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PRESSURE RELIEF V AL VE MAINTENANCE INSTR UCTIONS - PICTURE INDEX AND P AR TS LIST This document should be used in conjunction with the ‘standard’ installation document supplied with all AKO Pressure relief valves (PRVInformation&Cert). Water Level A B C D E F G H I J K L M N O P A = Dowty Washer B = Swivel Piece C = Coupling D = Schrader Valve E = Mild Steel Manifold Block F = Pressure Gauge Stainless Steel 63mm Glycerine Filled G = Plug (Pressure relief valves – without switch) H = Pressure Switch (2 switches inside a single housing) I = Hirshman Plug J = Gauge Washer K = Pressure Relief Valve Body L = Pressure Relief Valve Sleeve M = Pressure Relief Valve Flange/Ends N = Nut O = Washer P = Bolt Q = Permabond A131 R = Heavy Duty Foot Pump S = Leak Detection Spray T = Male Schrader Connection U = AKO Fitting Kit (100mm - 250mm) PICTURE 1 PICTURE 2 PICTURE 3 PICTURE 4 PICTURE 5 PICTURE 7 DRAWING 2 PART Q PART U PART R PART S PART T DRAWING 1 PICTURE 6 PARTS LIST PICTURE / DRAWING INDEX Telephone: 01327 312747 Fax: 01327 312565 e-mail: [email protected] Web: www.ako-valves.com

PICTURE / DRAWING INDEX · 2021. 5. 18. · K = Pressure Relief Valve Body L = Pressure Relief Valve Sleeve M = Pressure Relief Valve Flange/Ends N = Nut O =Washer P = Bolt Q = Permabond

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Page 1: PICTURE / DRAWING INDEX · 2021. 5. 18. · K = Pressure Relief Valve Body L = Pressure Relief Valve Sleeve M = Pressure Relief Valve Flange/Ends N = Nut O =Washer P = Bolt Q = Permabond

PRESSURE RELIEF VALVE MAINTENANCE INSTRUCTIONS -PICTURE INDEX AND PARTS LISTThis document should be used in conjunction with the ‘standard’installation document supplied with all AKO Pressure relief valves(PRVInformation&Cert).

WaterLevel

A

B

C

D

EF

G

H

I

J

K

L

M

NO

P

A = Dowty WasherB = Swivel Piece C = CouplingD = Schrader ValveE = Mild Steel Manifold BlockF = Pressure Gauge Stainless Steel 63mm Glycerine Filled G = Plug (Pressure relief valves – without switch)H = Pressure Switch (2 switches inside a single housing)I = Hirshman PlugJ = Gauge WasherK = Pressure Relief Valve BodyL = Pressure Relief Valve SleeveM = Pressure Relief Valve Flange/EndsN = NutO = WasherP = Bolt Q = Permabond A131R = Heavy Duty Foot PumpS = Leak Detection SprayT = Male Schrader ConnectionU = AKO Fitting Kit (100mm - 250mm)

PICTURE 1 PICTURE 2 PICTURE 3 PICTURE 4 PICTURE 5

PICTURE 7 DRAWING 2

PART Q

PART U

PART R

PART S PART T

DRAWING 1PICTURE 6

PARTS LIST

PICTURE / DRAWING INDEX

Telephone: 01327 312747 Fax: 01327 312565 e-mail: [email protected] Web: www.ako-valves.com

Page 2: PICTURE / DRAWING INDEX · 2021. 5. 18. · K = Pressure Relief Valve Body L = Pressure Relief Valve Sleeve M = Pressure Relief Valve Flange/Ends N = Nut O =Washer P = Bolt Q = Permabond

1. In it’s complete state the AKO valve should look like Picture 1. Pleasenote there may not be a pressure switch (Parts List - Part H). If there isnot a pressure switch it will be replaced with a plug (Parts List - Part G).

2. ENSURE THE VALVE IS DE-PRESSURISED BEFORE ANY WORK ISCARRIED OUT. Check the sleeve as well as the gauge (the gauge maybe faulty!). Exhaust all air from the valve using the Schrader connection(Picture 7).

3. Disconnect the complete manifold (Picture 2) from the main valve body (Picture3) using Points B/C (Pictures 4/5).

4. Disconnect the swivel piece (Parts List - Part B) using Point A (Picture 4) fromthe valve body, leaving just the bare valve (Picture 6).

5. Thoroughly clean all internal and external threads using a wire brush and air line.

6. DEPENDING ON THE SIZE OF THE AKO VALVE, ORDER THECORRECT FITTING TOOL (Parts List - Part U) REFER TO THERELEVANT SET OF FITTING INSTRUCTIONS(FI10-50mm/FI40-80mm/FI100-250mm).

7. All parts must be reconnected using A131 Permabond glue (Part Q) toensure a leak tight seal.

8. Connect swivel piece (Parts List – Part B) to main body of the refurbished PinchValve. Ensure the Dowty Washer (Parts List – Part A) is between the fitting andthe valve body. Ensure a tight connection - BEWARE NOTTO DAMAGE THEFEMALE ALUMINIUM THREAD OF THE PINCH VALVE.

9. Connect the complete manifold (Picture 2) back onto the valve body using pointB/C (Pictures 4/5). Ensure that again there is a tight connection and that thepressure gauge is facing the front (Picture 1).

10.The pressure relief valve must be left undisturbed for 24 hours to ensure thePermabond glue is dry.

11.IT IS ESSENTIAL THAT THE PRESSURE RELIEF VALVE ISCOMPLETELY LEAK TIGHT. The valve should be tested under water at 6 barsto ensure the valve does not have any visible leaks. Connect the AKO foot pump(Parts List - Part R) to the AKO Pressure relief valve (Picture 7). You will heara click when the pump and valve are connected. Inflate the valve using an AKO footpump, charge the valve to 6 bars for testing. Disconnect the air supply by slightlyturning the Schrader valve clockwise (be careful not to disturb the threadconnection), and look/listen for any leaks.

12.Carry out a water test by submerging the valve to the level of the pressure switchDO NOT SUBMERGE THE PRESSURE SWITCH – (Drawing 1) - If thereis not a pressure switch the valve can be fully submerged.

13.Initially there will be bubbles coming from the flange connections but after a fewminutes these will disperse. Wipe away any air bubbles from the valve andconnections. This process may need to be repeated a number of times. Any airbubbles reappearing will indicate there is a leak.

14.Inspect the valve fully for leaks, paying extra attention to the thread connections.

15.If there does not appear to be any leaks remove the valve from the water. The gaugeshould be marked to show the set air pressure and then monitored for 24 hours toensure the valve is leak tight – (Drawing 2).

16.If leaks can not be detected underwater, leak detection spray (Parts List - Part S)should be used. This is available from AKO UK Ltd. Spray onto suspect areas andlook for air bubbles.

17.If a leak has been identified the complete process should be repeated (or repair ofindividual part/problem carried out). If there are still problems with the valveleaking please contact the AKO Technical Department.

PRESSURE RELIEF VALVE MAINTENANCE INSTRUCTIONSSleeve replacement

PRESSURE RELIEF VALVE MAINTENANCE INSTRUCTIONS

Replacing Damaged Parts1. In it’s complete state the AKO valve should look like Picture 1. Please

note there may not be a pressure switch (Parts List - Part H). If there isnot a pressure switch it will be replaced with a plug (Parts List - Part G).

2. Identify damaged part from Parts List and order from AKO UK.

3. ENSURE THE VALVE IS DE-PRESSURISED BEFORE ANY WORKIS CARRIED OUT. Check the sleeve as well as the gauge (the gaugemay be faulty!). Exhaust all air using the Schrader connection(Picture 7).

4. Disconnect the complete manifold (Picture 2) from the main valve body(Picture 3) using Points B/C (Pictures 4/5).

5. Disconnect the swivel piece (Parts List – Part B) using Point A (Picture4) from the valve body, leaving just the bare valve (Picture 6).

6. Thoroughly clean all internal and external threads using a wire brush and airline.

7. Disconnect the damaged part from the manifold block ensuring other partsare not disturbed. Clean any threads as required.

8. All parts must be reconnected using A131 Permabond glue (PartsList - Part Q) to ensure a leak tight seal.

9. Reconnect the new replacement part to the manifold block, ensuring all othermanifold parts are not disturbed.

10. Connect the complete manifold (Picture 2) using point B/C (Pictures 4/5).Ensure that again there is a tight connection and that the pressure gauge isfacing the front (Picture 1).

11. The pressure relief valve must be left undisturbed for 24 hours to ensure thePermabond glue is dry.

12. IT IS ESSENTIAL THAT THE PRESSURE RELIEF VALVE ISCOMPLETELY LEAK TIGHT. The valve should be tested under water at6 bars to ensure the valve does not have any visible leaks. Connect the AKOfoot pump (Parts List - Part R) to the AKO Pressure relief valve (Picture7). You will hear a click when the pump and valve are connected. Inflate thevalve using an AKO foot pump, charge the valve to 6 bars for testing.Disconnect the air supply by slightly turning the Schrader valve clockwise (becareful not to disturb the thread connection), and look/listen for any leaks.

13. Carry out a water test by submerging the valve to the level of the pressureswitch – DO NOT SUBMERGE THE PRESSURE SWITCH –(Drawing 1) - If there is not a pressure switch the valve can be fullysubmerged.

14. Inspect the thread connections on the replacement part to ensure there arenot any leaks. During the test also check the rest of the valve to ensure thereare no other leaks.

15. If there does not appear to be any leaks remove the valve from the water. Thegauge should be marked to show the set air pressure and then monitored for24 hours to ensure the valve is leak tight – (Drawing 2).

16. If leaks can not be detected underwater, leak detection spray (Parts List -Part S) should be used. This is available from AKO UK Ltd. Spray ontosuspect areas and look for air bubbles.

17. If a leak has been identified the complete process should be repeated. If thereare still problems with the valve leaking please contact the AKO TechnicalDepartment.

13 Alvis Way, Royal Oak Trading Estate,Daventry, Northants NN11 8PG.

Tel: 01327 312747Fax: 01327 312565e-mail: [email protected]: www.ako-valves.com