Vag HYDRUS G Manual

KAT 1611-B1 Edition1 12-18
Operation and Maintenance Instructions
VAG HYDRUS®G Underground Hydrant

Contents
VAG reserves the right to make technical changes and
use materials of similar or better quality without express
notice. The pictures are non-binding.
Inhalt
1 General 3
1.1 Safety 3
1.2 Proper use 3
1.3 Identification 3
2 Transport and Storage 3
2.1 Transport 3
2.2 Storage 3
3 Product features 4
3.1 Features and function description 4
3.2 Applications 4
3.3 Permissible and impermissible modes of
operation 4
4 Installation into the pipeline 4
4.1 Conditions required on site 4
4.2 Assembly instructions and fitting 4
4.3 Assembly of the VAG HYDRUS®G
Underground Hydrant 4
4.3.1 HYDRUS®G flange version 4
4.3.2 HYDRUS®G BAIO Spigot end version 4
5 Set-up and operation of the valve 5
5.1 Visual inspection and preparation 5
5.2 Function check and pressure test 5
5.3 Initial operation 5
5.4 Operation 6
5.4.1 Opening the hydrant 6
5.4.2 Closing the hydrant 6
6 Maintenance and repair 7
6.1 General safety instructions 7
6.2 Inspection and operation intervals 7
6.3 Maintenance work and replacement of
parts 7
6.3.1 Design 7
6.3.2 Cleaning and lubrication 7
6.3.3 Visual and function check 8
6.4 Maintenance 8
6.4.1 Disassembly of the entire bonnet (7.1) 8
6.4.2 Replacing the stem (7.3); packing
sleeve (7.2) or sliding disks (7.4) 8
6.4.3 Replacement of the complete main
valve assembly (15) or the valve cone
(15.3) 8
7 Trouble-shooting 9
8 How to contact us 9

VAG Operation and Maintenance Instructions • 3
1 General
1.1 Safety
These Operation and Maintenance Instructions must
be observed and applied at all times along with the
general “VAG Installation and Operation Instructions
for Valves” (see www.vag-group.com / Category: Ins-
tallation and Operation Instructions).
Arbitrary alterations of this product and the parts supplied with it
are not allowed. VAG will not assume any liability for consequenti-
al damage due to non-compliance with these instructions.
When using this valve, the generally acknowledged rules of tech-
nology have to be observed (e.g. national standards, EN 1074-6
hydrants, fitness for purpose requirements and appropriate veri-
fication tests, etc.). The installation must only be carried out by
qualified staff (see also Section 6.1 General safety instructions).
For further technical information such as dimensions, materials or
applications, please refer to the respective documentation (KAT
1611-A).
VAG valves are designed and manufactured to the highest stan-
dardst and their safety of operation is generally ensured.. How-
ever, valves may be potentially dangerous if they are operated
improperly or are not installed for their intended use.
Everyone dealing with the assembly, disassembly, operation,
maintenance and repair of the valves must have read and under-
stood the complete Operating and Maintenance Instructions (Ac-
cident Prevention Regulations, ANSI Z535).
Before removing any protective devices and/or performing any
work on the valves, depressurise the pipeline section and ensure
it is free of hazards. Unauthorised, unintentional and unexpected
actuation as well as any hazardous movements caused by stored
energy (pressurised air, water under pressure) must be prevented.
In case of equipment that must be monitored and inspected, all
relevant laws and regulations, such as the Industrial Code, the
Accident Prevention Regulations, the Ordinance of Steam Boilers
and instructional pamphlets issued by the Pressure Vessels Study
Group must be complied with. In addition, the local accident pre-
vention regulations must be observed.
When a valve needs to be dismantled from a pipeline, fluid may
emerge from the pipeline or the valve. The pipeline must be emp-
tied completely before the valve is dismantled. Special care needs
to be taken in case of residues which may continue flowing.
1.2 Proper use
The VAG HYDRUS®G Underground Hydrant is a valve for instal-
lation in drinking water pipeline networks.
Refer to DVGW technical standard W331 for deployment and cor-
rect installation.
For the respective technical application ranges (e.g. operating
pressure, medium, temperature) please refer to the product-rela-
ted documentation (KAT 1611-A).
For any alternative operating conditions and applications, the
manufacturer’s written approval must be obtained!
These Operation and Maintenance Operation Instructions contain
important information on the safe and reliable operation of the
VAG HYDRUS®G Underground Hydrant.
Observing these Operation and Maintenance Instructions helps
you to:
•Prevent hazards
•Reduce repair costs and down-times of the valve and/or the
entire equipment
•Improve the operational safety and useful life of the equipment.
1.3 Identification
According to DIN EN 19 all valves bear an identification label spe-
cifying the nominal diameter (DN), nominal pressure (PN), body
material and the manufacturer’s logo.
After installation in the pipeline cap the following information can
been seen on the name plate when viewed from above.
VAG Manufacturer’s name
DN Nominal diameter of the valve
PN Nominal pressure of the valve
Version - flange or BAIO®plus
Installation depth (important for spare part definition)
Date of manufacture
VAG name plate
Picture 1: VAG name plate
2 Transport and Storage
2.1 Transport
For transportation to its installation site, the valve must be packed
in stable packaging material suitable for the size of the valve. It
must be ensured that the valve is protected against atmospheric
influences and external damage. When the valve is shipped under
specific climatic conditions (e.g. overseas transport), it must be
specially protected and wrapped in plastic film and a desiccant
must be added.
The factory-applied corrosion protection and any assemblies
must be protected against damage by external influences during
transport and storage.
2.2 Storage
The VAG HYDRUS®G Underground Hydrant must be stored with
the opened stopper in the horizontal position.
The elastomeric parts (seals) must be protected against direct
sunlight and/or UV light otherwise their long-term sealing function
cannot be guaranteed. Store the valve in a dry and well-aerated
place and avoid direct radiator heat. The protective cover protects
functionally important components from dust and other external
impurities.
Do not remove the protective caps of the connections / flanges
and the packaging materials until immediately prior to assembly.
The valve can be stored in ambient temperatures ranging from

VAG Operation and Maintenance Instructions • 4
-20 °C to + 50 °C (protected by adequate covers). If the valve is
stored at temperatures below 0 °C, it should be warmed up to at
least +5° C before installation and before it is put into operation.
3 Product features
3.1 Features and function description
In its dimensions, function and hygienic characteristics the VAG
HYDRUS®G Underground Hydrant meets current standards.
• VP 325 Hydrants, requirements and tests
• EN 1074-6 Hydrants, requirements, fitness for purpose and ve-
rification tests
3.2 Applications
Due to the EPDM gasket materials used the standard version of
the VAG HYDRUS®G Underground Hydrant is suitable for the
following media:
• Water, at a maximum temperature of 50°C
The use of media containing oil and gas may damage the lining
and gaskets and is thus not permissible.
For information about the corresponding temperature limits, ple-
ase refer to the product-related technical documentation (KAT
1611-A).
In case of deviating operating conditions and applications, please
consult the manufacturer.
3.3 Permissible and impermissible modes of
operation
The maximum operating temperatures and operating pressures
specified in the technical documentation (KAT 1611-A) must not
be exceeded.
The pressure applied to the closed valve must not exceed its ra-
ted pressure.
For reasons of cavitation safety the maximum flow rate should not
exceed 1.5 times the Kv-value according to applicable technical
standards.
The valve may only be operated in fully opened position. Regu-
lation of the flow may only take place via the extraction valves
located on the standpipe.
Extracting water while the shut-off cone is in a partially open po-
sition can cause cavitation effect in the seat area, resulting in lea-
kiness.
For correct operation of the valve DVGS standard W 331 must be
complied with.
The metallic limit stops when the hydrant is in open and closed
position are clearly noticeable. The design of the installed sealing
system guarantees tightness in this position. It is thus not neces-
sary to exert extra force to close the valve into an end position.
This may cause an overload of the limit stops, or result in the valve
being stuck in an end position or damaged.
4 Installation into the pipeline
4.1 Conditions required on site
Observe the provisions of the DVGW standard W 331
when installing the VAG HYDRUS®G Underground
Hydrant.
The flange version of the VAG HYDRUS®G is deli-
vered with a multifunction seal integrated in the flange. An additi-
onal flat seal for the flange connection to the pipeline should not
be used. The multifunction seal should not be removed, because
doing so will impair the function of the hydrant during operation.
To reliably drain the underground hydrant we recommend the ad-
ditional installation of the VAG seepage stone.
Without a seepage stone the lower draining point must be sur-
rounded by packed gravel or crushed rock that permits draining.
The draining area (immediately above the flange connection) must
never be blocked by the external application of sealants
4.2 Assembly instructions and fitting
Check the valve for possible damage that it may have occurred
during transport and storage. Until installation the valve is protec-
ted from dirt accumulating during construction site operations via
a factory mounted cover (13 or 21).
4.3 Assembly of the VAG HYDRUS®G
Underground Hydrant
Remove the protective flange cover (13) prior to attachment to the
pipeline, for a version with BAIO®spigot end detach the transport
guard (21) from the spigot end.
Picture 2: : Detailed view of assembly instructions
13
6
19
20
21
4.3.1 HYDRUS®G flange version
Multifunction sealing ring (6) is pressed in at the factory and is
used as a sealing for the pipeline flange. An additional flat seal
should not be used.
After attaching the underground hydrant tighten the flange bolting
crosswise.
4.3.2 HYDRUS®G BAIO Spigot end version
Push the spigot end into the socket all the way to the stop and
turn the hydrant 45° clockwise all the way to the noticeable metal-

VAG Operation and Maintenance Instructions • 5
lic stop. While doing so make sure that the safety ring (19) locks
into place and that it is seated on the socket on the face side. You
may need to manually push it down. Check the function of the
interlock by turning it back.
Pull down the protective rubber lining (20) over the 3 cams located
on the outside of the socket.
Picture 3: Detailed view of spigot version
19
20
Before filling in the pipe trench install the appropriate VAG seepa-
ge stone for the safe draining of the underground hydrant.
In addition, observe the installation guidelines set out in DVGW
worksheet W 331 to install the HYDRUS®G.
Picture 4: Seepage stone
Seepage stone
5 Set-up and operation of the valve
5.1 Visual inspection and preparation
Before putting the valve and the equipment into operation, per-
form a visual inspection of all functional parts.
The fittings are sufficiently lubricated at the factory for purposes of
assembly, storage and transport. For maintenance work specified
in accordance with M 392 the lubricant for drinking water lines
approved for foodstuffs or drinking water,
• KLÜBERSYNTH VR 69-252 N (with KTW approval for drinking
water) manufactured by Klüber Lubrication München AG,
must be used.
5.2 Function check and pressure test
Prior to installation the working parts of the valve must be ope-
ned up completely and closed at least once and the movement
checked.
Caution!! During a pressure test of the pipeline the
closed valve may only be put under a load up to its no-
minal pressure (see technical data sheet KAT 1161-A).
Caution!! According to the technical standard a leaka-
ge rate of only E in accordance with DIN EN 1226-1 is
guaranteed for the draining seal that is active when the
cone is open. This means that there is no tightness gu-
arantee on the part of the manufacturer for a pressure
test in this position.
For test pressures higher than the approved nominal pressure the
hydrant must be disassembled and the flange blanked using a
blind flange .
Newly installed pipeline systems should first be carefully flushed
to remove all foreign matter. Should any residue or impurities exist
in the pipeline they may clog the internals during the flushing pro-
cess. This may impact the tightness function of the fitting or da-
mage the lining of the shut-off cone.
In particular, after repairs are carried out, but before putting new
systems into operation, the pipeline system must be flushed again
with a fully opened valve. Any cleaning or disinfecting agents used
may not corrode the fitting materials. The fitting is normally closed
by being turned in clockwise direction.
5.3 Initial operation
VAG HYDRUS®G Underground Hydrants are delivered in versi-
ons with
a) self-closing outlet claw cover (2.1)
b)claw, muzzle protector and plastic cover (2.2).
Installation of the standpipe must be carried out according to the
version of claw used.
Lift up self-closing outlet claw cover (2.1), or remove plastic out-
let claw cover (2.2). Attach and tighten standpipe. Check that the
base pins are properly seated in the claw (1.1) by shaking the
standpipe.
Fill the piping section. In doing so the underground hydrant can be
used to release air and be flushed afterwards.
Caution!! The hydrant shut-off valve must always be
completely open. Throttling of the flow may only take
place via the valves on the standpipe.
Throttling the hydrant shut-off valve may result in high
flow velocities occurring within the valve

VAG Operation and Maintenance Instructions • 6
Picture 6: VAG HYDRUS®G with claw, muzzle protector and plastic cover (2.2)
Picture 5: VAG HYDRUS®G with self-closing claw cover (2.1)
Standpipe
Standpipe
2.1
1.1
2.2
1.1
5.4 Operation
5.4.1 Opening the hydrant
Lift street cap cover at lifting support and turn sideways until the
street cap is freely accessible.
Clean claw (1.1) and claw cover (2.1/2.2) in street cap. Lift up self-
closing outlet claw cover (2.1), or remove plastic outlet claw cover
(2.2).
From above Insert standpipe with claw nuts bolted downwards
into the claw (1.1.) and turn clockwise until the claw (1.1) is firmly
seated. Check that the base pins are properly seated in the claw
(1.1) by shaking the standpipe.
Caution! Make sure the standpipe valve is wide open, allowing air
to escape when opening the hydrant shut-off valve.
Open by slowly and completely turning the hydrant shut-off hand-
ling key anti-clockwise (approx. 9 turns) until the clearly noticeable
metallic limit stop.
The metallic limit stops when
the hydrant is in open and
closed position are clearly
noticeable. The design of
the installed sealing system
guarantees tightness in this
position.
It is thus not necessary to
exert extra force to close
the valve into an end po-
sition. This may cause an
overload of the limit stops,
or result in the valve being
stuck in an end position.
Flush underground hydrant
and standpipe with the wa-
ter flowing out. In new con-
dition the underground hydrant requires torque of approx. 40 Nm
to open. This can increase significantly during operation depen-
ding on maintenance condition.
Caution! Before opening the underground hydrant the
operator must make sure that no initial gate valve im-
mediately upstream from the underground hydrant is
closed. Because the underground hydrant closure de-
vice opens down into the pipeline, a strong rise in ope-
rating torque would occur due to the incompressibility
of the water, perhaps causing damage to internal parts.
Caution! The hydrant shut-off valve must always be
completely open. Regulation of the quantity dispensed
many only take place via the valves on the standpipe.
When throttling the hydrant shut-off valve high flow ve-
locities occur in interim position that may result in cavi-
tational effects.
5.4.2 Closing the hydrant
Do not close the standpipe completely. With the standpipe valve
open slightly close it by evenly turning the handling key for the hy-
drant shut-off slowly and completely (approx. 9 turns) in clockwise
direction towards the metal limit stop.
Caution !! By not opening the standpipe valve strong
overpressure can build up when closing the hydrant
shut-off.
Picture 7: Hydrant operation
Limit stop in
closed position
Limit stop in
open position

VAG Operation and Maintenance Instructions • 7
Make sure to drain the hydrant.
After approx. 2 minutes loosen the standpipe from the claw (1.1)
by turning anti-clockwise. Afterwards lock claw cover (2.2) and
claw (1.1) into place (the self-closing claw cover closes by itself)
and close street cap safe for traffic.
6 Maintenance and repair
6.1 General safety instructions
Prior to the performance of inspection and maintenance work on
the valve or its assemblies, shut-off the pressurised pipeline, de-
pressurise it and secure it against inadvertent activation.
After completing the maintenance works and before resuming
operation, check all connections for proper fastening and tight-
ness. Perform the steps described for initial set-up as described
under Section 5 “Set-up and operation”.
Statutory and local provisions as well as the safety and accident
prevention regulations must be observed and complied with at all
times.
Servicing, maintenance and inspection work as well as the repla-
cement of spare parts must only be done qualified staff. The plant
operator is responsible for determining the suitability of the staff or
for ensuring that they have the relevant qualifications.
If the operator’s employees do not have the qualifications requi-
red, they need to attend a training course. This training course can
e.g. be held by VAG Service employees.
In addition to this, the plant operator needs to ensure that all em-
ployees have understood these Operation and Maintenance Inst-
ructions as well as all further instructions referred to in them.
Protective equipment such as safety boots, safety helmets, gogg-
les, protective gloves etc. must be worn during all work requiring
such protective equipment or for which such protective equip-
ment is prescribed.
Improper or wrong use of the valve should be avoided. Prior to the
performance of any work on the valve and equipment it must be
ensured that the relevant pipeline section has been depressurised
and/or de-energised.
6.2 Inspection and operation intervals
Tightness, movement and corrosion protection of the VAG HYD-
RUS®G Underground Hydrant should be checked at least once
every 4 years (DVGW worksheet W 392).
Depending on operating experience this maintenance schedule
can be shortened or prolonged.
6.3 Maintenance work and replacement of
parts
6.3.1 Design
The design view in Fig. 8 is a partial overview of the following de-
scriptions of work procedures.
6.3.2 Cleaning and lubrication
Use KLÜBERSYNTH VR 69-252 N (with KTW approval for drinking
Picture 8: Design and assemblies
Pos. Benennung Material Assembly
1.1 Self-closing claw EN-JS 1050 1. Complete self-
closing claw
1.2 Sealing ring Brass
1.3 O-ring NBR
2.1 Claw EN-JS 1050
2. Complete claw
2.2 Claw cover
with cord Polyamide
2.3 Mouthpiece
closure NBR
3 Disk A2-70 3. Disk DIN 125-17
6 Sealing ring NBR /
polyamide 6. Sealing ring
7.1 Bonnet EN-JS 1050
7. Complete bonnet
7.2 Packing sleeve Brass
7.3 Stem 1.4021
7.4 Sliding disk Polyamide
7.5 O-ring NBR
8Hexagonal
bolt M16 A2-70 8. Hexagonal bolt
9 Stem square cap EN-JS 1050 9. Stem square cap
11 Name plate Plastic 11. Name plate
13 Protective cap Plastic PP 13. Protective cap
15.1 Stem nut Brass
15. Complete main
valve assembly
15.2 Pressure tube 1.4301
15.3 Valve cone EN-JS 1050/
EPDM
15.4 Bolt rivets 1.4305
16.1 Draining sleeve 1.4305 16. Complete drai-
ning protection
16.2 Draining protec-
tion Polyethylene
17 Hollow ball,
green Plastic PP 17. Hollow ball, green
HYDRUS®G1
Single shut-off
HYDRUS®G2
Double shut-off

VAG Operation and Maintenance Instructions • 8
water) manufactured by Klüber Lubrication München AG.
6.3.3 Visual and function check
• Easy movement of hydrant shut-off
• Integrity of the claw (1.1) for use in standpipe.
• Drain function of the hydrant. Complete draining should be com-
pleted within 5 minutes. Should draining not take place within
this period it is highly probable that the drain hole is clogged.
• The following may resolve the problem:
a) Create internal pressure (max. 24 bar) using a manual pump
with the shut-off closed
b) Disassemble main valve assembly and mechanically clean
(e.g. slat with nails) drain hole (see 7.1)
c) a) and b) are unsuccessful, the fitting will have to be
excavated and replaced
• Function and cleanliness of internal parts of hydrant, cleaning by
flushing a short time, water always leads away from standpipe
and hose without any problem.
• Tightness of the hydrant shut-off. The frequent cause of leaks is
foreign matter (e.g. plastic shavings, etc.) These can be remo-
ved by flushing or by extraction using auxiliary tools.
6.4 Maintenance
Make sure to follow 6.1 for all maintenance and servicing work.
Refer to VAG Spare Parts List KAT 1611-E for all required spare
parts.
The VAG HYDRUS®G Underground Hydrant has an integrated
safety interlock for the main valve assembly. If after removing the
bonnet (7.1) the main valve assembly is moved upwards it cannot
be expelled from the jacket pipe. The integrated internal fixed stop
on the front side of the jacket pipe prevents this. After turning
approx. 30° clockwise the main valve assembly is unlocked and
can be extracted. This makes it impossible for the main valve as-
sembly to be expelled unintentionally due to uncontrolled residual
pressure.
6.4.1 Disassembly of the entire bonnet
(7.1)
Clean the upper section of the underground hydrant in the area of
the bonnet. Remove the two bolts (8) on the bonnet attachment.
Turn stem square cap (9) clockwise until stem (7.3) is completely
unwound from stem nut (15.3). Remove the bonnet from above.
6.4.2 Replacing the stem (7.3); packing
sleeve (7.2) or sliding disks (7.4)
Disassemble bonnet as described in 7.5.1. Remove the stem
square cap by loosening the cylinder screw on the front side. Pull
off the stem square cap and the name plate. Completely undo
the screw connection between the packing sleeve (7.2) and the
bonnet (7.1). Pull off the stem (7.3) and completely disassemb-
le all individual components. Replace parts as necessary in ac-
cordance with Spare Parts List KAT 1611-E. Assembly is done in
the opposite order.
6.4.3 Replacement of the complete main
valve assembly (15) or the valve cone
(15.3)
When removing the main valve assembly (15) make sure to obser-
ve the general safety instructions in 6.1.
Before beginning disassembly open the hydrant for a short time
with opened initial gate valve (approx. 3-4 turns clockwise) to al-
low any air collected upstream from the hydrant shut-off to es-
cape. The initial gate valve can then be closed with the hydrant
shut-off in open position.
Clean the upper section of the underground hydrant in the area of
the bonnet. Remove the two bolts (8) on the bonnet attachment.
Turn stem square cap (9) clockwise until stem (7.3) is complete-
ly unwound from stem nut (15.3). Then turn the stem (7.3) back
approx. 3 turns in clockwise direction. Use both hands to grasp
below the bonnet (7) and pull up as far as it goes. You may need
to employ additional tools. Then screw off the stem in clockwise
direction and pull off the complete bonnet from above.
Use stem nut to turn main valve assembly approx. 30° anti-clock-
wise and then completely remove from above.
Then grind off the front part of the bottom bolt rivet (15.4) below
the valve cone (15.3) and knock out the bolt rivets. From below
pull the valve cone out of the pressure pipe (15.2) and insert the
pre-drilled replacement valve cone and fasten using the included
bolt and the self-securing cap nut.
Installation is done in the opposite order.
Picture 9: Maintenance
Picture 10:Spare parts set shut-off cone with bolt and self-securing cap nut
30°

VAG Operation and Maintenance Instructions • 9
7 Trouble-shooting
Name Material Assembly
Hydrant hard to open Initial gate valve closed Open initial gate valve and try again
Hydrant sticky Wear and tear and bearing Replace the entire bonnet or sliding disk, as described
in 6.4.1/6.4.2.
Tightness on the hydrant shut-off. Foreign material (e.g. plastic
shavings) are stuck between
the valve cone (15.3) and valve
seating socket
Flush hydrant by opening the hydrant shut-off valve for
a short time. Then check tightness again.
Still leaking from hydrant shut-off Damage to the valve cone
(15.3) or the valve seating so-
cket
Remove the main valve assembly (see 6.4.3) and repla-
ce the valve cone (15.3). If valve seating socket is da-
maged the complete hydrant will have to be replaced.
For all repair and maintenance work, please observe the general
safety instructions described in Section 6.1!
8 How to contact us
Head office
VAG GmbH
Carl-Reuther-Str. 1
68305 Mannheim
Germany
Telephone: [phone]
Fax: [phone]
[email protected]
http://www.vag-group.com
Service
Our service hotline can be reached 24/7 world-wide. In case of
emergency, please contact us by phone.
Service hotline: +49 621 - 749 2222
Service per email: [email protected]

Edition1 - 12/2018
VAG GmbH
Carl-Reuther-Str. 1
68305 Mannheim
Germany
Tel. [phone]
Fax [phone]
[email protected]
www.vag-group.com