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.

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Gasket sets:
Hexagon with dolly:
Size: Item nummer:
DN20-80 RB DN25-65 FB 600262
DN100 RB DN80 FB 600263
DN125-150 RB DN100-125 FB 600264
DN200 RB DN150 FB 600269
ISO-ange:
Size: Item nummer:
DN200 RB 600266
DN250-300 RB DN200-250 FB 600265
DN400 RB DN300 FB 600267
DN500 RB DN400 FB 600268
9. Scrapping
Almost every part in BROEN Ballomax® valves are made of reusable materials.
The type of the materials is described on the data sheet of each valve.

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10. Appendix
Standard mounted ange for gears – ISO 5211
Reduced port
DN valve Flange type D1 D2 D3 D4 t Boltholes
125 F07 90 55 70 913,5 4
150 F10 125 70 102 11 14,5 4
200 F12 150 85 125 13 14,5 4
250 F14 175 100 140 17 17,6 4
300 F16 210 130 165 21 23,5 4
350 F16 210 130 165 21 23,5 4
400 F25 300 200 254 17 27, 5 8
500 F30 350 230 298 21 28,5 8
Full port
DN valve Flange type D1 D2 D3 D4 t Boltholes
100 F07 90 55 70 913,5 4
125 F10 125 70 102 11 14,5 4
150 F12 150 85 125 13 14,5 4
200 F14 175 100 140 17 17, 6 4
250 F16 210 130 165 21 23,5 4
300 F16 210 130 165 21 23,5 4
350 F16 210 130 165 21 23,5 4
400 F30 350 230 298 21 28,5 8

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11. Mounting and disassembly of gear on
a valve as well as adjustment.
Please read the instructions thoroughly before beginning of the procedures and
contact BROEN, if there are any questions.
The valve is a shut-o valve. The valve is to be left in the fully open or fully closed
position.
Normally the valve is delivered in fully open position. In fully open position the
indicator line on the end of the stem is pointing in the longitudinal axis of the valve.
The operation of the valve (from fully open to fully closed position) is done by
rotating the stem the maximum distance. The distance in gear and valve is 90°.
Note: BROEN A/S recommends, that the gear is mounted and adjusted before the
valve is installed in the pipe line, while there still is free view to the ball inside the
valve. Is the gear mounted and adjusted after the installation of the valve in the pipe
line, then it is no longer possible to control, that the position of the ball is in fully
open or fully closed position. Wrongly positioning of the ball can cause damage on
the seats of the valve and leakage from the valve in closed position.
Disassembly of the gear from the valve
1. Close the valve.
2. Remove the four (or eight) mounting screws and lock washers.
3. Remove the gear from the valve.
Mounting of gear on the valve (handwheel or chainwheel)
1. Place the gear and the valve in the same position (both open or both closed).
2. Most gearboxes comprise a reduction cone, which is equipped with a key. If
the reduction cone is supplied separately or falls out, the cone has to be tted/
placed correctly.
3. Choose the wanted mounting position of the gear box. Activate the gear box
with the valve stem and put the gear box in position upon the valve.
4. Mount the gear box (and if necessary also on insulation gasket) upon the valve
by means of the four (or eight) mounting screws.
Do not forget the lock washers!

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Tighten the screws as shown in table A below.
Tabel A - Torque
Fastener dimension M6 M8 M10 M12 M16 M20 M30 M36
Bolt dimension:
Steel 8,5 Nm 20,5 Nm 41 Nm 71 Nm 170 Nm 350 Nm 1190 Nm 2100 Nm
Bolt dimension::
Galvanized steel (klass 70) 5,9 Nm 14,5 Nm 30 Nm 50 Nm 50 Nm 244 Nm 445 Nm 651 Nm
5. Adjust the open and close position stop as shown in the following chapter
“Adjustment of gear after mounting upon the valve”.
Adjustment of the position end screws
Fig. T.1 overview of components.
The open and close position stops prevent the actuator of rotating beyond the
open and closed positions of the valve. Each stop can be adjusted. The stops are not
preadjusted by the gear box manufacturer. We refer also to the instructions of the
valve for specic demands of the closed position of the valve.
Adjustment of gear after mounting on valve
Size DN10-DN150
How to adjust the stop for closed position
1. Remove the protection cap (A) from the counter nut on the stopscrew for the
closed position.
2. Loosen the counter nut (B) on the end screw for the closed position and loosen
the end screw a few turns.
3. Turn the handwheel (or another operating device) so the valve is in closed
position.
4. Turn the stopscrew for the closed position clockwise until there is a feeling of
resistance from the end screw, when it is in contact with the gear in the actuator.
5. Hold the end screw so it does not turn, when the counter nut (B) is tightened.
6. Put the protection cap back (A) on the counter nut.

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Fig. 8.
Fig. 9.
Fig. 10.
Fig. 11.
How to adjust the stop for open position
1. Remove the protection cap (A) from the counter nut on the end screw for the
open position.
2. Loosen the counter nut (B) on the end screw for the open position and loosen
the open screw a few turns.
3. Turn the handwheel (or another operating device), so that the valve is in open
position.
4. Turn the end screw for open position clockwise until there is a feeling of
resistance from the end screw, when it is in contact with the gear in the
actuator.
5. Hold the end screw, so it does not turn, when the counter nut (B) is tightened.
6. Put the protection cap (A) back on the counter nut.
The exact position of the ball in open and closed position, is very important
ensuring the tightness of the valve. If it is possible to see inside the valve, the
position has to be controlled carefully.
Open position: The ball is exactly adjusted, so that the opening ush with
connection ends and the seal rings of the valve seat.
Closed position: There should be full contact/overlap between the ball and the seal
rings of the valve seat.
Size DN200 – DN500
First adjust the open position
1. Rotate the stem and ball counterclockwise from closed position towards
open position.
2. While rotating counterclockwise look inside the valve. Continue rotating
counterclockwise until the ball is aligned up according to the seat gaskets of the
valve. See gure 3.
3. Set the adjustment screw of the gear, so that the operation of the valve is
limited to this position.
If the ball is rotated too far – see gure 9 – and a re-adjustment is necessary it is
important that the ball is not aligned by rotating clockwise .
Do instead following:
1. Close the valve.
2. Align the ball again in open position by rotating the ball counterclockwise .
3. Readjust the adjustment screw.
Note: It is important that the open position always is adjusted by rotating the stem
and ball counterclockwise in order to avoid backlash in the gear and the valve,
that disrupts the adjustment.

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In cases where the disassembly or mounting of valves with electric actuators is
needed – follow carefully the instructions in the guidelines of the actuator or
contact BROEN.
Reduceret ow Full ow Maximum output torque
from gear [Nm]
DN250 DN200 1500
DN300/350 DN250 3000
DN400 DN300/350 6500
DN500 DN400 16000
Ventil DN250 DN300 & DN350 DN400 DN500
Mål 21 mm 28 mm 34 mm 43 mm

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12. User manual for BROEN Ballomax®
hot tapping tool.
Fig. 1
Important:
If hot tapping valves are used on systems with temperatures over 100°C, steam can
be generated, which is led out through the ush valve. Be aware of the danger of
burn.
After welding of the hot tapping valve upon the pipe line it is recommended to
make a tightness test of the weld. For this a test plug is needed which is part of hot
tapping tools set
BROEN Ballomax® hot tapping tool
DN Vare nr. L D2 H D1 Tilsvej-
sende
Gevind f.
kobl. 5kt. Nøgle DIA. Kugle Bor dia. Anbefa- let RPM
15 68102015 127 ø23 53 ø42,4 ø21,3 G 7/8 5mm ø15 ø14 400
20 68102020 127 ø23 53 ø42,4 ø26,9 G 7/8 5mm ø15 ø14 400
25 68102025 143 ø28 63 ø51 ø33,7 G 1 1/8 5mm ø20 ø19 300
32 68102032 145 ø33 68 ø57 ø42,4 G 1 1/2 5mm ø25 ø24 300
40 68102040 178 ø42 96 ø76,1 ø48,3 G 1 3/4 7mm ø32 ø30 250
50 68102050 198 ø52 107 ø88,9 ø60,3 G 2 1/4 7mm ø39 ø37 200
65 68102065 205 ø54 118 ø108 ø76,1 M64x2 8mm ø49 ø48 200
80 68102080 200 ø80 137,5 ø127 ø88,9 M76x2 8mm ø63 ø60 150
100 68102100 225 ø97 163,2 ø152,4 ø114,3 M95x2 *10/12mm ø78 ø76 125

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Fig. 14.
Fig. 13.
Hot tapping procedure for DN15 and DN20 BROEN Ballomax® hot tapping
valve:
Put a 14mm drill in the drilltool and pull the drill all the way back in the house. The
drill can if necessary be held by the means of the stung box screw.
Mount the hot tapping tool upon the valve. It should be ensured, that the hot
tapping valve can be closed. Open the hot tapping valve and push the drill to the
contact with the pipe line.
Mount the drilling machine. A hose is mounted on the ush valve in order to lead
the district heating water and chips away from valve.
Open the ush valve.
Set the revolutions of the drilling machine as given in delivered table.
The drilling should be done with frequently interruptions to protect the drill and to
secure, that only small chips are created, which much easier can be ushed away.
When the drilling is complete, the drill is pulled all the way into the hot tapping tool.
The hot tapping valve can now be closed. If a chip blocks the close of the valve, the
ball is turned 180° back and the valve is closed. The hot tapping tool can now be
dismounted.
The hot tapping installation is now completed.
Hot tapping procedure for DN25, DN32, DN40 and DN50 BROEN Ballomax®
hot tapping valve:
Each valve dimension uses a coupling in connection with the hot tapping tool.
The same coupling is also used in connection with the test plug for the tightness
test.
The enclosed table shows what dimensions of drill can be used.
A drill extension can be used for both types of drill holders.
Fig. 12.
Fig. 15.

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The drawing (Fig. 16) shows the hot tapping of a DN25 hot tapping valve.
Mount the coupling on the hot tapping tool. Mount the correct drill. Remember that
the pilot drill should only be showing app. 4mm. Pull the drill all the way back in the
hot tapping tool.
Mount the hot tapping tool on the valve. It is to be ensured that the hot tapping
valve can be closed. Open the valve full and push the drill forward until contact with
the pipeline. Open the ush valve. Mount the drilling machine.
Set the revolutions of the drilling machine according enclosed table. The drilling is
executed with a light pressure on the drill and with frequent interruptions to protect
the drill and release the chips. When the drilling is done, the drill is pulled all the way
into the hot tapping tool.
It is important that uid pressure is kept on the drill to secure that the drilled part
remains in the cup drill. The hot tapping valve can be closed. If a chip prevent, the
valve in closing, the ball is turned 180° back and the valve can be closed.
Fig. 16.

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Fig. 17.
Hot tapping procedure for DN65, DN80 and DN100 BROEN Ballomax® hot
tapping valve.
These valves have an internal thread for connection of the hot tapping couplings.
The mounting procedure for the connection of the hot tapping tool is similar to the
procedure used for the smaller hot tapping valves.
It is recommended to use the delivered reduction gear and tension unit for hot
tapping with the mentioned valves and use a drilling machine with revolution
control. Hereby a controlled drill operation is obtained with a central pressure on the
cup drill.
It is very important, that the recommended revolutions of the cup drills are
respected. Reduction gear ratio: 7:1.
The gure describes the lineup and how the dierent components are situated.
In the transport case all the relevant hexagon keys for the mounting and operation
of the dierent hot tapping valves are found.
IMPORTANT:
1. The pilot drill is not to be further out than the cup drill (max. 4mm). Hereby it
can be assured that the valve can be closed, when the cup drill is pulled all the
way back.
2. The ush valve is to be remain open during the hot tapping process to ensure,
that the drilled part is kept in the cup drill, until the valve can be closed.
CAUTION: The appearance of the holder of the cup drill can change appearance
pending on the manufacturer.