Kammer 35000 Series Technical specifications

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
Section Page
General Information 2
Installation 2
Quick Check 3
Maintenance 3
Remove and Install Actuator 5
Disassemble and Assemble Valve 7
Trouble-shooting Chart 8
Table of Contents
08.96

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
1 GENERAL INFORMATION
These instructions are designed to support
you when unpacking, installing and per-
forming maintenance work on the valves.
Users and maintenance personnel should
carefully read these instructions before
installing, operating or performing main-
tenance work. There is a separate set of
instructionsforaccessories(specialseat/plug
fittings, diaphragm actuators, handwheels,
special seats, etc.).
These instructions do not contain any
information on Kämmer positioners.For this,
see corresponding instructions for the
installation, maintenance, trouble-shooting,
adjustment and operation of Kämmer
positioners.
To avoid damage or injury to personnel
or equipment, always heed all warnings
and instructions. Unprofessional re-
conditioning, the use of foreign replace-
ment parts or the performance of other
maintenance steps than those described
here, may cause a loss of efficiency or
lead to personnel injury or damage to
parts, and render the warranty void
1.1 UNPACKING
1.1.1 Each delivery includes a packing slip. When
unpacking, check all delivered valves and
accessories using this packing slip.
1.1.2 Larger valves can be lifted using slings on
the yoke rods or, if present, on the lugs
provided for this purpose. If slings are used,
attach them so that the outer tubing or
attaching parts are not damaged.
Important:Ifslingsareused,beawarethat
the centre of gravity of the valve may be
abovetheliftingpoint.Inthiscase,secure
or support the valve against rotating, to
prevent damage or personnel injury.
1.1.3 Report transport damage to the carrier
immediately.
1.1.4 In case of discrepancies, contact your
nearest dealer.
1.2 INSTALLATION
1.2.1 Clean tubing prior to installing.
1.2.2 If possible, install the valve in an upright
position (actuator on top), to ease maint-
enance. An upright installation position is
important with low-temperature applications,
in order to keep the distance between the
packing material and the medium as large as
possible. The packing material then retains
theambienttemperatureasmuchaspossible.
Important: Do not insulate extension
bonnets that are provided for hot or cold
services
1.2.3 Make sure that sufficient overhead clearance
above the actuator is maintained, to allow for
disassembly of plug from the valve body (see
following table).
1.2.4 After installing, check direction of flow again.
The direction of flow is shown by the arrow on
the housing.
1.2.5 Ifthe valve is to be welded into the line, make
sure that the valve is shielded from excessive
heat.
1.2.6 Connect supply pressure and signal lines.
Control valves can be supplied with a
positioner. The end connections for supply
pressure and signal are clearly marked.
Actuator and positioner are suitable for max.
4.2 bar (60 psi) supply pressure. If the supply
pressure exceeds the pressure specified on
the nameplate, a pressure reducing station is
required. If instrument air is not available,
install an oil separator/air filter in the air inlet
line. All connections must be free of leaks.
Actuator clearance
size (mm)
37/47 95
38/48 140
39/49 140
39D/49D 140

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
1.3 QUICK CHECK:
Before operating, check the valve as follows:
1.3.1 Open and close the valve, and observe the
movement of the actuator stem. The
movement must be smooth and linear.
1.3.2 Check for maximum stroke through change
ofsignal(forpneumaticpositioners,0.2-1.0
bar or corresponding split-range values; for
IP positioners, 4-20 or 0-20 mA).
1.3.3 Check all air connections for leaks.
1.3.4 The packing gland nut must always be
tightened slightly more than finger-tight.
IMPORTANT: An excessively tightened
gland nut can cause excessive packing
wear and can hinder the free movement
of the plug stem.
1.3.5 Check fail-safe position. To do this, close
supply pressure and observe whether the
valve opens or closes as prescribed.
1.3.6 After using at fluctuating temperatures, re-
tighten all bolt connections and check for
leaks.
2 MAINTENANCE
Check valves for correct functioning at regular
intervals (at least once every 6 months) as follows.
Thischeck can bemadewhen installedand in many
cases without interrupting production. If internal
defectsaresuspected,seesectionon„Disassembly
and Assembly of Valve“.
2.1 Examine gaskets for leaks and if necessary
re-tighten bolts (see Fig. 1).
2.2 Check bellows gasket and test connection
- if present - for external leaks.
2.3 Checkvalvefordamagecausedbycorrosive
residues or corrosive vapours.
2.4 Clean valves and if necessary re-paint.
2.5 Check packing bolts for correct tightening.
Glandnutsonpackingmayonlybetightened
slightly more than finger-tight, or only tight
enough to ensure a proper seal.
IMPORTANT: An excessively tightened
gland nut can cause excessive packing
wear and can hinder the free movement of
the plug stem.
2.6 If possible, open and close valve and check
formaximum stroke and smoothmovement of
the plug stem. Irregular movement of the plug
stem may indicate internal defects.
Note: With graphite packing, irregular move-
ment of the plug stem is normal.
IMPORTANT: Keep hands, hair, clothing,
etc. away from all moving parts. Failure to
do so can lead to serious injury.
2.7 Check all accessories for firm seating.
2.8 If possible, close supply pressure and check
the fail-safe position.
2.10 Check stem boot for wear.
2.11 Check actuator for leaks. To do this, spray
housing, air connections and plug stem guide
withsoapsudsandnoteanybubbleformation.
2.12 Clean plug stem.
2.13 Check air filter, if present, and if necessary
replace insert.

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
Zero adjustment locknut
Typical actuator and valve configuration
Fig. 1
Actuator stem
travel indicator disc
Cap
Locknut
Gland nut
Clamping nut
Plug stem

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
REMOVE AND INSTALL ACTUATOR
General Information
We recommend separating the actuator from the
valve during all repair work.
However, many maintenance and adjusting
operations can be carried out in installed condition.
3.1 Remove actuator
Foractuatorswithspring-to-close,goto3.1.1
Foractuatorswithspring-to-open,goto3.1.2
3.1.1 Remove cap and nameplate. Tighten zero
adjusting nut until it just touches the surface
of the spring housing. This relieves the plug
from actuator spring pressure .
3.1.2 Using a wrench, secure the actuator stem
against turning and using a second wrench
loosen the locknuts.
IMPORTANT: The actuator stem must not
be rotated, as this will cause damage to
the diaphragm.
3.1.3 Loosen gland and clamp nuts.
3.1.4 Secure plug stem against turning and un-
screw actuator from plug stem by rotating
counter-clockwise.
IMPORTANT:Ensurethatthe plugassem-
bly is not rotated with the plug seated.
Thismaycause irreparabledamagetothe
seating faces.
3.1.5 Remove actuator and remove at the same
time loc nut, travel indicator disc, gland nut
and clamp nut.
3.2 Install actuator
Information:
• Before the actuator is installed, it must
be calibrated according to section 3 of the
instructions „Pneumatic and Electro-pneu-
matic Actuators“.
• All worn or damaged parts must be re-
placed. Reusable parts must be clean.
3.2.1 Position actuator with clamp nut, gland nut,
locknutsand travelindicator disc on the valve.
3.2.2 Only for „spring-to-close“ actuators:
Screw actuator onto plug stem by rotating
clockwise,untiltheyokeplatejust touchesthe
valve housing and the actuator is aligned for-
wards.
IMPORTANT: Ensure that the plug assem-
blyis not rotated withthe plug seated. This
may cause irreparable damage to theseat-
ing faces.
Only for „spring-to-open“ actuators:
Liftplugstemandscrewintotheactuatorstem
until the distance between „plug in seat“ and
„plugraised“approximatelycorrespondstothe
specified stroke.
3.2.3 Tighten clamp nut and gland nut.
3.2.4 Adjustseat tightness by screwing/unscrewing
the plug stem in/out of the actuator stem.
Important: Ensure that the plug assembly
is not rotated with the plug seated. This
may cause irreparable damage to theseat-
ing faces
Openvalve,makeadjustment,closevalveand
check for leaks.
3.2.5 After adjusting, secure the locknuts and the
travel indicator disc lying between them
against actuator stem and align the travel in-
dicator on the yoke rod.

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
Packing kit see
spare parts list
Trim see
spare parts list
Travel indicator disc
Locknut
Gland nut
Packing follower
Clamping nut
Bolt/stud
(depending on design)
Bonnet
Gasket
Lockwasher
Body
Nut
Locknut
Bore for adjustable
face pin tool
Fig. 3
Bore for
hooked spanner
Fig. 2

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
4 DISASSEMBLE AND ASSEMBLE VALVE
4.1 Disassemble Valve
(see Fig. 2)
4.1.1 Remove bonnet flange bolting and raise
bonnet and plug assembly.
Caution: heavy assemblies may require
a hoist
4.1.2 Unscrew seat ring using seat ring tool and
carefully press plug stem evenly out of the
upper body.
4.1.3 With valves DN 80 / kv 63 and larger, the
plug head can be unscrewed (see Fig. 3).
Remove plug head from stem by securing
valve stem against rotation with a hooked
spanner and turning plug head with an
adjustable face pin tool.
4.1.3 Check seating faces ofseat ring and plug for
damage.Gasketsurfacesmustbecleanand
free of damage.
4.1.4 Press guides, packing and packing follower
from below using a drift (the drift must have
aslightlylargerdiameterthantheplugstem).
Important: To prevent damage to the plug
or plug stem, followtheabove instructions
precisely.
4.1.5 If a seat surfaces need re-machining, seat
andplugseatingsurfacesmustbereworked.
Theseat angleon theplug is30°,on theseat
ring 25°. If the valve is correctly assembled,
lapping is not required.
Important: When re-machining the plug,
protect plug stem from damage. The seat
surface must be concentric to the plug
stem.When re-finishing theseat, the seat
surface must be concentric to the seat
outer diameter.
4.2 Assemble Valve
(see Fig. 2)
4.2.1 Allwornordamagedparts mustbereplaced.
Reusable parts must be clean. expenable
parts such as gaskets, packing and O-rings
should always be replaced.
4.2.2 Insert seat ring and tighten. For torques, see
following table.
4.2.3 If necessary, screw plug head back on to stem
and carefully guide plug stem through the
bonnet, to avoid damage.
4.2.4 Insert new bonnet gasket.
4.2.5 Position bonnet slowly and absolutely upright
on body, to avoid damage to seat/plug.
4.2.6 Tighten bonnet flange bolts alternating
crosswise finger-tight and then tighten with a
wrench. For torques, see following table.
4.2.7 Replacepackingbyinsertingpackingringsone
atatimetappingeachonedownwitha suitable
bushing.
IMPORTANT: ensure that the gaps in the
packing rings are distibutedevenly around the
circumferance in the packing box (gaps not in
line).
Note: different packings and fitting sequence
is shown in the spare parts list.
6.2.8 Insert packing follower. Fit gland nut for
transport purposes only. Gland nut to be fitted
correctly and tightened down when actuator is
mounted.
Size Body Torque
material
DN 15/25 (1/2/1") 1.4581 cast 125 Nm
1.4571 forged 125 Nm
DN40/50(11/2/2") 1.4581 200 Nm
1.4571 255 Nm
DN 80 (3") 1.4581 230 Nm
1.4571 270 Nm
DN 100 (4") 1.4581 400 Nm
1.4571 500 Nm
DN 150 (6") 1.4581 450 Nm
1.4571 600 Nm
Hex bolt. Waisted bolt Studs
Thread DIN 933 DIN 2510 DIN 939
A2-70 1.7709 1.7258 CK 35
M 8 20 Nm – – –
M 10 35 Nm – – 20 Nm
M 12 60 Nm 44 Nm 36 Nm 35 Nm
M 16 145 Nm 115 Nm 92 Nm 80 Nm
M 20 280 Nm – – –
M 24 250 Nm – – 270 Nm

Maintenance Instructions
Control Valve Series 35 000
KÄMMER VENTILE GMBH • MANDERSCHEIDTSTRASSE 19 • D - 45141 ESSEN • TEL.: ( 0201) 89 19 – 5 • FAX: ( 0201) 89 19 – 600
Trouble-shooting Chart
Fault Possible Cause Remedy
Stem motion 1. Packing excessively tightened 1. Tighten gland nut slightly more than „finger-tight“
impeded 2. Operating temperature too 2. Note operating data and contact dealer
high for selected trim
3. Supply pressure inadiquate 3. Check system for leaks in the supply pressure or signal lines. Re-
tighten the connections, if necessary replace leaky lines
4. Positioner defective 4. See operating instructions for positioner
Excessive 1. Bonnet loose 1. See step 4.2.5 for correct tightening of bonnet.
leakage 2. Worn or damaged 2. Re-machine or replace seat ring/plug.
seat ring/plug
3. Gaskets damaged 3. Replace gaskets
4. Inadiquate actuator thrust 4. Check air feed. If air feed is OK, contact dealer.
5. Plug incorrectly adjusted 5. Correctly adjust plug according to step 3.2.4
6. Incorrect direction of flow 6. Check specification. Contact dealer
7. Handwheel incorrectly 7. Adjust handwheel
adjusted (acts like end stop)
Inadiquate flow 1. Plug incorrectly adjusted 1. Correctly adjust plug according to step 3.2.4
(short stroke)
2. Positioner defective 2. See operating instructions for positioner
3. Operating requirements 3. Check operating data. Contact dealer
too high
Plug slams 1. Plug adjustment incorrect 1. Correctly adjust plug according to step 3.2.4
2. Inadiquate supply pressure 2. Check supply pressure, seal leaks, remove blockage
3. Trim too large for 3. Replace trim
flow rate