Operating instructions - Translation of the original - 3-way ball cock Type 403x KIESELMANN GmbH Paul-Kieselmann-Str.4-10 D - 75438 Knittlingen +49 (0) 7043 371-0 Fax: +49 (0) 7043 371-125 www.kieselmann.de sales@kieselmann.de
1. List of contents 1. List of contents...1 2. Information for your safety...2 3. Marking of security instructions in the operating manual...2 4. Safety instructions...3 4.1 Field of application...3 4.2 General safety instructions...3 4.3 General notes...3 5. Installation informations...3 5.1 Installation instructions...3 5.2 Welding guidelines...3 6. Maintenance...3 6.1 Maintenance...3 6.2 Cleaning...3 7. Function...4 8. Technical Data...5 9. Disassembly and assembly...5 9.1 Disassemby...5 9.2 Assembly...5 10. Drawing...6 11. Dimensions...7 12. Sealing kit...7 13. Spare parts list...8 14. Declaration of incorporation...9 1
2. Information for your safety We are pleased that you have decided for a high-class KIESELMANN product. With correct application and adequate maintenance, our products provide long time and reliable operation. Before installation and initiation, please carefully read this instruction manual and the security advices contained in it. This guarantees reliable and safe operation of this product and your plant respectively. Please note that an incorrect application of the process components may lead to great material damages and personal injury. In case of damages caused by non observance of this instruction manual, incorrect initiation, handling or external interference, guarantee and warranty will lapse! Our products are produced, mounted and tested with high diligence. However, if there is still a reason for complaint, we will naturally try to give you entire satisfaction within the scope of our warranty. We will be at your disposal also after expiration of the warranty. In addition, you will also find all necessary instructions and spare part data for maintenance in this instruction manual. If you don't want to carry out the maintenance by yourself, our KIESELMANN service team will naturally be at your disposal. 3. Marking of security instructions in the operating manual Hints are available in the chapter "safety instructions" or directly before the respective operation instruction. The hints are highlighted with a danger symbol and a signal word. Texts beside these symbols have to be read and adhered to by all means. Please continue with the text and with the handling at the valve only afterwards. Symbol Signal word Meaning DANGER ATTENTION NOTE Imminent danger which may cause severe personal injury or death. Dangerous situation which may cause slight personal injury or material damages. Marks application hints and other information which is particularly useful. ak 12.1.11 Safety informations 2
4. Safety instructions 4.1 Field of application The 3-way ball cock can be used as multiple way valve in the drinks and food industry, the pharmaceuticals and chem. Industry and the bio-technology sector. ATTENTION To avoid danger and damage, the fitting must be used in accordance with the safety instructions and technical data contained in the operating instructions. 4.2 General safety instructions DANGER Dismantling the valve or valve assemblies from the plant can cause injuries from fluids or gases flowing out. Dismantle the valve or valve assembly only when the plant has been rendered pressure-less and free of liquid and gas. 4.3 General notes NOTE All data are in line with the current state of development. Subject to change as a result of technical progress. 5. Installation informations 6. Maintenance 5.1 Installation instructions The installation position is without import. External forces due to the installation must always be avoided. 5.2 Welding guidelines Sealing elements integrated in weld components must generally be removed prior to welding. To prevent damage, welding should be undertaken by certified personnel (EN287). Use the TIG (tungsten inert gas) welding process. NOTE Impurities can cause damage to the seals. Clean inside areas prior to assembly. 6.1 Maintenance The maintenance intervals depend on the operating conditions "temperature, temperature-intervals, medium, cleaning medium, pressure and opening frequency. We recommend replacing the seals every 2 years. The user, however should establish appropriate maintenance intervals according to the condition of the seals. NOTE Lubricant recommendation EPDM; Viton; K-flex NBR; HNBR; Silicone Thread Klüber Paraliq GTE* Klüber Paraliq GB 363* Teflon grease Interflon* *) It is only permitted to use approved lubricants, if the respective fitting is used for the production of food or drink. Please observe the relevant safety data sheets of the manufacturers of lubricants. 6.2 Cleaning In order to ensure continuous hygienic conditions during operation, the surfaces between the valve body and the ball must be cleaned. Open and close the valve several times from the open position. With an angle of rotation of 20, cleaning fluid flows into the area between the ball and casing. A time-dependent actuation in the angle of rotation range 20-45 makes the cleaning process more efficient. The duration and the number of actuations should be adjusted according to the type of dirtying and the degree of dirtying. 3
7. Function The 3-way ball cock has as a distributor valve the function several tube to each other for opening or to closing. The possible assembly-line ways in dependence of the stop functions linked with it are shown in the Tab. 1 on page 4 as valve positions. The desired valve position can be positioned by a rotary movement by means of hand strength in a swivelling angle of 360. Valve position L - Ball Valve position 1 connections B - C open connection A close Valve position 2 connections A - C open connection B close Valve position T - Ball Valve position 1 connections A - B - C open Valve position 2 connections A - C open connection B close Valve position 3 connections A - B open connection C close Valve position 4 connections B - C open connection A close Tab. 1 4
8. Technical Data Valve size: DIN: DN 25 - DN 80 Connections: Male part DIN11851 (G) Flange connection (Fl) Liner/nut DIN11851 (K/M) Temperature range: Ambient temperature: +4 to +45 C Product temperature: +0 to +95 C medium dependent Sterilization temperature: EPDM +140 C (SIP 30 min) PTFE +130 C (SIP 30 min) NBR +110 C (SIP 30 min) VITON +140 C (SIP 30 min) Operation pressure: 10 bar Vacuum: 1,5-10 -6 mbar x L / S (test pressure 0,5mbar) Material product contact: (varied according the valve type) Stainless steel: 1.4301 / AISI304 1.4404 / AISI316L Surfaces: Ra < 0,8µm e-polished Material of seals: NBR / PTFE VITON / PTFE EPDM / PTFE 9. Disassembly and assembly see Fig. 1 /page 6 9.1 Disassemby NOTE When exchanging the seals, the ball cock itself has be disassembled out of the system. It is imperative to observe the applicable safety information. Dismount the ball cock out of the system. Replacing the casing seals (3), (5), (6), (19) Unscrew the flange (4) (2x), (18) and (17). Dismantle the O-rings (5)(2x), (6)(4x), (19)(2x) and seals (3)(4x). Remove the ball (2) out of the housing (1). Replacing the sealing package (10), (11), (12) Unscrew the screw (20) and remove the hand lever (21). Unscrew the screw (16) and remove the locking disc (8). Remove the plain bearing (14) and the pressure spring (13) from the axis (7). Dismantle the axis (7) with sliding ring (9) downwards. Take the sealing package (10/11/12) out of the housing (1). 9.2 Assembly Thoroughly clean and slightly lubricate mounting areas and running surfaces. (see Maintenance on page 3). Assemble in reverse order. NOTE Mount the sealing package (10/11/12) in the sequence shown under view (Detail right top). Push the bearing ring (10), the V-rings (11) (3x) and the thrust collar (12) with the mounting sleeve (M) into the limit stop. When mounting the ball (2) and the axis (7), regards for exact match from the marks on the axis (7) and the position of the ball (2) (see fig. right). The mark points on the switch axis correspond to the respective ball openings. Mount the hand lever according to fig. 1 / page 6. L-ball T-ball 5
10. Drawing Example: ball cock, T-ball with male part flange 1 = Housing 2 = Ball T-Form Ball L-Form 3 = Thrust collar 4 = Coupling - Male part (G) - Small flange (Fl) - Liner/nut (K/M) 5 = O-ring 6 = O-ring 7 = Axis 8 = Locking disc 9 = Sliding ring 10 = Bearing ring 11 = V-ring Package 12 = Thrust collar 13 = pressure spring 14 = Plain bearing 15 = Straight pin 16 = Socket screw 17 = Blind flange 18 = Coupling - Male part (G) - Small flange (Fl) - Liner/nut (K/M) 19 = O-ring 20 = - Saucer head screw - Socket screw 21 = Hand lever - 1.4301 - GFK M = Mounting sleeve Fig. 1 6
11. Dimensions G-G-G K/M-G-G Fl-Fl-Fl with rinsing connection heatable lever GFK Stainless steel with Sensor mounting GFK Stainless steel DN D1 D2 d3 L1 L2 L3 L4 L5 L6 L7 L8 L9 K 25 26 Rd52x1/6 10 128 64 118 139 75 154 65 165 180 77 32 32 Rd58x1/6 10 140 70 124 154 84 166 71 165 180 83 40 38 Rd65x1/6 10 160 80 129 175 95 186 77 165 180 93 50 50 Rd78x1/6 10 170 85 138 188 103 198 92 165 180 99 65 66 Rd95x1/6 10 200 100 152 222 122 228 110 165 180 114 80 81 Rd110x1/4 14 230 115 194 257 141 256 126-285 128 12. Sealing kit Pos. (3), (5), (6), (9), (10), (11), (12), (14), (19), (M) DN NBR/PTFE EPDM/PTFE VITON/PTFE mounting sleeve* M 25 4085 025 000-000 4085 025 000-054 4085 025 000-051 4084 080 021-057 32 4085 032 000-000 4085 032 000-054 4085 032 000-051 4084 080 021-057 40 4085 040 000-000 4085 040 000-054 4085 040 000-051 4084 080 021-057 50 4085 050 000-000 4085 050 000-054 4085 050 000-051 4084 080 021-057 65 4085 065 000-000 4085 065 000-054 4085 065 000-051 4084 080 021-057 80 4085 080 000-000 4085 080 000-054 4085 080 000-051 4084 100 021-057 *) included in seal kit 7
13. Spare parts list Item. Designation Material 1 Housing 1.4301 / 1.4404 2 Ball 1.4301 / 1.4404 3 Thrust collar PTFE 4 Coupling - Male part - Small flange - Liner/nut 1.4301 / 1.4404 5 O-Ring - NBR - EPDM - VITON 6 O-Ring - NBR - EPDM - VITON 7 Axis 1.4301 / 1.4404 8 Locking disc 1.4308 9 Sliding ring PTFE 10 Bearing ring PTFE 11 V-Ring Package PTFE 12 Thrust collar PTFE 13 Pressure spring 1.4310 14 Plain bearing PTFE 15 Straight pin DIN7 1.4301 16 Socket screw 1.4301 17 Blind flange 1.4301 / 1.4404 18 Coupling - Male part - Small flange - Liner/nut 1.4301 / 1.4404 19 O-Ring - NBR - EPDM - VITON 20 Saucer head screw 1.4301 21 Hand lever GFK / 1.4301 8
Declaration of incorporation Translation of the original Manufacturer / authorised representative: Authorised representative, for compiling technical documents: KIESELMANN GmbH Paul-Kieselmann-Str. 4-10 75438 Knittlingen Germany Achim Kauselmann KIESELMANN GmbH Paul-Kieselmann-Str. 4-10 75438 Knittlingen Germany Product name pneum. Lift actuators pneum. Rotary actuators Ball valves Butterfly valves Single seat valves Flow control valves Throttle valve Overflow valve Double seat valve Bellow valves Sampling valves Two way valves Tankdome fitting Function Stroke movement Rotary movement Media cutoff Media cutoff Media cutoff Control of liquefied media Control of liquefied media Definition of fluid pressure Media separation Sampling of liquids Sampling of liquids Media cutoff Prevention of overpressure and vacuum, Tank cleaning The manufacturer hereby states that the above product is considered as an incomplete machine in the sense defined in the Directive 2006/42/EC on Machinery. The above product is exclusively intended to be installed into a machine or an incomplete machine. The said product does not yet conform to all the relevant requirements defined in the Directive on Machinery referred to above for this reason. The specific technical documents listed in Appendix VII, Part B, have been prepared. The Authorized Agent empowered to compile technical documents may submit the relevant documents if such a request has been properly justified. Commissioning of an incomplete machine may only be carried out if it has been determined that the respective machine into which the incomplete machine is to be installed conforms to the regulations set out in the Directive on Machinery referred to above. The above product conforms to the requirements of the directives and harmonized standards specified below: DIN EN ISO 12100 Safety of machinery Knittlingen, 20. 07. 2012 Klaus Dohle General Director