Operation and Maintenance Manual SIGMA Piston Intake Valve 217 Titusville Road Union City, PA 16438 Tel: 814.438.7616 Fax: 814.438.8163 www.all-americanhose.com Read Instruction Manual before use. Operation of this device without understanding the manual and receiving proper training is a misuse of this equipment. A person who has not read and understood all operating and safety instructions is not qualified to operate the SIGMA Intake Valve. The Instruction Manual is intended to familiarize firefighters and maintenance personnel with the operation, servicing and safety procedures associated with the valve. This manual should be kept available to all operating and maintenance personnel. Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1.0 Meaning of Safety Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.0 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.1 Intake Valve Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.2 Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3.3 Use with Salt Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5.0 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5.1 Adjusting Relief Valve Set-Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6.0 Air Bleeder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7.0 Repair/Maintenance Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7.1 Placing Valve in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 8.0 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9.0 Maintenance Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10.0 Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 11.0 Warranty Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Section 1.0 Section 3.0 Meaning of Safety Words General Information A safety related message is identified by a safety alert symbol and a signal word to indicate the level of risk involved with a particular hazard. Per ANSI standard Z535.4-1998 the definitions of the three signal words are as follows: The Intake Valve is intended for use on the Intake Steamer Port (Intake Manifold) of a fire engine. The valve is kept closed while the water supply is being established from a hydrant or another pumper. This prevents the pump from losing its prime. Once the supply hose is filled and under pressure, and the air has been vented from the hose, the valve may be opened and pumping established. For safety and protection of the hose, Intake valve, pump and supply tank, an adjustable pressure relief valve mounted on the bottom of the Intake Valve will open (factory set to 150 psi) to relieve any excess pressure. indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Section 2.0 For drafting from a dry hydrant or other water source it is possible to utilize the Intake Valve, however the air bleeder must be closed and if a Storz connection is being used, the pressure gasket (black) must be replaced with a suction gasket (gray) provided (see section 6). Safety Kinks in supply hose may reduce water flow and cause injury or death to persons dependant on water flow. Injury or Death can result from burst hoses and fittings. Be sure the pressure relief valve is set at the proper pressure for the type of hose and equipment you are using. See NFPA 1961 and NFPA 1962. This equipment is intended for use by trained personnel for fire fighting. Its use for other purposes may involve hazards not addressed by this manual. See appropriate guidance and training to reduce risk of injury. Avoid rapid closing of valves and nozzles to prevent water hammer. Per NFPA 1962 the pressure relief valve is not designed to protect against water hammer. Maximum operating pressure 280 PSI. Do not exceed 280 PSI on either the inlet or outlet sides of the valve. Valve must be properly connected. Mismatched or damaged connections may cause leaking or uncoupling under pressure and could cause injury. Section 3.1 Features and Benefits • Cast-in flow vane reduces cavitation and minimizes friction loss • Valve Body is hard anodized and powder coated inside and out, and Polymer piston is immune to corrosion • Sacrificial Zinc Anode protects valve body and wetted metal parts from corrosion • User performed preventive maintenance possible with tool provided • Grease fitting keeps the piston and spindle lubricated • Low Profile, Valve extends only 11.5" from end of Intake • Easy access air vent valve prevents loss of pump prime • Adjustable relief valve output can be directed in any one of four directions • Meets NFPA slow-close requirements. • 5 Year Warranty 1 Section 3.2 Corrosion Snap-tite Hose uses a multi-step process to fight corrosion. The body of the valve is hard coat anodized and powder coated inside and out, the piston is manufactured of a high-strength polymer, the valve stem is stainless steel, and the remaining wetted parts are protected by a sacrificial zinc anode. In addition, the effects of corrosion can be minimized by good maintenance practice. See section 9.0 for Required Preventative Maintenance. Section 3.3 Use with Salt Water Use in a salt water environment is permissible provided valve is thoroughly cleaned & flushed with fresh water after each use. The service life of the valve may be shortened due to the corrosive effects of salt water in contact with aluminum and is not covered under warranty. Grease the spindle thoroughly using the grease fitting in the center of the hand wheel after each use with salt water and adjust the Preventative Maintenance schedule accordingly. Section 4.0 mounted in any of four discharge directions. To change the orientation of the relief valve, remove the four M8x25mm socket head cap screws (with 6mm Allen Wrench), orient the valve as you desire and replace the cap screws using thread locking compound similar ® to Loctite 243 to prevent loosening due to vibration. 1. The pressure setting screw should be adjusted to allow the relief valve to work at the intended pressure. Over tightening of this screw to prevent the relief valve from discharging water could prevent proper functioning even if the setting is adjusted at a later time. 2. Semi-annually, the setting of the relief valve should be verified. Apply the set-pressure and observe the relief valve for any water discharge. Adjust the setting until the correct amount of pressure causes the relief valve to open. Pressure Relief Valve should be exercised and operationally verified Semi-Annually Section 5.1 Adjusting Relief Valve Set-Pressure Note: The adjustable relief valve is factory-set to 150 psi. Specifications Raise / Lower Set Screw Physical Characteristics: Body: High Strength Aluminum Exterior: Hard coat Anodize and Powder Coated Interior: Hard coat Anodize and Powder Coated Piston: Corrosion proof Polymer Spindle: Corrosion resistant Stainless Steel Weight: 31 lbs. Flow / Pressure: Maximum Working Pressure: 280 psi (1930 kPa) Burst Pressure: 720 psi (4965 kPa) Maximum Flow: 2000 gpm Pressure Relief Valve: Type: Double spring, Cartridge type, Adjustable from 100 – 200 psi (690 – 1380 kPa). Factory set at 150 psi (1035 kPa). Section 5.0 Pressure Relief Valve A bottom mounted pressure relief valve is included with each valve assembly. Its purpose is to protect the valve, pump, truck tank, and supply hose from excess pressure. It may be set at any pressure between 100 and 200 psi (factory-set to 150psi ) and can be 2 A B C Pressure PSI kPa A 100 670 B 150 1035 C 200 1380 The relief valve can be adjusted by turning the adjustment set screw (center of cap) clockwise to increase the setpressure or counterclockwise to lower it. As you can see in the diagram there are “target areas” to reach for standard pressure settings that can be done without pressurizing the valve. (A) = 100 psi (670 kPa), (B) = 150 psi (1035 kPa), (C) = 200 psi (1380 kPa). To verify or set to a specific relief point, follow this procedure: 1. Manually adjust to a target setting of 200 psi to start - Using a 6mm Allen Wrench, turn the set screw in the center of the relief valve clockwise until you see the first thread (target setting of 200 psi) of the housing cap. Do not over-tighten (more than three threads showing) as this could prevent proper functioning even if the setting is adjusted at a later time. 2. Bring water to the valve the best way possible – an external pump or another truck's pump and connecting through a short piece of hose that matches the inlet connection size/type. Making sure the intake valve is in the “closed” position, purge air from valve (see Section 6.0) while pressurizing by opening the air bleeder valve, waiting for a solid stream of water to exit the purge holes prior to closing the bleeder valve. Care should be taken not to exceed the working pressure of the valve or pump. Section 6.0 Air Bleeder Valve The Sigma Intake Valve is equipped with an Air Bleeder Valve which will allow the air to escape when the intake supply hose is first charged to prevent loss of prime. The Air Bleeder Valve is the red knurled knob located at the top of the intake valve. Open the bleeder valve to allow air to be purged from the intake supply hose and Sigma Valve. When water exits the purge hole, the air has been removed and it is now safe to close the bleeder valve, open the intake valve and turn on the pump. Loss of prime can interrupt water flow and cause injury or death. Always purge air through the air bleed to prevent possible loss of prime. 3. Pressurize the Intake Valve to the desired relief pressure and adjust the set screw (counterclockwise) until the relief valve opens. Lower the supply pressure and the relief valve will reset (approximately 10% lower than set pressure) and repeat until set pressure is within your specification. 4. Mark the relief valve with the new set-pressure so that all operators are familiar with the new setting. 3 Section 7.0 Repair/Maintenance Kits See Reference Schematic Below Indicator Part Number Description A FSG40 4" Storz Inlet Pressure Gasket (BLACK) A FBG40 4" Storz Inlet Suction Gasket (GRAY) A FSG50 5" Storz Inlet Pressure Gasket (BLACK) A FBG50 5" Storz Inlet Suction Gasket (GRAY) B STZLK Storz Lock repair Kit (includes spring, screw and lever) C SVAE Sacrificial Zinc Anode D SVKK Knob Kit (includes knob and hardware) E SVZB Grease Fitting Repair Kit (includes Zerk fitting, bolt and washer) F SVHK Hand-wheel Kit (includes hand wheel, knob, and hardware) G SVBK Air Bleeder Kit (includes both screw/plug and set screw) H SG40 4" Female Outlet Swivel Gasket H SG50 5" Female Outlet Swivel Gasket H SG60 6" Female Outlet Swivel Gasket I SVSK Seal Kit, Sigma Valve (includes all needed O-rings and Bearing rings for Intake Valve) - (Included with purchase of new Valve) J SVDT Piston Seat Ring Removal Tool - (Included with purchase of new Valve) K SVPG Piston Seat (color white - not normally needed for standard repairs) L FRV M - Relief Valve Assembly 4 ea. Socket Head Cap Screw (M8 x 25 mm) Intake Valve Parts Kits F G E H I D C B L K A 4 M J Section 7.1 Place Valve in Operation 1. The Snap-tite Intake Valve permits safe, controlled flow of water to the pump intake, and has been manufactured to the latest NFPA standard for the fire hose connections. 2. Exercise caution when handling, or placing the Intake Valve into service. Do not attempt to operate above the set-point pressure of the relief valve and never above the full working pressure rating of 280 psi (1930 kPa). 3. Verify the outlet thread connections match the truck connections 4. To prepare the Intake Valve for use, thread the Long Handle Female Swivel connector onto the Intake Manifold of the truck. Check that the air bleed (red knob), located on the top of the valve, is fully open. When using the valve as a draft port, connect the hard suction line with the valve in the open position and air bleed valve closed. Section 8.0 Preventive Maintenance The Snap-tite Sigma Intake Valve will give many years of trouble free service provided the maintenance program is followed properly. Valve should be depressurized for service prior to removal. 1.The valve should be “Exercised” (fully opened and closed) at least three times per month. 5. If Storz connections are utilized, make sure the Storz latches are in the lock position when the hose is attached and that the indicator markings align before using. 6. Make sure the Intake Valve is closed by turning the hand wheel clockwise until it stops. 7. When the line to the Intake Valve is charged, allow trapped air to escape through air bleed valve until water comes out of the purge port, then close the air bleed valve by turning clockwise until seated. Loss of prime can cause cavitation and/or water hammer causing injury or death. Always bleed/remove air with air valve to prevent possible loss of prime. 8. Once air is purged from the line, open the Intake Valve to supply water to the truck by turning the hand wheel counter-clockwise to open. 2.The valve MUST be removed, cleaned, and Preventative Maintenance performed at least semi-annually, or more often as water quality and use may require. 9. Avoid rapid opening and closing of the Intake Valve to reduce the effect of water hammer. LIST OF ITEMS REQUIRED BEFORE STARTING THE PREVENTATIVE MAINTENANCE: Note: The Snap-tite Intake Valve comes standard with a Storz pressure gasket (black) installed. For use in drafting (vacuum) applications, it will be necessary to change the Storz gasket to a suction gasket (gray) that is included with new valve purchase. When changing the gasket, make sure air is not trapped, creating a bubble under the seal by using a flat bladed screw driver to release any trapped air, taking care not to scar the surface of the gasket. • Piston Seat Ring Removal Tool (Included with new valve) If needed, order Snap-tite part number #SVDT • Seal Kit (Included with new valve) – Re-order part number #SVSK (Individual seals not available to purchase) • 1/2" Drive Socket Wrench • 3" Socket Extension • 9/16" Socket 5 • 8mm (metric) Allen Wrench (to remove ball on hand wheel) • 6mm (metric) Allen Wrench (to set or remove relief valve) • 1/8" Allen Wrench (to remove Storz Lock) • 5/64" Allen Wrench (to remove Air Bleeder Valve set screw) • 3/8" Allen Wrench (to remove Anode, Piston Guide Pin, & NST ball bearing plug) • Small instrument screwdriver or O-ring pick • Grease Gun with Zerk Coupling • Lithium Grease (Ref: Mobil AW-2) • Nylon/Plastic Brush for Valve Body • Wire Brush for Center Spindle 6. Removal of Piston O-Ring and Guide Pin: With piston removed you will have easy access to piston bore o-ring located in groove of body casting. Remove and clean the O–ring. Clean and inspect the O-ring groove, and inspect/clean the Guide Pin next to the Center Spindle. 7. Inspection/Replacement of Zinc Anode: With the valve disassembled, inspection of the zinc anode can be made from the valve outlet opening but is also designed to be removed from the outside of the valve body without removing the hand wheel. The zinc anode is designed to react to galvanic corrosion before the other wetted metals used to manufacture the valve. Once severe corrosion is obvious on the anode, note the time span from when valve was placed in service and adjust PM schedule to fit, then remove and replace the anode. To replace anode, removal is from the outside of the valve behind the hand wheel. Removal of the hand wheel is not necessary. Rotate the hand wheel to an opening large enough to access the anode plug. Using a 3/8" Allen wrench, remove the anode plug (See “Reassembly Instructions on page 7 for replacement instructions). Replace with new Zinc Anode (P/N-SVAE) • Shop Rags • Liquid Soap • Loctite 243 Thread Sealant (to replace Zinc Anode) ® Disassembly: Remove Intake Valve from truck. (Reference Preventative Maintenance Schematic on page 7) 1. Place the Intake Valve in a position allowing easy access to the piston bore (as viewed through the valve outlet). 2. Removal of NST Swivel Gasket: Using no tools, remove the Swivel Gasket from the Female-swivel Outlet Coupling and inspect. (Avoid using tools as they may score surface of seal) If seal is scored in any way re-order correct size Swivel Gasket identified in section 7.0 3. Removal of Piston Seat Ring: Using hand wheel, open valve to remove piston from seat. Insert Piston Seat Ring Removal Tool (P/N - SVDT) into the Piston Seat Ring (PSR) and using the socket wrench and extension, remove the PSR. This may require some force and a second person to stabilize the valve body. 4. Inspection of Piston Seat Gasket: On the reverse side (when removed from valve body) of the PSR is a white piston seat gasket and a metal seat ring. Inspect and clean the gasket seal face, threads of the PSR, and the Piston Seat O-ring. If the gasket seat face is scored in any way, remove from PSR (no tool needed) by pulling from inside diameter, remove metal seat ring, O-ring, and inspect/replace. 5. Removal of Piston: Turn the hand wheel clockwise (close) continuously to remove piston from the valve bore. Inspect and clean the piston seal surface (flat ring on dome side), the piston’s outer barrel, and the center female thread of the piston. 6 8. Clean Valve: Clean the inside of the valve thoroughly with rags, soap, and nylon brush to remove any hard water chlorides or water sediment. 9. Inspection of Center Spindle: Clean and inspect the center spindle. If there is build up on the spindle it should be removed and brushed. (It is Stainless Steel so a wire brush can be used) 10. Removal of Hand Wheel & Center Spindle: To remove the Center Spindle: Remove the Zerk Fitting bolt & washer with the 9/16" Socket. Remove the hand wheel and let spindle drop (hint: onto rag or towel to protect threads), from backside. Clean and lubricate the Center Spindle with grease. Clean and grease Center Spindle O-ring. Inspect and replace as necessary the O-ring, and the two bearings found in valve body (easily removed). NOTE: Removal of hand wheel (to replace ball handle) can be accomplished without disassembly of valve and removal of piston but be sure that valve is in “Closed” position so that the piston and spindle don’t drop into valve body. Preventative Maintenance Schematic Bearing Ring* Guide Pin Piston Bore O-Ring Groove Swivel Gasket (NST Coupling) Center Spindle O-Ring* Piston Bore O-Ring* Bearing Ring* Piston Piston Flat Seal Surface Piston Seat O-Ring* Metal Seat Ring Piston Seat (White) Zerk Fitting Bolt/Washer Piston Seat Ring (PSR) Q Ring Piston Removal Tool (P/N-SVDT) Hand Wheel B Center Spindle NOTE: * = Parts contained in seal kit (P/N-SVSK) Reassembly: Reference Preventative Maintenance Schematic above. 1. Reinstall Center Spindle: After cleaning or replacing the Center Spindle, making sure that the bearing rings are placed on both sides of spindle bore and the spindle O-ring is lubricated with lithium grease, insert through body and trap in place with hand wheel. Replace Zerk Bolt/Washer and tighten until snug to secure spindle in hand wheel. 2. Replace Zinc Anode: Place Loctite 243 on anode plug threads and replace anode plug from outside of valve body, through hand wheel gaps. Use 3/8" Allen Wrench to tighten plug. ® 3. Replace Piston O-ring: Lubricate Piston O-ring with Lithium Grease and install Piston Bore O–ring into groove in body (see schematic above for exact location). Additional grease may be added at this time to help lubricate the Piston’s outer barrel when replaced. 4. Return Piston: Put piston, with domed end out onto Center Spindle and align one of the four round holes in the piston with the Guide Pin. Turn the hand wheel counter-clockwise, drawing the piston back into the valve bore. Turn until it stops in the fully retracted position. 5. Replace Piston Seat O-Ring and Piston Seat Ring: The Piston Seat and metal seat ring in most cases will stay attached to the Piston Seat ring, if separated replace on PSR – white seat ring first, then the metal seat ring (no tools needed). Grease and Insert the PSR O–ring and place in groove and start to thread the PSR assembly by hand, into the valve body. Using the Socket Wrench, 3" extension and the Piston Seat Ring Removal Tool (P/N-SVDT), finish installing the PSR into the valve body until it is flush with the body. 6. Replace the Swivel Gasket (do not grease) in the Female Swivel Outlet Coupling. 7. With the valve in the open position, using the grease gun, give 3 to 5 pumps through the Zerk fitting located in the center of the hand wheel to lubricate the spindle/piston threads. 8. Close and open - “Exercise” (see page 5) the valve several times to assure smooth operation. Verify Pressure Relief Setting: The Pressure Relief Valve should be checked Semi-Annually (see Section 6) The Snap-tite Intake Valve will give many years of trouble free service provided the preventative maintenance program is followed properly. 7 Section 9.0 Maintenance Record DATE STATION / LOCATION TRUCK BY COMMENTS Section 10.0 Troubleshooting SYMPTOM - Valve Leakage Leaks from NST Outlet Coupling: Remove valve from truck, check for debris in or around the swivel gasket. Open valve and visually inspect piston seat O-ring, wipe seal and piston face with a soft rag. Check O-ring and piston face for damage on the sealing surfaces and re-lubricate the O-ring before re-installation on truck. Leakage from behind hand wheel: Should leakage be observed behind the hand wheel/from spindle, any causes will almost always necessitate removal of the piston from the valve body – please follow the “Preventative Maintenance” instructions found in Section 8. Leakage from Zerk Fitting: The Zerk Fitting has a small check valve internal to its design. Should you observe leakage from here, replacement is necessary. Order part number SVZB to correct. Binding, erratic operation, does not open or close: Check for debris in the valve that prevents free movement of the piston. Inspect valve for internal 8 corrosion caused by hard water or infrequent maintenance and cleaning. Clean and lubricate valve per “Preventative Maintenance” instructions in Section 8. Storz coupling will not connect: If the connection is hard to make the Storz gasket may be raised. Check for fluid and/ or trapped air under the gasket, using a flat blade screwdriver, burp the seal and drain any fluid. Do not grease the Storz Gasket. Any alterations to the Intake Valve and its markings could diminish safety and constitutes a misuse of this product. Dissimilar metals coupled together can cause galvanic corrosion that can result in the inability to unscrew the threads or complete loss of thread engagement over time. Per NFPA 1962, if dissimilar metals are left coupled together an anti-corrosive lubricant should be applied to the threads. Also the coupling should be disconnected and inspected at least quarterly. Section 11.0 Warranty Sigma Intake Valve Product Warranty All-American Hose warrants its Sigma Intake Valve to be free from defects in materials and workmanship for a period of ten (10) years from date of original purchase. This warranty shall provide for the repair or replacement of product proven to have failed due to faulty materials or workmanship during normal fire ground use. The Sigma Intake Valve must be maintained according to procedures described in maintenance manual #03-1174ME. Our warranty is limited as follows: w All returned products must be accompanied by an RGA# (Return Goods Authorization) given by All-American Hose. Unauthorized returns will be refused. w All defective products must be returned to All-American Hose within 30 days of warranty claim. w Our warranty on replacement products is limited to the remaining term from the original purchase. w Our total liability is limited solely to the purchase price of the goods involved. w There are no implied warranties, whether of merchantability, fitness for a particular purpose or otherwise consequential and indirect. w This warranty does not extend to products subjected to misuse, accident, improper application, storage, modification or repair. 217 Titusville Road Union City, Pennsylvania 16438-8698 USA Ph: 814-438-7616 Fax: 814-438-8163 www.all-americanhose.com 10YR WARRANTY 9 ! WARNING ! FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND/OR PROPERTY DAMAGE. This document and other information from All-American Hose, its subsidiaries and authorized distributors, provides product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operation conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by All-American Hose and its subsidiaries at any time without notice. 03-1174ME-1111 ISO-9001 Certified Quality Management System