Vag HYDRUS G Manuel

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

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

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

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: +49 (621) 749-0

Fax: +49 (621) 749-2153

[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. +49 6 21 749-0

Fax +49 6 21 749-2153

[email protected]

www.vag-group.com

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