Vag EROX plus Penstock User manual

KAT 2452 - Edition4 - 01-04-2019
VAG EROX®plus Penstock
Installation and Operating Instructions

Table of Contents VAG reserves the right to make technical changes and use
materials of similar or better quality without prior notice. The
pictures used are typical and non-binding.
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 4
3 Product features 4
3.1 Features and function description 4
3.2 Fields of application 5
4 Installing the valve 5
4.1 On-site requirements 5
4.2 Installing the valve 5
4.2.1 Fixing the VAG EROX®plus Penstock to the
structure with anchor bolts 5
4.2.2 Assembly of the VAG EROX®plus Penstock;
Control distance measure of slide plate 7
4.2.3 Channel mounting 7
4.3 Installation position 8
4.4 Assembly instructions and fasteners 8
5 Set-up and operation 8
5.1 Visual inspection and preparation 8
5.2 Function check and pressure test 8
6 Actuators 9
6.1 General 9
6.2 Operation torques 9
6.3 Assembly of the electric actuator 9
7 Maintenance and repair 10
7.1 General safety instructions 10
7.2 Inspection and operation intervals 10
7.3 Maintenance work and replacement of parts 10
8 Trouble-shooting 10
9 How to contact us 11

VAG Installation and Operating Instructions • 3
Bridge
Picture 1: Transport position of the EROX®plus Penstock
1 General
1.1 Safety
These Installation and Operation 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: Installation and Operating Instructions).
Arbitrary alterations of this product and the parts supplied with it
are not allowed. VAG does not assume any warranty or liability for
consequential damage arising from non-compliance with these
instructions. When using this valve, the generally acknowledged
rules of technology have to be observed (e.g. DIN standards,
DVGW guidelines, VDI directives, etc.). The Penstock must only
be installed by qualified, specially trained staff. For further techni-
cal information such as dimensions, materials or applications,
please refer to the respective documentation (KAT-A 2452).
VAG valves are designed and manufactured to the state of the art
and their safety of operation is ensured in general. However,
valves may be potentially dangerous if they are operated impro-
perly or are not applied for the intended use.
Everyone dealing with the assembly, disassembly, operation,
maintenance and repair of the Penstock must have read and un-
derstood the complete Operating and Maintenance Instructions
(Accident Prevention Regulations, VBG 1 §14 ff [Regulations is-
sued by the Trade Associations].
The pressure in the pipeline section must be relieved and hazards
must be eliminated before protective devices are removed and/or
work is performed on penstocks. Unauthorised, unintentional and
unexpected actuation as well as any hazardous movements
caused by stored energy (pressurised air, water under pressure)
must be prevented.
For equipment for which monitoring is mandatory, the relevant
laws and regulations such as the Industrial Code, Accident Pre-
vention Regulations, Boiler Inspection Regulations, AD Data
Sheets (AD = Boiler Study Group) etc. must be complied with. In
addition to this, local accident prevention regulations must be
complied with.
For customised models of the VAG EROX®plus Penstock, please
read the order-related instructions which may be included sepa-
rately and/or are included in the order documentation.
Arbitrary alterations of this product, the parts and accessories
supplied with it are not allowed. VAG does not assume any liabili-
ty for any hazards and damage resulting from the improper use of
the product and from non-compliance with the instructions con-
tained in this document.
1.2 Proper use
The VAG EROX®plus Penstock is a shut-off and modulating
valve for use in wastewater systems.
Its standard version is suitable for sealing pipelines and openings
in constructions (depending on the nominal diameter) up to a
pressure of 10 m water column (1.0 bar) and for modulating the
flow rate. The pressure-rate is valid for both direction.
For the respective technical application ranges (e.g. operating
pressure, medium, temperature) please refer to the product-rela-
ted documentation (KAT-A 2452).
Any deviating operating conditions and applications require the
manufacturer‘s prior written consent!
These Installation and Operation Instructions contain important
information on the safe and reliable operation of the VAG ®plus
Penstock.
Compliance with these Installation and Operation Instructions
helps:
• to prevent hazards,
• to reduce repair costs and down-times of the Penstock and/or
the entire equipment,
• to improve the operational safety and useful life of the equip-
ment.
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.
A rating plate is attached to the body and contains at least the fol-
lowing information:
VAG Manufacturer’s name
DN Nominal diameter of the valve
PN Nominal pressure of the valve
Serial number of the valve and Date of manufacture
2 Transport and storage
2.1 Transport
For transportation to its installation site, the Penstock must be pa-
cked in stable packaging material suitable for the size of the Pen-
stock. The container also needs to ensure that the Penstock is
protected against weather influences and damage. When the
Penstock is transported over long distances (e.g. overseas) and
exposed to special climatic conditions, it needs to be protected
by sealing it in plastic wrapping and adding a desiccant.
Any assemblies must be protected against damage by external
influences during transport and storage.
The VAG EROX®plus Penstock must be transported lying flat on
its rear side and in almost closed position (cf. Picture 1). Special
varieties and Penstocks in nominal sizes which due to their overall
size cannot be transported in a lying position will be delivered in a
special transport rack.
When actuators are mounted to the bridge of the Penstock, safe
bearings for the actuators need to be provided to prevent the
joints from being exposed to shunt loads.
For transport purposes and also to support assembly, lifting de-
vices such as cables and belts must always only be attached to
the bridge of Penstock (see Picture 1). The actuator, which may
have been assembled, is not suitable for this purpose. The length

VAG Installation and Operating Instructions • 4
Picture 2: Standart Version
EROX®plus
Picture 3: EROX®plus with
open frame
Top
traverse
Frame
Stem
Stem nut
Gate
Retainer
Wall seal
Picture 4: EROX®plus design
and positioning of the cables/belts must ensure that the Penstock
is in a vertical position during the entire lifting procedure.
For Penstock that have been factory-packed in transport crates
(wooden crates), the centre of gravity of the entire unit must be
taken into account.
2.2 Storage
The VAG EROX®plus Penstock must be stored lying flat on its rear
side.
The elastomeric parts (seals) must be protected against direct
sunlight and/or UV radiation as otherwise their long-term sealing
function cannot be guaranteed. Store the Penstock in a dark, dry
and well-aerated place. The direct exposure of the Penstocks to
radiation heat emitted by sources of heat should be avoided. Pro-
tect any assembly units important for proper function such as the
stem, stem nut, sealing ring or gate against dust and other dirt by
adequate covering.
The Penstock can be stored in ambient temperatures ranging
from -20 °C to +50 °C (protected by adequate covers). If the Pen-
stock 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
The VAG EROX®plus Penstock is a shut-off and modulating valve.
It seals pipelines or openings in constructions up to a pressure
(depending on the nominal diameter) of 10 m water column (1.0
bar). The pressure-rate is valid for both direction.
The following pressure ratings apply for the standard versions:
DN 150 to DN 300: up to 10 m WC (1.0 bar)
DN 400 to DN 800: up to 8 m WC (0.8 bar
DN 900 to DN 1200: up to 7 m WC (0.7 bar)
above DN 1200: up to 6 m WC (0.6 bar)
As a standard, the VAG EROX®plus Penstock is available in nomi-
nal diameters from DN 150 to DN 1200 in the following versions:
• for flange connection (F)
• with smooth surfaced bottom seal (G)
• The VAG EROX®plus Penstock is available in two basic versi-
ons
Standard version EROX®plus (Picture 2) with closed frame, com-
pact valve, ready for assembly, with non-rising stem and integra-
ted stem bearing. This version should preferably be used for non-
submerged installation as the sensitive components moving in
relation to each other (stem, stem nut and stem bearing) are ar-
ranged directly on the Penstock. In submerged installation, they
would come into direct contact with the medium and be difficult
to service. Also, the soiling of the operating components increa-
ses the operating torques and may even lead to the Penstocks
not being operable any more, which means increased wear and
tear and a shorter useful life.
Special version EROX®plus-O (Picture 3) with open frame. This
version is also delivered ready for assembly and especially serves
as basic version for all solutions with rising stem. This version
should preferably be used for submerged installation, as in this
case the sensitive components moving in relation to each other
(stem, stem nut and stem bearing) are arranged at the same level
as the actuator (handwheel, electric actuator or gear box). In sub-
merged installation, these components are located outside the
medium, are therefore easily accessible at any time and can be
easily serviced. Contrary to the standard version described abo-
ve, the EROX®plus-O type with rising stem has constantly low
operating torques and little wear of the actuating components.
The VAG EROX®plus Penstock has a sturdy, torsion-resistant
frame construction. It remains dimensionally stable when the
Penstock is mounted to walls (of evenness within the tolerances
of DIN EN 18202).
The wide tolerance wall seal reliably compensates any permissib-
le unevenness of the wall. In the standard version shown, the
stem runs on slide bearings located in the top traverse of the
frame. When the stem is turned via the stem nut, the gate is mo-
ved up or down. The gate runs safely and backlash-free in the la-
teral frame sections.
The VAG EROX®plus Penstock has some advanced technical fea-

VAG Installation and Operating Instructions • 5
Penstock
dimensions (mm) 400x400 500x500 600x600 700x700
max. leakage
(1%)
liter/
minute 0,048 0,06 0,072 0,096
Penstock
dimensions (mm) 900x900 1000x1000 1200x1200
max. leakage
(1%)
liter/
minute 0,108 0,12 0,144
Table 1: Leakage rates Note: The table refers to "on seating" pressure. For "off
seating" pressure the values can be multiplied by 3.
tures which form the basis of its reliable and tight sealing function
and ensure low operating torques.
Locking system:
This additional locking system (used from DN 700 on) effectively
supports the tightness of the upper lateral seal.
Profiled seal:
The specially shaped profiled seal inserted in the frame section
ensures the excellent tightness of the Penstock. To replace the
profiled seal, it is not necessary to dismantle the Penstock.
Bottom seal:
The wide, voluminous and flat bottom seal ensures reliable
sealing of the gate when the Penstock is in closed position.
Patented sliding wedge system:
The VAG sliding wedge system combines the advantages of the
sliding system (good guiding properties, vibration-free, valve can
also be used in intermediate position) with those of the wedge
system (relief of the load on the seal, reduced wear, low operating
forces and excellent, reliable tightness).
As the wedges are connected in series, more wedges can be
used and the frame sections remain compact and rigid.
3.2 Fields of application
The VAG EROX®plus Penstock is used in sewage treatment
plants, in raw water and waste water pipelines as well as in indus-
trial applications and flood protection. The special feature of the
VAG EROX®plus Penstock is its very high degree of tightness
which considerably exceeds the leak rates admissible according
to the standard for sluice gates and penstocks (DIN 19569, Part
4).
As a standard, the VAG EROX®plus Penstock is equipped with
EPDM seals. Therefore it can be used for the following fluids:
• Water
• Raw water and cooling water
a: Locking system b: Patented VAG sliding wedge system
d: Bottom seal
Picture 5: EROX®plus special technical features
c: Profildichtung
a
b
d
c
• Municipal waste water
• Weak acids and alkaline fluids
For fluids containing fats and oils, a variety with NBR seals are
available.
For information about the corresponding temperature limits,
please refer to the product-related technical documentation (KAT-
A 2452).
In case of deviating operating conditions and applications, please
consult the manufacturer.
4 Installing the valve
4.1 On-site requirements
The installation area must be prepared for the installation of the
VAG EROX®plus Penstock. On the installation site it must be en-
sured that the constrution is even and free from pores in the area
of the entire supporting surface. The concrete quality must be at
least that of strength grade C 25 according to DIN 1045/DIN 1084.
Furthermore, the dimensional tolerances according to DIN 18202
must be complied with. In this connection, Table 2, surface even-
ness tolerances line 7 applies.
This means:
• 3 mm maximum deviation per 1 metre of concrete surface
and/or
• 5 mm maximum deviation per 2 metres of concrete surface
• The edges of the structure must not be broken off to ensure
that the sealing ring rests completely on concrete.
If a pipe runs into the construction it is essential to ensure that the
pipe end is flush with the construction. Existing old valve parts
(e.g. old frames) need to be removed completely before the as-
sembly of a new penstock.
4.2 Installing the valve
4.2.1 Fixing the VAG EROX®plus Penstock to
the structure with anchor bolts
First check whether the clear dimension of the opening matches
the nominal diameter of the VAG EROX®plus Penstock. The clear
dimension of the opening must never be larger than the nominal
Limit values of evenness tolerances in mm according to DIN EN18202
Distance between
measuring points Line 5 Line 6 Line 7
0,1
m 5 3 2
1
m 10 5 3
4
m 15 10 8
10
m 25 20 15
15
m 30 25 20
Table 2: Table tolerances in Civil Engineering (DIN18202)

VAG Installation and Operating Instructions • 6
Table 3: Drill hole and anchor bolt size
1. Drill the drill hole
2. Clean the bore hole with a
brush and blow out the dust
3. Insert the cartridge
4. Insert anchor rod with
rotary movement
Excess adhesive swells
from the bore hole
5. Attention! Remo-
ve swollen adhesive!
5. Observe the curing time!
6. Install the
penstock. Ob-
serve the tightening torque !
Before exposing the Penstock
to any loads, the setting time
of the adhesive must have
expired.
If the Penstock is anchored to
a humid surface, the setting
times must be doubled!
Picture 6: Proper handling of chemical anchors
Montage
Nm
Tinst
+20 ∞C
20 min.
90∞
1. 2. 3.
4. 5. 6.
Nominal
diameter
Drill hole
diameter
Number of drill
holes
Deep of drill
holes Anchor bold size max. tightening
torque
400x400 Ø 14,5 mm 4 110 mm M12x160/97 mm 40 Nm
500x500 Ø 14,5 mm 8 110 mm M12x160/97 mm 40 Nm
600x600 Ø 14,5 mm 8 110 mm M12x160/97 mm 40 Nm
700x700 Ø 17 mm 10 125 mm M16x190/95mm 60 Nm
800x800 Ø 17 mm 10 125 mm M16x190/95mm 60 Nm
900x900 Ø 17 mm 12 125 mm M16x190/95mm 60 Nm
1000x1000 Ø 17 mm 12 125 mm M16x190/95mm 60 Nm
1200x1200 Ø 17 mm 14 125 mm M16x190/95mm 60 Nm
size borehole
diameter borehole number borehole depth anchor size max. torque
moment borehole diameter borehole number borehole depth anchor size max. torque
moment
1300x1300 Ø 18 mm 10 175 mm M16x220/160 60 Nm 18 mm 5 125 mm M16x190/95mm 60 Nm
1400x1400 Ø 18 mm 10 175 mm M16x220/160 60 Nm 18 mm 5 125 mm M16x190/95mm 60 Nm
1500x1500 Ø 18 mm 10 175 mm M16x220/160 60 Nm 18 mm 7 125 mm M16x190/95mm 60 Nm
1600x1600 Ø 18 mm 12 175 mm M16x220/160 60 Nm 18 mm 7 125 mm M16x190/95mm 60 Nm
1700x1700 Ø 18 mm 12 175 mm M16x220/160 60 Nm 18 mm 7 125 mm M16x190/95mm 60 Nm
1800x1800 Ø 18 mm 14 175 mm M16x220/160 60 Nm 18 mm 9 125 mm M16x190/95mm 60 Nm
The VAG EROX®plus Penstock is now tightened evenly and crosswise on the building wall until the holders just rest against
the building wall. Thus, the wall seal of the slider is optimally biased to the building wall. It is essential to wait for the prescri-
bed hardening time of the chemical compound anchors before full load of the VAG EROX®plus Penstock.
width of the VAG EROX®plus Penstock. The profiled seal which
seals the penstock against the wall must rest completely on the
even wall surface.
At the beginning of its assembly the VAG EROX®plus Penstock is
opened completely. Place the penstock gate in front of the ope-
ning in the structure so that the opening is completely centred in
the clear opening of the penstock. In this installation position, the
construction of the penstock ensures that the minimum distance
to the wall is observed when you drill the anchoring holes for the
chemical anchors.
The VAG EROX®plus Penstock is now aligned with a level and
then fixed with e.g. with stays. The profiled seal which seals the
penstock against the wall must rest completely on the even wall
surface of the structure.
The VAG EROX®plus Penstock may now be used as a drilling
template. With a suitable drill (for the size of the drill hole see Pic-
ture 4) the holes for the anchor bolts are drilled through the holes
of the attachment claws. Afterwards the holes must be blown
out. Any loose drilling dust remaining in the holes will affect the
bonding strength of the chemical reaction holes.
Any incorrect drilled holes must be properly closed before the
Penstock is attached. This prevents the steel reinforcement of the
concrete exposed by drilling from carrying corrosion into the
structure.
Anchor bolts (chemical reaction anchors) must be installed accor-
ding to the instruction of the suppliers of the chemical reaction
anchors. Please only use the attachment material included in the
scope of supply (see Figure 7) observe the instructions provided
on the proper handling of chemical anchors (Picture 8).
After the setting time unfasten the VAG EROX®plus Penstock to
remove any excess synthetic mortar which may have emerged
from the holes with a screw driver or chisel. Any excess adhesive
that remains outside the holes prevents the correct seating of the
penstock wall seal on the structure and thus affects the sealing
effect.
Now the VAG EROX®plus Penstock is fastened evenly to the sur-
face of the structure and the bolts are fastened cross-wise to the
wall of the structure until the retainers rest evenly on the surface
of the wall. This ensures that the wall seal of the penstock is opti-
mally pre-tensioned on the wall surface. Before full load is applied
to the VAG EROX®plus Penstock, the prescribed setting time of
the chemical reaction anchor bolts must have expired.

VAG Installation and Operating Instructions • 7
The now operational VAG EROX®plus Penstock must be cleaned
from drilling dust and drilling residues, in particular the inner area
between the frame and the gate as well as the thrust wedges.
4.2.2 Assembly of the VAG EROX®plus
Penstock; Control distance measure of slide
plate
When mounting the anchor rods for the upper mounting holes
(see picture 9), attention must be paid to compliance with the dis-
tance dimension C (see table above) due to the risk of collision
between the slide plate and the anchor rod.
Tighten the nuts on the upper anchor rods so that the distance C
between the slide plate and the cross member is largely the same
over the entire width. By slightly opening the slide plate, check if
it opens without collision.
4.2.3 Assembly of the VAG EROX®plus
Penstock on a pipe flange (EROX®plus version
with flange adapter)
The version VAG EROX®plus has a flange adapter and is inten-
ded for attachment to a pipe flange EN 1092-2 PN 10. In sizes DN
150 up to and including DN 600, the VAG EROX®plus is connec-
ted to the pipe flange via a flange adapter.
On the tube side, the flange adapter is provided with threaded
bolts. They are used to mount the adapter plate to the pipe flan-
ge. The threaded bolts are acc. to DIN EN 1092-2, PN 10. A seal
provided with the seal between the pipe flange and the flange ad-
apter (Picture 7).
Attention! When mounting to a pipe flange with collar,
the flange thickness must be compensated by interpo-
sing washers between flange and adapter plate. Thus,
an undue bending of the adapter flange is prevented
when tightening the fastening nuts.
The flange adapter is also provided with threaded bolts on the sli-
de side. Here, the slider is mounted on the holders. After assem-
bly, the flange adapter on the slide side serves as a bearing sur-
face for the wall seal of the VAG EROX®plus slide valve (Picture 8).
Slide the spindle slide with the holder holes over the threaded
bolts and screw them firmly onto the adapter plate using the sup-
plied fastening parts. The fastening nuts are alternately tightened
crosswise until all holders are in metallic contact with the flange
adapter.
For assembly, the nuts and washers supplied must be used.
Attention! Since the threaded bolts are not symmetri-
cal, it is important to pay attention to the correct ori-
entation when mounting the adapter plate. The slide-
side threaded bolt must be arranged laterally and
vertically.
4.2.4 Channel mounting
On the sides and in the invert of the channel, box outs must be
prepared to receive the frame (see picture 11). When securing the
penstock in the box outs for grouting, make sure that it is free
from tension.
Before installing the penstock, check whether its dimensions
match the inner dimensions of the channel. The inner dimensions
of the channel must not exceed the outer dimensions of the pen-
stock frame.
Install the penstock with its slide gate closed. First install the ad-
justment screws supplied in the threaded anchor plates located
on the sides of the penstock frame. Then lower the closed pen-
stock into the box out of the channel.
Using a spirit level, first align the penstock sill so that the bottom
seal is flush with the channel invert. It may be necessary to secu-
re the penstock using wooden wedges. Aligning the penstock sill
flush with the invert prevents the build-up of sediments in the seal
area.
Picture 9: Montage Ankerstangen für obere Befestigungsbohrung
Upper mounting holes
Pipe flange
Threaded
bolts
Flange adapter
Retainer
Picture 8: Assembly of the penstock on the adapter plate
Pipe flange
Nuts and
washers
Picture 7: Mounting of the adapter plate to the pipeline flange
Seal
Spacers
Threaded
bolts
Flange adapter

VAG Installation and Operating Instructions • 8
Furthermore, the penstock must be centred between the channel
walls. Now secure the penstock into position in the vertical box
outs using the adjustment screws and make sure that the frame
sill is perpendicular to both channel walls. If necessary, secure
the penstock using wooden wedges or other supports. Care must
be taken to avoid twisting or deforming the guide rails of the pen-
stock frame during this installation step.
Close the vertical box outs between the concrete walls and the
penstock frame using formwork boards. Now the vertical box
outs and the sill box out can be grouted with concrete. Observe
the manufacturer’s instructions regarding the processing of the
concrete. Make sure that no concrete enters the areas of the slide
gate guide rails in the penstock frame or comes into contact with
the operating elements (stem, stem nut, etc.).
It is absolutely necessary to observe the curing times of the grout
specified by the manufacturer. No pressure must be applied on
the penstock until the grout has completely hardened.
When the grout has hardened, the VAG penstock is ready for
operation. Before putting the penstock into service, inspect it es-
pecially in the area of the seals for any dirt or concrete residues
and clean the parts, if necessary.
4.3 Installation position
The VAG EROX®plus Penstock is assembled vertically, i.e. with
the stem in a vertical position, at the opening in the construction.
Should installation be required in other installation positions, ple-
ase consult the manufacturer.
Permissible Not permissible
Picture 10: Installation position of the VAG EROX®plus Penstock
4.4 Assembly instructions and fasteners
Before assembly, check the Penstock for possible damage that it
may have suffered during transport and storage. Protect the Pen-
stock against dirt on the construction site by adequate covering
until installation.
Prior to installation, all components essential for proper function,
such as the stem, stem nut, gate, sliding elements and sliding
wedges as well as the wall seal must be thoroughly cleaned to re-
move all dirt particles. VAG does not assume any liability or war-
ranty for consequential damage caused by dirt, shot-blasting gra-
vel residue etc.
The operability of the functional parts must be checked prior to
installation.
Should the Penstock be repainted later on, it must be ensured
that no paint is applied to the functional parts. The identification
plates must not be painted over either. If the equipment is sand-
blasted for cleaning prior to installation, these parts must be ade-
quately covered. If solvents are used for cleaning, it must be en-
sured that the solvents do not destroy the seals of the pipeline or
the Penstock.
For the assembly of the VAG EROX®plus Penstock it must be en-
sured that suitable load suspension devices as well as transport
and lifting equipment are available.
5 Set-up and operation
5.1 Visual inspection and preparation
Before putting the Penstock and the equipment into operation,
perform a visual inspection of all functional parts. Check whether
all bolted connections have been properly fastened.
The Penstock have been factory-lubricated for assembly, storage
and transport purposes. Depending on their condition, they may
have to be relubricated at set-up.
Recommended lubricants:
Stem, stem nut: Klüberplex BE 31-502
• Seal, gate: Fuchs Chemplex Si 2
Fuchs Notropeen Si 1
Klüberbeta VR 67-17002
5.2 Function check and pressure test
Before installation, the function parts of the Penstock have to be
opened and closed completely at least one time and their opera-
bility has to be checked.
Ensure that no objects are present near the opening of the struc-
ture which might block the movement of the gate.
Warning! The pressure exerted on the closed valve
must not exceed it belastet werden (siehe technisches
Datenblatt KAT-A 2452).
When operating the penstock for the first time, ensure that gate
and any mounted actuating components move evenly, vibration-
free and without noise. These components must never be jam-
med and their movement must neither be blocked nor otherwise
impaired.
100
100
200
200
Picture 11: Example of a channel installation of the VAG EROX®plus Penstock

VAG Installation and Operating Instructions • 9
Picture 12: Screws sealed to the electric drive on delivery
Penstock dimension A
x A [mm]
Max. operating torque
non-rising stem rising
stem
150 … 300 30 Nm 30 Nm
400 … 600 40 Nm 40 Nm
700 60 Nm 60 Nm
800, 900 100 Nm 100 Nm
1000, 1200 120 Nm 100 Nm
1300, 1400 180 Nm 180 Nm
1500 200 Nm 200 Nm
1600 220 Nm 220 Nm
1700, 1800 250 Nm 250 Nm
1900 … 4000 defined in project documentation
Table 4 Operating torques
Especially after repair work but also during the set-up of new
equipment, the pipeline system must be cleared again with the
Penstock fully open. As a standard the Penstock is closed by tur-
ning the operating square end clockwise (via an operating key, a
handwheel or an electric actuator).
The dimensions of the stems and actuators allow the operation of
the Penstock by one person using the handwheel. Extensions for
operation are not permissible and may cause damage to the Pen-
stock due to excessive loads.
Limit stops in the Penstock limit the travel. Trying to turn these
components beyond the limit stops using excessive force may
damage the penstock. Check the proper function of the limit
stops by opening and closing the Penstock several times.
The dimensions of the stems and actuators allow the operation of
the Penstock by one person using the handwheel. Extensions for
operation are not permissible and may cause damage to the Pen-
stock due to excessive loads.
Limit stops in the Penstock limit the travel. Trying to turn these
components beyond the limit stops using excessive force may
damage the penstock. Check the proper function of the limit
stops by opening and closing the Penstock several times.
6 Actuators
6.1 General
Directly mounted actuators/drives or VAG extension spindles in
many different types are available for the VAG EROX®plus Pen-
stock.
Actuators mounted directly to the penstock bridge (pneumatic,
hydraulic or electric actuators) are only designed for the operating
conditions specified in the order. The adjustment of the limit stops
(OPEN, CLOSED) must not be changed without the manufacturer‘s
consent.
If the Penstock and the actuator are delivered separately, e.g. on
a headstock, the limit switches must be adjusted on site before
the actuator is put into operation.
The limit switches are adjusted in compliance with the operation
instructions of the respective manufacturer of the actuator, such
as AUMA, Rotork etc. When a gear unit is retrofitted, its nominal
torque and the adjustment of the limit stops (OPEN and CLOSED)
must be adapted to the Penstock.
For detailed information about drives and actuators, please refer
to the operation manuals of the manufacturers (e.g. AUMA,...).
Non-compliance with these Introductions may lead to physical in-
jury and death and/or cause damage to the equipment. If actua-
tors powered by external energy (electric, pneumatic, hydraulic)
have to be disassembled from the Penstock, the safety instruc-
tions in Chapter 1.1 must be observed and the external energy
source must be switched off.
6.2 Operation torques
Operation torques are the maximum required torques [in Nm] at
the drive stem at full differential pressure and with a calculated
safety factor. If required, please contact us to enquire about the
respective torques and/or controlling torques for electric actua-
tors.
6.3 Assembly of the electric actuator
The electric actuator is mounted to the bridge or to remote con-
trol components such as a ROTAG headstock.
The Penstock is switched off:
• path-dependent in open position
• torque-dependent in closed position.

VAG Installation and Operating Instructions • 10
The switching points of remote control components have to be
adjusted on site. The torque switches serve as overload protec-
tion in intermediate positions. If the Penstock is retrofitted with an
electric actuator, the limit switches have to be adjusted after the
assembly of the actuator. For information about adjustment, ple-
ase refer to the operation instructions of the manufacturer of the
electric actuator.
The relevant safety regulations of the VDI/VDE and the instruc-
tions of the manufacturer of the electric actuator must be com-
plied with.
The electric actuator must only be operated with a control unit
connected. If limit switches and torque switches are not connec-
ted and properly adjusted, the Penstock and the electric actuator
may be damaged. In this case the manufacturer does not assume
any liability.
Upon delivery, the adjustment screws and connection bolts of the
gear unit and electric actuator are sealed by adhesive labels or
identified by colour markings. If these identifications are broken
later on, this will result in the loss of the manufacturer‘s warranty.
7 Maintenance and repair
7.1 General safety instructions
Prior to any inspection and maintenance work on the Penstock or
its assemblies the valve must be de-pressurised. Depending on
the type of the fluid conveyed, all required safety regulations must
be complied with!
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.
Any damage that may be caused by electric current and current
flow must be prevented. Couplings and connections must never
be disassembled when they are under pressure or energised.
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 the relevant qualifications.
In case the operator’s employees do not have the qualifications
required, they need to attend a training course. This training
course can e.g. be held by VAG Service employees.
Upon the customer’s request, the penstock can be assembled by
VAG’s Technical Service.
The plant operator needs to ensure that all employees have un-
derstood these Installation and Operation Instructions as well as
all further instructions referred to in them.
Protective equipment such as safety boots, safety helmets,
goggles, protective gloves etc. must be worn during all work re-
quiring such protective equipment or for which such protective
equipment is prescribed.
Improper , wrong and abrupt use of the Penstock should be avoi-
ded. Prior to the performance of any work on the Penstock and
equipment it must be ensured that the relevant pipeline section
has been depressurised and/or de-energised.
7.2 Inspection and operation intervals
The tightness, operability and corrosion protection of the Pen-
stock should be checked at least once per year according to the
German (DVWG Guidelines W 392). In case of extreme operating
conditions inspection should be performed more frequently.
Upon the customer’s request, inspection and maintenance of the
penstock can also be performed by VAG’s Technical Service.
7.3 Maintenance work and replacement of
parts
Spare parts and parts subject to wear and tear can be replaced.
All replacement work must be done by skilled staff. Detailed inst-
ructions for the replacement of spare parts and parts subject to
wear and tear are enclosed with the delivery of spare parts and
parts subject to wear and tear.
Moving parts, such as threaded stems, stem nuts and stem bea-
ring elements, are all to be lubricated regularly, at least once a
year, with a water-repellent lubricant. We recommend that you
use the lubricant Klüberplex BE 31-102.
The gaskets must also be lubricated at least once a year when
moving parts are operated in drinking water or used for flood pro-
tection purposes. We recommend that you use the lubricants:
Fuchs Chemplex Si 2
Fuchs Notropeen Si 1
Klüberbeta VR 67-17002
Klübersynth®VR 69-252 N.
Der VAG EROX®plus Penstock must be operated at least once a
year in order to maintain its functional capability. Coarse dirt
should also be removed from the VAG EROX®plus Penstock at re-
gular intervals, at least twice per year.
No other maintenance work is required.
8 Trouble-shooting
For all repair and maintenance work, please observe the general
safety instructions described in Section 7.1!

Edition 4 - 01-04-2019
[email protected]
www.vag-group.com
Problem Possible causes Troouble-shooting
Penstock hard to operate
Stem dirty Clean stem and relubricate
Stem nut dirty Clean stem nut and relubricate
Stem nut worn Replace stem nut
Foreign matter in lateral sealing
groove Clean sealing groove
Penstock cannot be closed completely
Obstacle in flow passage Remove blocking objects (branches, stones...) from the
flow passage
Foreign matter in lateral sealing
groove Clean sealing groove
Wrong adjustment of electric
actuator
Check the torque adjustment of the electric actuator and
readjust it, if required, according to the manufacturer‘s
instructions
Penstock does not seal
Penstock not completely closed Close penstock completely
Obstacle in flow passage Remove blocking objects (branches, stones...) from the
flow passage
Seal damaged Replace seal
Table 5: Trouble-shooting
9 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: [phone]
Service per E-Mail: [email protected]