Vag GA Industries FIGURE 200 User manual

INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
FIGURE 200
RUBBER FLAPPER CHECK VALVE
TABLE OF CONTENTS
Introduction ….………………………… 2
Receiving & Storage .....……………… 2
Description of Operation .....………… 2
Valve Construction ......………………. 2
Installation ......…………………………. 3
Preventive Maintenance ....………….. 3
Trouble Shooting ...…………………… 3
Disassembly ....………………………… 3
Reassembly ....…………………………. 4
Visual Position Indicator …..………….. 4
Limit Switch Installation/Adjustment …. 4
Backflow Actuator Installation ….….…. 5
Parts & Service ………………..…….…. 6
Repair Kits ……………………………… 6
Warranty .……………………………….. 6
234 Clay Avenue • Mars, PA 16046 USA
Telephone [phone] • Fax [phone]
E-mail: [e-mail]
Manual Number 200-IOM-110520

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Figure 200 Rubber Flapper Check Valve
INTRODUCTION
This manual will provide the information to
properly install, operate and maintain the valve
to ensure a long service life. The GA Industries
Figure 200 Rubber Flapper Check Valve is
designed to provide years of dependable
operation. This manual will provide you with the
information needed to properly install and
maintain the valve and to ensure a long service
life.
The valve is of the swing check type utilizing an
angled seat and fully encapsulated, resilient
disc. It opens to allow fluid flow in the forward
direction and closes automatically to prevent
flow in the reverse direction.
The Figure 200 can handle a wide range of
fluids including those containing suspended
solids. The valve’s size, flow direction,
maximum working pressure, and series number
are cast on the valve body or stamped on the
nameplate.
CAUTION
Do not use valve for line testing at pressures
higher than nameplate rating or damage to valve
may occur.
The “Maximum Working Pressure” is the non-
shock pressure rating of the valve at 150˚ F. The
valve is not intended as an isolation valve for
line testing at pressures higher than the valve
rating.
RECEIVING AND STORAGE
Inspect valves upon receipt for damage in
shipment. Unload all valves carefully to the
ground without dropping. Do not allow lifting
slings or chains to contact the backflow actuator
or visual position indicator (if provided). Use
eye bolts or rods through flange bolt holes to lift
large valves.
Valves should remain crated, clean and dry until
installed to avoid weather related damage. For
storage longer than six months, apply a thin coat
of approved lubricant to the flexible disc.
Do not remove flange protectors until ready to
install or expose flexible disc to sunlight or
ozone for an extended period.
DESCRIPTION OF OPERATION
The valve is designed to automatically prevent
reverse flow. During forward flow conditions, the
movement of the fluid forces the disc to the open
position allowing 100% unrestricted flow area
through the valve. Upon flow reversal, the disc
automatically returns to the closed position to
prevent reverse flow.
Figure 1
VALVE CONSTRUCTION
The standard GA Industries Figure 200 Rubber
Flapper Check Valve is constructed of rugged
ductile iron with a reinforced rubber flexible disc.
See the specific Materials List submitted for the
order if other than standard construction. The
disc is the only moving part assuring long life
with minimal maintenance. The body (1) is
flanged for connection to the pipeline with an
Item
Description
Standard Material
1
Body
Ductile Iron
2
Cover
Ductile Iron
3
Flexible Disc
Buna-N Rubber Encapsulated Steel
4
Gasket
Buna-N
5
Cover Bolt
Stainless Steel

3
open top sealed with a cast cover (2). The
flexible disc (3) is retained by the cover.
An optional valve mounted position indicator,
with or without limit switch, is available to
provide local and remote position indication.
These also can be field installed (see Page 4).
An optional backflow actuator is available to
manually open the valve to allow reverse flow.
The backflow device can be easily installed in
the field (see Page 5).
INSTALLATION
The Figure 200 Rubber Flapper Check
Valve must be properly installed for proper
operation. It may be installed in either horizontal
or vertical (flow-up) applications. However,
when horizontal, the valve must be installed with
the nameplate facing up. In all installations, the
arrow cast in the valve cover must be pointed in
the direction of forward flow.
Do not remove flange protectors until ready to
install and ensure there is no debris inside the
valve before installation.
Flanged valves should only be mated with flat-
faced pipe flanges equipped with full-face
gaskets.
CAUTION
The use of ring gaskets or mating flanges with a
raised face may damage valve flanges.
The valve and adjacent piping must be
supported and aligned to prevent imposing
stress on the valve. Once the flange bolts or
studs are lubricated and inserted around the
flange, uniformly hand tighten. Then tighten the
bolts to the recommended torque in graduated
steps using the cross-over tightening method. If
leakage occurs, allow gaskets to absorb fluid
and check torque and leakage after 24 hours.
Do not exceed bolt rating or extrude gasket.
PREVENTIVE MAINTENANCE
The Figure 200 Rubber Flapper Check Valve
requires no scheduled lubrication or
maintenance. The valve can be inspected or
serviced without removal from the line.
Valve Inspection: If internal inspection of the
valve is required, follow the disassembly
instructions provided below.
TROUBLESHOOTING
Common problems and solutions are presented
below to assist you in troubleshooting the valve
assembly in an efficient manner.
• Leakage at flanges
Tighten bolts, replace gasket.
• Valve leaks backwards when closed
Inspect disc for damage and replace. Inspect
metal seating surface; clean if necessary.
• Valve does not open
Check for obstruction in valve; see Disassembly
procedure below. Operating pressure may
be insufficient to open valve. If less than 0.5
PSIG review application with factory
• Leakage at Backflow Actuator
Remove line pressure and exercise actuator. If
leak persists, replace seals in actuator; see the
Backflow Actuator Seal Replacement Procedure
on Page 6.
DISASSEMBLY
The valve can be disassembled for inspection or
repair while in the line or when removed if more
convenient. All work on the valve should be

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performed by a skilled mechanic with proper
tools. A power hoist should be employed when
disassembling large valves.
WARNING
Lock out any associated pumps. Isolate the
valve and relieve pressure before removing it
from the line or disassembling while in the line or
pressure may be released causing bodily harm.
Relieve pressure and drain the pipeline. Refer
to figure 2 on page 2. Remove the cover bolts
(4), pry cover (2) loose and lift off valve body.
Remove flexible disc (3) and inspect for cracks,
tears or damage in rubber sealing surface.
Inspect seating surface in body for damage.
Clean and inspect parts. Replace worn parts as
necessary.
REASSEMBLY
Clean gasket surfaces on body and cover with a
stiff wire brush in the direction of the serrations
or machine marks. Clean seating surface in
body with emery cloth. Lay disc (3) over seat
with beaded seating surface directed down
toward machined seat. Lay cover gasket (5)
and cover (2) over bolt holes and disc hinge.
Insert lubricated bolts (4) noting that the bolts
in the hinge area are longer than the other
cover bolts. Incrementally and uniformly tighten
cover bolts in a cross over pattern.
VISUAL POSITION INDICATOR OPERATION
The optional visual position indicator (Figure 2)
provides a local indication of the flexible disc’s
position.
The counterweight (11) rests against the back of
the flexible disc and pivots as the disc swings
from closed to open. The word CLOSED is
exposed when the valve is closed and OPEN
when the valve is fully open.
VISUAL POSITION INDICATOR FIELD
INSTALLATION
WARNING
Lock out any associated pumps. Isolate the
valve and relieve pressure before removing it
from the line or disassembling while in the line or
pressure may be released causing bodily harm.
WARNING
Do not field install the visual position indicator
unless the valve is in the horizontal position or
damage to the indicator assembly may result.
Once the indicator is installed, the valve may be
installed in a vertical (flow up) pipe
•Remove pipe plug from the port in the
cover
•Apply sealant to threads on the lower
bushing (10)
•Insert counterweighted end of assembly
(9) through the port and tighten,
ensuring the indicator flag (23) and
channel bracket (25) are parallel to the
valve’s centerline.
•Proper action can be verified by lifting
the counterweight. Do not attempt to
move the indicator flag by hand.
•Re-pressurize and check for leaks. If
further tightening is needed, ensure
indicator remains parallel to valve
centerline.
Figure 2
Item
Description
Material
9
Position Indicator Assembly
See Figure 3
10
Counterweight Arm
Stainless Steel
11
Counterweight
Stainless Steel
LIMIT SWITCH INSTALLATION AND
ADJUSTMENT
An optional single pole double throw (SPDT)
limit switch can be provided for remote indication
of valve position. The limit switch can be
supplied with the visual position indicator
assembly or added later. Refer to Figure 3.

5
To install the limit switch on the visual position
indicator assembly:
•Attach the limit switch mounting bracket
(29) to the channel bracket (25) using
the limit switch bracket mounting screws
(30).
•Mount the limit switch (28) on the
bracket using the limit switch mounting
screws (31) so that the switch’s
“whisker”is on the left side of the flag
(23) when looking at the flag.
Typically, the limit switch contacts close when
the valve is closed. Adjust the switch position so
that the indicator flag (23) actuates the switch
when the valve is fully closed. DO NOT
ADJUST THE FLAG POSITION.
Figure 3
Item
Description
Material
19
Lower Bushing
Brass
20
Roller
Stainless Steel
21
Roller O-Ring
Buna-N Rubber
22
Retaining Ring
Stainless Steel
23
Indicator Flag
Stainless Steel
24
Indicator Flag Screw & Washer
Stainless Steel
25
Channel Bracket
Aluminum
26
Upper Bushing w/Flush Port
Stainless Steel
27
Upper Bushing O-Ring
Buna-N Rubber
28
SPDT Limit Switch
See Switch for
Model Number
29
Switch Mounting Bracket
Aluminum
30
Bracket Mounting Screw & Nut
Stainless Steel
31
Switch Mounting Screw
Stainless Steel
BACKFLOW ACTUATOR OPERATION
The actuator is not designed to open the valve
with pressure at its outlet. Therefore, prior to
using the actuator, close the pump isolation
valve and relieve line pressure between the
check valve and isolation valve. To open the
valve, loosen the jam nut (15) turn the T-handle
clockwise. The handle should turn easily.
When resistance is felt, the disc has reached its
body stop and is in the fully open position. Then
open the isolating valve to allow backflow
through the valve.
WARNING
Relieve line pressure before using back flow
actuator or damage may occur.
Upon completion of the backflushing operation,
turn the T-handle fully counterclockwise to allow
the valve disc to return to the closed position.
Lock the backflow actuator in the closed position
with the jam nut (15). The system is again ready
for normal operation.
BACKFLOW ACTUATOR FIELD
INSTALLATION
•Isolate the rubber flapper check valve,
depressurize and drain pipeline.
WARNING
Removal of the bottom plug while under
pressure may cause bodily harm.
•Remove the pipe plug in the bottom
boss of the valve.
•Inspect the backflow rod (16) and
ensure the T-handle has been turned
fully counterclockwise. The rod should
extend about 1” past the end of the
brass backflow tube (14). Apply thread
sealant to brass threads.
•Insert the threaded end of the assembly
into the valve boss. Slowly turn the
assembly into the boss. Continue
turning the assembly into the valve for a
tight fit.
•Introduce pressure and check for leaks.
Tighten if needed.

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Figure 4
Item
Description
Material
12
Rod Wiper
Urethane
13
Rod Seal
Buna-N Rubber
14
Backflow Tube
Brass
15
Jam Nut
Stainless Steel
16
Backflow Rod
Stainless Steel
17
T-Handle
Stainless Steel
18
Setscrew
Stainless Steel
Backflow Actuator Seal Replacement:
There are two parts (12 & 13) on the
backflow actuator that are subject to wear.
Before replacing the seals, the pipeline must
first be depressurized and drained. Next,
remove the backflow assembly from the
valve by turning the Backflow tube (14)
counterclockwise. Disassemble the actuator
as follows:
•Remove the Set Screw (18) with an
Allen wrench.
•Loosen the jam nut (15) and spin it back
until it’s just under the T-Handle (17).
Turn the T-Handle fully clockwise (17),
then remove the Setscrew (18), T-
handle (17) and jam nut (15) from the
Backflow rod (16).
•Remove the rod (16) from the tube (14)
by hand turning it counterclockwise. Do
not use tools that would score or
damage the smooth sealing surface.
•Using a pick remove the rod wiper (12)
and rod seal (13) from the end of the
backflow tube (14).
•Inspect and if needed clean the inside of
the backflow tube.
•Lubricate rod wiper and rod seal with
approved grease and install in the
grooves in the backflow tube.
•If necessary, clean the backflow rod with
fine emery cloth. Lubricate the non-
threaded portion with approved grease
and thread into the backflow tube being
careful not to damage the rod seal or
wiper.
•Install jam nut, T- handle and setscrew.
•Turn T-handle fully counterclockwise.
•Apply thread sealant to bushing and
carefully thread into valve taking care
not to cross-thread the bushing.
•Introduce pressure and check for leaks.
Tighten if necessary.
PARTS AND SERVICE
Parts and service are available from your local
representative or the factory. Make note of the
Valve Size, Series No., and Serial No. located
on the valve nameplate and contact:
VAG USA, LLC
234 Clay Avenue
Mars, PA 16046 USA
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
REPAIR KITS
Repair Kit includes Buna-N flexible disc (3) and
cover gasket (4).
Size
Kit Number
Part Number
2”
RF2
2-80-16000-005
2½”
RF2.5
2-80-16000-062
3”
RF3
2-80-16000-008
4”
RF4
2-80-16000-009
6”
RF6
2-80-16000-010
8”
RF8
2-80-16000-011
10”
RF10
2-80-16000-000
12”
RF12
2-80-16000-001
14”
RF14
2-80-16000-002
16”
RF16
2-80-16000-003
18”
RF18
2-80-16000-004
20”
RF20
2-80-16000-006
24”
RF24
2-80-16000-007
WARRANTY
The Warranty for GA Industries valves is
included in our Terms and Conditions which can
be found here: https://gaindustries.com/terms

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