BROEN BALLOMAX User manual

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Ballomax
ENERGY EFFICIENCY - DESIGNED TO LAST
BROEN BALLOMAX®
USER MANUAL
STANDARD BALL VALVES VERSION 2.0

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Read more in the chapter “General information” on page 4.
Warning! Media can be hot and cause burning.
Do use safety goggles and gloves.
Read more in the chapter “Installation and welding” on page 7.
Warning! Wrong installation can result in severel damage or that the
valve is not functioning correctly. These general instructions
do not cover all possible operating scenarios.
For a more specic guidance about the usage of the valve
or its qualication at the desired use, please contact BROEN.
Read more in the chapter “Change of gasket set” on page 31.
Warning! Media can be hot and cause burns.
Use safety goggles and gloves.

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Content
BROEN valves user manual
1. General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Instructions and precautions before installation and operation. . . . . . . . . . .7
5. Installation and welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6. Commissioning and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
7. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9. Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BROEN Ballomax® – further useful information
11. Mounting and disassembly of gears on a valve as well adjustment . . . . 13
12. User Manual for BROEN Ballomax® hot tapping tool. . . . . . . . . . . . . . . . . . . . . 17
13. User Manual for BROEN Ballomax® branching valve . . . . . . . . . . . . . . . . . . . . . 21
14. Instructions for transportable gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15. Flexible extensions and planetary gear for underground valves. . . . . . . 26
16. Change of gasket sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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1. General information
BROEN Ballomax®Steel ball valves
BROEN Ballomax® is designed with highest possible safety and functionality in mind,
but we recommend reading this manual thoroughly.
The technical data is not binding and can be changed without any notice. Please
see our general terms and conditions. Further information can be obtained upon
request. It is the responsibility of the project owner and installer to choose products
suitable for the intended purpose and secure that pressure data and performance
data is not exceeded. Updated installation manuals apply.
The entire system should be depressurized and emptied before any kind of removal,
change or repair of a single component – no matter if the components are defective
or not.
BROEN ball valves are intended for installation in heating-, cooling- and district
heating- installations with treated water, that does not corrode neither carbon steel
nor materials in the O-rings or seals.
The valve house is made in carbon steel and the stem and ball are made in stainless
steel.
The ball seats are made of carbon reinforced Teon (PTFE). The stem stung box is
done with FPM- (Viton) and EPDM- O-rings.
The valve is tight in both directions and can be mounted in both directions.
Local legislation must always be observed.
Approvals
BROEN Ballomax® ball valves in steel are approved according to the demands in
(PED) 2014/68/EU for pressurized equipment, module H. Module H is the module for
complete quality control.
Quality management
BROEN A/S has been ISO 9001 certied since 2001:2015.
The ISO certicate has been approved by Bureau Veritas Quality International Ltd.,
London, one of the leading international authorities in the eld of ISO certication.
Bureau Veritas conducts regular audits to check the operation of the system.
ISO 9001 covers all processes of production ow and customer service - from the
rst idea to the product, through drawings, materials, production, as well as control
and testing procedures, packaging, shipping, personnel training, contracts and
technical documentation, maintenance and claims handling.

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2. Marking
Each product is marked with a self-adhesive label, based on aluminum foil,
resistant to weather conditions, on which all relevant information about the
product are given.
Label example:
• BALLOMAX® - trade name: BALLOMAX, DZT, AH30 FITTINGS,
• DN 50 - nominal size,
• PN 40 - pressure class,
• Material: P235GH - valve body material,
• Temp. - minimum and maximum medium temperature for the valve used,
• Fluid Group 2 - group of liquids according to 2014/68 / EU or information
on the medium (eg steam)
• Date - month and year of the valve’s production and test,
• BROEN POLAND sp. O.o. 58-200 DZIERŻONIÓW - name and address of the
manufacturer,
• CE 0062 - CE mark number of the Bureau Veritas notication
• www.broen.com - manufacturer’s website
• 100331 - label number

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3. Transportation and storage
It is important to check if the valve or its parts has been damaged during
transportation. If there are any transportation damages BROEN recommends
receiving the delivery and then immediately contacting BROEN.
BROEN recommends to control that the delivery is as agreed – number, size, type
and equipment and etc.
Information about damages, defects or irregularities according to the agreement
should immediately be informed to BROEN.
Store the valve in a clean and dry place before installation. Do not remove the
protection caps before immediate installation.
Use lifting straps when lifting larger valves. Do not lift the valve in its
actuator, stem or handle (Fig. 1, 2 & 3).
If in doubt about the weight of the valve to be lifted, you can see its weight in the
Ballomax® catalogue or on BROEN’s homepage – www.broen.com.
Fig. 2.

Fig. 3.

Fig. 1.

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Fig. 4.
4. Instructions and precautions before
installation and operation
Present instructions should be carefully reviewed before mounting and operation of
Ballomax®ball valves:
• The entire system should be depressurized and emptied before any type of
disassembly, replacement or repair of a single element, regardless of whether
the elements are damaged or not.
• Control that the valve is suitable and approved for the used media and the
desired application. The valve is not suitable for steam! Here a valve suitable for
high temperatures is to be used.
• Operate the valve, if possible, to ensure that the valve is not defective from
storage or transportation.
• If the valve is used as an end valve in the pipeline, there has to be installed a
pressure tight ending or blind ange after the valve and the valve is to be left in
the open position (Figure 4).
• In order to ensure safe operation the manual gear or actuator cannot be
removed or dismantled, without special precautions are taken, if the valve is
under pressure and/or there is a ow.
• BROEN recommends, that the valve is installed in the pipeline with minimal
vibrations. In the installation it is recommended to avoid stress and to relieve
the valve for exposed longitudinally pressure and tensile load.

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Fig. 5.
Fig. 7.
Fig. 6.
5. Installation and welding
Welding
The pipe line is to be cleaned thoroughly before the installation of the valves, as any
impurities can damage the surface of the valve and seals.
Do not remove the manual gear or actuator from the valve unless it is absolutely
necessary. In the event the manual gear or actuator is to be removed during or after
the installation, then contact BROEN customer service or see instructions in the
chapter “Instruction for mounted gear”.
Electric welding (TIG, MIG) is recommended for all BROEN Ballomax® ball valves in
steel. Valves larger than DN150 should always be welded in the pipe line by means
of electric welding.
Do not overheat the valve during the welding – there is a risk for damage of the
seals. It is recommended, that the welding is done by qualied personnel.
Cool the valve (after welding) before normal use. The valve should only be operated,
when the valve is cooled suciently.
The welding is only to be done on the ends of the valve and not on the body of the
valve, as this will damage the seals in the valve.
For further information refer to the guidance on the valve.
The valve can be placed in both vertical and horizontal position, and during the
entire welding process it should be noticed, that the valve must be in open position.

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Welding of larger valves ≥ DN 200 full port / DN 250 reduced port.
The valve must remain open during welding to protect the ball.
At risk of overheating there should a pause in the welding process.
The ground connection must not be connected to the valve.
Flange mounting: The valve should only be mounted by qualied personnel and
follow valid norms and standards. The valve should be in open position during
mounting in order to ensure, that dirt and coatings do not ruin the surface of
the seals. The mating surface of the ange on the pipe should be parallel to the
mating surface of the valve. The centerline of the valve and the pipeline should
also be correctly aligned. The length of the valve should be the same as the length
between the anges in the pipeline also taking account the thickness of the gaskets.
The anges of the pipeline should be compatible with the anges on the valve. For
detailed information, please see standard EN 1092-1.
6. Commissioning and operation
After installation of the valve the pipe line should be ushed thoroughly. During this
process the valve is to be open.
Testpressure at commissioning
If a pressure test of the system is needed, the following procautions are to be
considered:
• The building of pressure is to be done slowly and gradually in order to prevent
pressure surge and hammering.
• During the pressure test of the pipeline (1,5 x PN) the valve is to be in the open
position.
• BROEN Ballomax® ball valves are designed to be fully open or fully closed.
Control that the valve is either fully open or fully closed position against the
endstop.
• Take care that the maximum and minimum temperatures, of the valve, is not
exceeded! The maximum operating pressure and minimum-/maximum-
temperatures are shown on the label of the valve. Graphs with allowable
pressures in given temperatures can be found in the technical catalog.

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7. Operation
Handle operated valves
When the valve is open the handle ush the pipeline. Fig. A.
Gear mounted valves
The valve opens when the gear is turned clockwise. Valves prepared for installation
of gear/actuator. The position indicator at the end of the stem indicates the position
of the ball in relation to the stem.
The opening and closing of the valves are to be done slowly and carefully in order to
prevent pressure surge in the pipe line.
8. Maintenance
The valves do not demand extra service under normal conditions, but to ensure
correct function of the valves, it is recommended to open and close the valves once
yearly.
Correct functionallity of the valve demands correct quality of the water and
installation. The valve house is made in carbon steel and is as such not resistant to
corrosion.
Corrosion from the outside can be avoided be either installing the valve in dry
environment or equip the valve with a watertight insulation or another surface
protection (not oil).
The stung box in the stem is designed to last for the lifetime of the valve.
In specially unfavorable conditions minor leakages can occur. This can be solved
with a change of the o-ring, which can be done without draining the valve of
pressure or media.
Be aware of all special conditions and contact BROEN if necessary.
If it is necessary to change O-rings on the stem, BROEN should be consulted for
guidance and safety instructions. More information can be found under chapter 15 –
“Change of gasket sets”.
Fig. A.