without notice
www.orbinox.com
SYMPTOM
CAUSE
SOLUTION
Leakage between weir gate and
concrete wall
Concrete wall does not meet the
required std.
Un-install the weir gate and fix the
wall
Not enough construction sealant.
Un-install the weir gate, clean the
wall and apply a new layer of
construction sealant
Loose anchor bolts
Tighten anchor bolts
Incorrect anchor bolts
Check the „General Arrangement
Drawing‟and make sure the right
anchor bolts have been installed
Leakage through the seal
Foreign material trapped between
frame and seal
Remove the foreign material. Check
if there is any damage to the seal
Damaged seal
Replace seal
6.ENVIRONMENTAL CONSIDERATIONS
• The packaging is made from environmentally friendly materials. Dispose of the packaging through the available
recycling channels
• The valve is designed and manufactured with materials that can be recycled by specialised recycling firms. Once
the life of the product is expired, you have to consider a proper disposal of the product in order to prevent any
negative impact on the environment and allows for the recycling of valuable commodities
• Please follow the local environmental rules in your country for proper disposal
5. TROUBLE SHOOTING