ZWICK TRI-CHECK Series User manual

Operation Instructions
Butterfly check valve series
TRI-CHECK
(with counter weight and optional hydraulic damper)

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
1
Table of Contents
0INTRODUCTION...........................................................................................................2
1INTENDED CONDITIONS OF USE ..............................................................................2
2SAFETY INSTRUCTIONS............................................................................................2
2.1 General Safety Instructions........................................................................................................... 2
2.2Safety Instructions for the Operator.............................................................................................. 2
2.3 Special Dangers ............................................................................................................................. 3
2.4 Marking of butterfly valve .............................................................................................................. 4
3TRANSPORT AND STORAGE.....................................................................................5
4INSTALLATION............................................................................................................6
5PRESSURE TEST AND START-UP........ FEHLER! TEXTMARKE NICHT DEFINIERT.
6NORMAL OPERATION AND MAINTENANCE............................................................9
7TROUBLESHOOTING GUIDE................. FEHLER! TEXTMARKE NICHT DEFINIERT.
8CAUTION WITH USE OF THE BUTTERFLY VALVES IN -HAZARDOUS
ENVIRONMENTS .......................................................................................................11
9FURTHER INFORMATION.........................................................................................11
10 EU DIRECTIVES.........................................................................................................12
11 CONFORMITY ASSESSMENT PROCEDURE ACCORDING TO DIRECTIVE 97/23/EC OR
2014/68/EC………………………………………………………………………………………………..13

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
2
0 Introduction
These Instructions shall support the user of check valves of the Series TRI-CHECK with the
installation, operation and maintenance of the valves.
Attention
It will be dangerous for the user if the following „attention“-, „warning“- and
„danger“-notices
are not observed, and the liability of the manufacturer may
become ineffective.
In case of any question to the manufacturer, see addresses in clause 9.
1 Intended Conditions of Use
The sole purpose of Check valves of the Series TRI-CHECK is, after assembly in a pipe system
(between flanges or by welding to the pipe) to let pass or shut off media in the allowable direction,
pressure and temperature range, or to control the flow. For fluids with more than very small content
of solid particulates – especially hard and/or sharp ones – this series should not be used.
The ZWICK catalogue layout-sheets <Butterfly Valves TRI-CHECK> specify the admissible range
of p/t-rating.
Clause 2.2 < Important information for the user> shall be observed.
Warning
If a valve is used for permanent flow control at differen
tial pressure more than
about 0.
15 bar (liquid fluids) the flow parameters shall be accepted by the
manufacturer. Cavitation has to be avoided by all means.
2 Safety Instructions
2.1 General Safety Instructions
The safety requirements apply for valve units same as for the pipe system into which the valve is
installed and same as for the plant control system, to which the actuator is connected. This
instruction gives such advices only, which
More safety information may be included in the relevant manual of the actuator.
shall be observed additionally.
2.2 Safety Instructions for the Operator
It is not the valve manufacturer’s liability, and therefore it shall be observed by the user, that
⇒the valve is only used as specified in clause 1 < Intended Conditions of Use >,
Mortal
Danger
No valve shall be used, that’s certified pressure/temperature range (= "rating") is not
sufficient for the operating conditions: The relevant diagrams in the ZWICK catalogue
<Butterfly Valves TRI-
CHECK> specify this admissible range. See clause 9
<information>.
If other materials are used or at service conditions not included in the above mentioned
diagrams, the manufacturer shall be asked for release.
Ignoring these requirements could m
ean danger for the life or health of the user
and/or cause damage in the piping system.
Danger
The user shall check and ensure that the choice of the valve’s materials is suitable for
the fluids used.
The valve manufacturer is not liable for damage resulting from corrosion.
Ignoring these requirements could mean the danger of injury of the user and/or
cause damage in the piping system.
⇒the addition of a damper is only allowed after proper design and proper assembly,

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
3
⇒the pipe system has been installed by experts and that these systems are regularly inspected.
The stiffness of the body is designed to support the usual additional pipe forces Fzequal to
π/4٠DN²٠PS. Wafer type butterfly valves may support higher values of additional pipe forces
Fz
(PS = design pressure at ambient temperature)
. Contingent lateral forces taking effects to the valve must not exceed 10% of the forces
mentioned above.
⇒the valve has been connected to these systems by experts, especially a valve with butt-weld
ends,
⇒excessive pipe stress is to avoid in any case,
⇒the operating time of the check valve has been adjusted to the pipe system characteristics,
⇒the flow velocity in the pipe system is limited to usual values (e.g. 4 m/s for liquid fluids) and
that abnormal conditions such as vibration, water hammer, erosion (i.e. by wet steam),
cavitations and a relevant content of solid – especially abrasive – particulates in the fluid are
agreed by the manufacturer,
⇒at service temperature between >+50°C and <–20°C the valve and the valve connection
surfaces are protected from contact by the user,
⇒only experts for pressurized pipe systems operate and maintain the valve unit.
2.3 Special Dangers
Mortal
Danger
The valve shaft is tightened by a stuffing box. Before the bolting of this stuffing box is
loosened, be sure, that the pipe system is completely depressurized.
Mortal
Danger
Before loosening the locking screw (or the cover plate) at the body or before removing
the valve from the pipe the pipe system must be completely depressurized, so no
media can leak from the pipe uncontrolled. Be sure that the valve is approx. 5°-10°
opened and remains in this position to equalize the pressure at both sides.
The counter weight and the damper may– if necessary – on
ly be removed, if it is
secure that a possible back swing of the valve disc can be excluded.
This is
especially important for valves of large diameters.
Danger
Fittings, used as end valve: During normal operation, in particular in case of gaseous,
hot and/or hazardous media a blind flange or a filler cap must be on the free inlet. The
operation of such a fitting is not allowed.
Danger
If an end-of-line valve has to be opened in a pressurized line, this has to take place
very carefully and in a way that keeps spurting out media
from causing damage.
Attention when closing such a valve: Avoid getting one’s hand between body and
disc!
Danger
If a valve shall be disassembled from the pipe:
Take care, that the adjacent pipe system is completely drained, before the valve is
disassembled from the pipe. Take special care to residual amounts of the fluid that
remain trapped in the valve and/or in the adjacent pipe.
Disconnect the drive/limit switch first (acc. to manufacturer's documentation).
Danger
A check valve is usually operated only by the flow inside the pipe system. Especially a
check valve without damper can be caused to close abruptly
by a decrease in
pressure or even a slight pressure against the flow direction. The occurring pressure
hammer
s as well as the mass inertia of the swinging disc can result in forces that are
so enormous that the valve and/or the pipe can be damaged or even burst! Media can
possibly leak from the pipe system.

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
4
2.4 Marking of butterfly valve
Any butterfly valve carries a marking with following data (type plate, left column):
EC type plate:
For
Marking
Note
Manufacturer
Zwick GmbH
Address see Section 9 <Information>
Model no.
e.g.: C10125C-AA-11CP
Key no., see the ZWICK catalogue
S.-No.
e.g.: 02-03-7806
Corresponds to: year – month – serial production no.
Size
DN (and numerical
value)
Numerical value in mm, e.g. DN200 or in inch, e.g.
8"
PN / class
Numerical value for PN /
class
PN / class = Dimension standard for flanged butterfly
valves
PS
Numerical values in bar
or PSI
= maximum allowable pressure at 20°C /
maximum allowable pressure at max. temperature
TS
Numerical values in °C
or °F
= ambient temperature ~ 20°C /
maximum allowable temperature
Date
Year / month
ASME type plate:
For
Marking
Note
Manufacturer
Zwick GmbH
Address see Section 9 <Information>
Model no.
e.g.: C10125C-AA-11CP
Key no., see the ZWICK catalogue
S.-No.
e.g.: 02-03-7806
Corresponds to: year – month – serial production no.
Size
DN (and numerical
value)
Numerical value in mm, e.g. DN200 or in inch, e.g.
8"
PN / class
Numerical value for PN /
class
PN / class = Dimension standard for flanged butterfly
valves
CWP / PS
Numerical value in bar or
PSI
= pressure, upper limit of use at 20°C
max. T / TS
Numerical value in °C or
°F
= Temperature, upper limit of use
Date
Year / month
and marking for the material of parts that are connected to the media (type plate, right column):
for
Marking
Note
Body
Marking after material
standard
Material of the housing
Disc & Cl.
Material of the valve’s disc and clamp ring
Shaft
Material of the shaft
Seat
Material of the seat in the body
Lamin.
Material of the (removable) seat ring in the disc
Standards
API609B/ B16.34/ CE, etc.
Calculation and test standards
The type plate may not be damaged to identify the valve at all times.

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
5
3 Transport and Storage
⇒The valve shall be handled, shipped and stored with care.
⇒The valve shall be stored in the protective packaging or caps at the flanged or butt weld ends.
Store and transport it at a pallet or similar even to the place of installation.
⇒If the valve shall be stored before installation, store it in a closed building and protect the valve
from harsh environmental conditions, such as dirt, debris and humidity.
⇒Take special care to protect the metallic seat, the flange or butt weld end faces and the
damper from damage at transport.
⇒Valves must be stored in the same condition as they are delivered. The counter weight and the
damper (if applicable) must not be operated or removed. The counter weight / the valve disc
must remain fixed. The valve may not be able to swing until it has been installed.
Danger
Valves supplied without damper:
The valve must be moved with special care: The
unsecured disc could remove itself
from the closed position without extraneous cause (e.g. concussions)
Mortal
Danger
Valves of large diameters:
The disc of large diameter valves can weight several tons. The removal of the fixation
can cause the disc to
swing out of the closed position. This can lead to heavy injuries
and/or create forces strong enough to knock over for, for example, a fork lift. The
transport of such valve is only allowed with the interlocking immovably in place
and the disc in the closed position!

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
6
4 Installation
4.1. General
The requirements for the installation apply for valve units same as for the piping system into which
the valve is installed and as for the plant control system, to which the actuator is connected. This
instruction gives such advices only, which shall be observed additionally.
Danger
Check valves – especially wafer type valves – shall be transported and installed disc
closed only. Otherwise the disc could be damaged and the valve will no more be
tight.
Attention
When the valve is not yet installed: Prevent to get one’s hand between body and disc:
The Interlocking of the disc / the damper may only be removed and carefully be
operated when the check valve is installed in the pipe system.
If a butterfly valve is used in end-of-line-service, take
special care to assemble a blind
flange or a cover behind the valve.
Attention
The check valve is adjusted for the tight closed position by the manufacturer:
In the closed position the limit stop of the unit valve / actuator must be in the seat of
the check valve. The movement of the counter weight and the disc must by no means
be limited. The position of the counter weight on the lever is adjusted by the
manufacturer.
This adjustment of the counter weight must not be changed.
Mortal
Danger
Make sure that the valve is installed in the orientation approved by the manufacturer.
Usually the valve is installed in a horizontal pipe. The shaft of the valve usually is in a
horizontal orientation. The counter weight has to be positioned in a way that it closes
the disc in a clockwise direction.
The mounting orientation MUST be approved by the manufacturer.
Disregarding these rules can lead to damages on the valve and/or make the pipe
system burst and cause danger to health and life of the user!
Attention
Check valves with damper:
Make sure that the damper complements the design of the installation. The damper
has a direct influence on the opening and closing time of the valve. An improper
adjustment can cause unregulated and/or inadmissible
operating states of the
installation.
Dis
regarding these rules can lead to damages on the valve and/or make the pipe
system burst and cause danger to health and life of the user!
4.2 Installation
⇒Bring the valve in its protective packaging to the place of installation and do not unpack it
earlier.
⇒Check and be sure, that the valve and the actuator are free from damage. Valves or actuators
with visible damage must not be installed.
⇒Check and be sure, that the valve pressure class and the connecting type and dimensions and
the actuator data correspond to the plant data. See markings in the valve’s label.
Mortal
Danger
No valve shall be installed, that’s certified pressure/temperature range (= "rating") is not
sufficient for the operating conditions: This range is defined in the catalogue <
butterfly
valves TRI-CHECK>. See section 9 < information >.
If other materials are used or at service conditions not included in the above mentioned
diagrams, the manufacturer shall be asked for release.
Ignoring these requirements could mean danger for
the life or health of the user
and/or cause damage in the piping system.
At any doubt, contact the manufacturer.

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
7
⇒Wafer type Butterfly valves:
To protect damage of the valve disc at operation, be sure, that the clearance of the adjacent
pipe flanges is sufficient for the disc in full open position.
⇒Inspect and be sure, that the valve waterway and both adjacent pipe insides are free from dirt,
rust, pipe scale, welding slag and any other foreign material.
Mortal
Danger
Check valves with weight:
Make sure before assembly that
⇒the valve is installed in a way that keeps the disc from opening during assembly
⇒the weight has to be blocked accordingly
⇒it is by no means possible to reach between the body and the disc
⇒after assembly there is a sufficient lever arm for the weight to put the valve in the
closed position without working pressure
⇒the valve is smooth running
⇒the weight and the lever arm are not restricted in their movement
⇒the movement of the lever arm during operation cannot hurt a person or lead to
damages of the facility. Pay attention to the security clearance
⇒the fastening torques of the shaft packing are checked
⇒the transport lock is removed,
⇒the closed valve detains with full tax pressure in the position "CLOSE" until it is
inserted and securely fastened into the pipe,
⇒the stop is in the seat of the valve and not in the damper or any other part attached
to the valve
Disregarding these rules can lead to damages on the valve and/or make the
pipe system burst and cause danger to health and life of the user!
Mortal
Danger
Check valves with weight and damper:
Make sure before assembly that
⇒the valve is installed in a way that keeps the disc from opening during assembly
⇒the weight has to be blocked accordingly
⇒it is by no means possible to reach between the body and the disc
⇒after assembly there is a sufficient lever arm for the weight to put the valve in the
closed position without working pressure
⇒should the valve be rough running, check the fastening torques of the shaft packing
⇒the valve is smooth running
⇒the weight and the lever arm are not restricted in their movement
⇒the movement of the lever arm during operation cannot hurt a person or lead to
damages of the facility. Pay attention to the security clearance
⇒the fastening torques of the shaft packing are checked
⇒the damper is effective especially short before the seat
⇒the stop is in the seat of the valve and not in the damper or any other part attached
to the valve
Disregarding these rules can lead to damages on the valve and/or make the pipe
system burst and cause danger to health and life of the user!
⇒Check valves of the Series TRI-CHECK can only be operated in accordance to the
assigned flow direction. The valve has to be installed in a way that the direction of the
arrow on the body is the same direction from which pressure is put on the closed disc.
This direction must comply with the flow direction when the check valve is open!
⇒The preferred orientation of the valve puts the shaft in an exact horizontal position. Slight
deviations have to be approved by the manufacturer.

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
8
⇒For installation into an existing pipe system be sure, that the gap between the pipe ends
has sufficient clearance to protect all connecting surfaces (and gaskets) from damage.
But the gap shall not be larger than necessary to limit additional pipe load.
⇒It is recommended that the warming of the valve during start-up does not exceed 80 ° C / h.
In any case of doubt please consult the manufacturer.
⇒At temperatures exceeding 350 ° C the drive must be protected by suitable measures (here
the manufacturer is necessarily to consult).
⇒The flanged pipe ends shall be installed in line with the faces being parallel.
Flanged check valves only:
Attention
Check valves with flanged ends:
The sealing surfaces of check valves with flanged ends require the use of sealings per
EN1514-1 or ANSI B16.21. The mating flange surfaces shall be conform to EN 1092-1
or “stock-finish” conform to ANSI
B16.5, with flat mating faces (i.e. form C or form D or
form E). The manufacturer ZWICK shall release flanges of other standards or other
kinds of mating faces.
Attention
Check valves
with short face to face dimensions have to be inserted between the pipe
flanges with the disc in the closed position; otherwise the disc can be damaged and
the valve will not be tight anymore.
⇒When fastening the flange bolting, be sure, that the bolts centre the valve body correctly.
Attention
Wafer type butterfly valves series TRI-
CHECK may need flange bolts and studs with
different length for connection to the pipe flanges.
For bolting dimensions refer to ZWICK-document < Zw-Tri-Check-2010-A0>.
⇒The weld ends of the valve must be aligned and coplanar. The material of the valve and the
material of the pipe end must match – see material information on the name plate of the
valve. Opposing weld ends on the valve and the pipe must have matching diameters and
edge forms.
Butt-weld check valves only:
⇒Connect the welding cable not at the valve body, but at the pipe only.
⇒The seam shall be welded by experts to reduce stresses produced by the welding process
in the valve body and in the adjacent pipe. The body wall temperature shall be limited to
<300°C.
⇒Check Valves >DN 400:
Attention
Be careful at the welding process: The temperature in the valve body shall be
restricted to protect it from local deformation. The seam shall be welded with
interruption, alternating crossover, to limit the temperature in the seam area.
Ignoring these requirements could mean a permanent deformation in the valve body.
Even by 1/10 mm permanent deformation of the body seat (around the body necks)
the valve may become useless.
⇒The signals of the limit switch (if applicable) must indicate the correct position of the valve.
All Check valves:
⇒Recognizable malfunctions are to be remedied without fail before start of operation. See
clause 7 <Trouble shooting guide>
Danger
Defaults of signals and signalization could mean danger of injury of the user and/or
cause damage in the piping system.

Operation instructions Butterfly Check Valve Series TRI-CHECK, with
counter weight and optional hydraulic damper
ZWICK Armaturen GmbH D-58256 Ennepetal
Instructions No. Zw-Tri-Check-2016 / Rev.11
9
5 Pressure test and activation
The pressure tests of the valves have already been carried out by the manufacturer. For the
pressure test of a pipe section with built-in valves, the following should be noted:
⇒Rinse newly installed pipe systems carefully to remove all contaminant.
⇒Valve opened: the test pressure may not exceed value 1.5 x PS (according to the type
plate). (PS = maximum allowable operating pressure at 20°C).
⇒Valve closed: the test pressure may not exceed value 1.1 x ∆P(according to the type
plate).
If a valve should leak, pay attention to Section 7 <Help with malfunctions>.
6 Normal Operation and Maintenance
The valves are controlled by the flow inside the pipe systems. An intervention from the outside is
not permitted.
Regular maintenance is not required for valves. When at examination of the line section a leakage
is detected at a valve section 7 <troubleshooting> shall be observed.
For valves remaining permanently in the same position, it is recommended, to operate it 1x to 2x
each year to check their function.
Moreover it was recommended to provide free inlet and outlet distances of 5 x DN before and
behind the valve. The manufacturer has to be consulted in any doubt
Danger
A check valve is not self-
locking: A movement of the check valve is always to
be expected as long as there is media and/or pressure in the pipe system.
7 Help with malfunctions
When troubleshooting, strictly adhere to Section 2 <Notes on safety>.
Note 1:
Order spare parts by using all specification on the type plate.Only ZWICK Armaturen GmbH
original spare parts may be installed.
Note 2:
If it is determined after disassembly that housing and/or internal parts are not sufficiently resistant
against the medium, please inform the manufacturer and mention all specification on the type plate
Possible defect Remedy Remarks
Leakage at the pipe
flange or at a cover
flange connection
Tighten the flange bolting.
If this does not eliminate the leakage:
Replace the flange or cover gasket.
Observe clause 2.3 <Special Dangers> and order
cover gaskets and repair instruction from ZWICK.
To
order spare parts,
transmit all markings
from the valve tag.
Only original
ZWICK-parts shall
be used
Note 1: