KIESELMANN 406 Series User manual

Operating instruction
Translation of the original
Straight-way ball valve
industrial design
pneumatic und manual operation
Types 406x
416x
426x
GB
ENGLISHPDF • ak • 03/12/2020

KIESELMANN GmbH
Paul-Kieselmann-Str. 4-10
D - 75438 Knittlingen
( [phone] • 7 [phone]
www.kieselmann.de • [email protected]
Copyright: © KIESELMANN FLUID PROCESS GROUP

KIESELMANN GmbH Table of contents
4x6x_DGKH_EN 3
Table of contents
1 General informations ....................................................................................................................................................4
1.1 Informations for your safety ...............................................................................................................................................4
1.2 Marking of security instructions.........................................................................................................................................4
1.3 General designated use ......................................................................................................................................................4
1.4 Personnel .............................................................................................................................................................................4
1.5 Modifications, spare parts, accessories ............................................................................................................................5
1.6 General instructions ............................................................................................................................................................5
2 Safety instructions........................................................................................................................................................6
2.1 Intended use ........................................................................................................................................................................6
2.2 General notes.......................................................................................................................................................................6
2.3 General safety instructions.................................................................................................................................................6
3 Delivery, transport and storage .....................................................................................................................................8
3.1 Delivery.................................................................................................................................................................................8
3.2 Transport..............................................................................................................................................................................8
3.3 Storage.................................................................................................................................................................................8
4 Specification.................................................................................................................................................................9
4.1 Modular system...................................................................................................................................................................9
5 Function and operation ...............................................................................................................................................10
5.1 Description of function......................................................................................................................................................10
5.2 Control system and position indication ...........................................................................................................................11
6 Commissioning, service and maintenance ..................................................................................................................12
6.1 Commissioning..................................................................................................................................................................12
6.1.1 Installation instructions....................................................................................................................................... 12
6.1.2 General welding guidelines ................................................................................................................................. 12
6.1.3 ATEX - Guidelines ................................................................................................................................................ 12
6.2 Service................................................................................................................................................................................13
6.3 Cleaning .............................................................................................................................................................................13
7 Technical data ............................................................................................................................................................14
8 Disassembly and assembly .........................................................................................................................................15
8.1 Disassembly.......................................................................................................................................................................15
8.2 Assembly ...........................................................................................................................................................................15
9 Drawings and dimensions ...........................................................................................................................................16
9.1 Control units ......................................................................................................................................................................16
9.2 Drawings ............................................................................................................................................................................17
9.3 Dimensions ........................................................................................................................................................................18
10 Appendix ....................................................................................................................................................................19
10.1 Declaration of incorporation.............................................................................................................................................19

Operating instruction | KIESELMANN GmbH1 | General informations
4 / 19 4x6x_DGKH_EN
1 General informations
1.1 Informations for your safety
We are pleased that you have decided for a high-class KIESELMANN GmbH 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 ad-
vices contained in it. This guarantees reliable and safe operation of this product and your plant re-
spectively. 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, hand-
ling 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 war-
ranty. 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 GmbH - service team will
naturally be at your disposal.
1.2 Marking of security instructions
Hints are available in the chapter "safety instructions" or directly before the respective operation in-
struction. 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 Imminent danger which will result severe personal injury or
death.
WARNING Imminent danger which may result severe personal injury or
death.
CAUTION Dangerous situation which may cause slight personal injury or
material damages.
NOTICE An harmful situation which may result in damages of the product
itself or of adjacent vicinity.
INFORMATION Marks application hints and other information which is particu-
larly useful.
1.3 General designated use
The fitting is designed exclusively for the purposes described below. Using the fitting for purposes
other than those mentioned is considered contrary to its designated use. KIESELMANN GmbH can-
not be held liable for any damage resulting from such use. The risk of such misuse lies entirely with
the user. The prerequisite for the reliable and safe operation of the fitting is proper transportation
and storage as well as competent installation and assembly. Operating the fitting within the limits
of its designated use also involves observing the operating, inspection and maintenance instruc-
tions.
1.4 Personnel
Personnel entrusted with the operation and maintenance of the tank safety system must have the
suitable qualification to carry out their tasks. They must be informed about possible dangers and
must understand and observe the safety instructions given in the relevant manual. Only allow quali-
fied personnel to make electrical connections.

KIESELMANN GmbH | Operating instruction General informations | 1
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1.5 Modifications, spare parts, accessories
Unauthorized modifications, additions or conversions which affect the safety of the fitting are not
permitted. Safety devices must not be bypassed, removed or made inactive. Only use original spare
parts and accessories recommended by the manufacturer.
1.6 General instructions
The user is obliged to operate the fitting only when it is in good working order. In addition to the in-
structions given in the operating manual, please observe the relevant accident prevention regula-
tions, generally accepted safety regulations, regulations effective in the country of installation,
working and safety instructions effective in the user's plant.

Operating instruction | KIESELMANN GmbH2 | Safety instructions
6 / 19 4x6x_DGKH_EN
2 Safety instructions
2.1 Intended use
Straight-way ball valves are used as a shut-off valve in units of the beverage and food industry, the
pharmacy, the biotechnology as well as the chemical industry.
2.2 General notes
NOTICE - observe the operating instructions
To avoid danger and damage, the fitting must be used in accordance with the safety instructions
and technical data contained in the operating instructions.
NOTICE
All data are in line with the current state of development. Subject to change as a result of tech-
nical progress.
2.3 General safety instructions
WARNING
Risk of injury by outflowing medium
Dismantling the valve or valve assemblies from the plant can cause injuries.
– Medias flowing through the leakage drain outlet are to be drained off without splashing
into a discharge arrangement.
– Carry the disassembling only if when the plant has been rendered pressure-less and free
of liquid and gas.
WARNING
Risk of injury by moving parts
Do not grab into the valve when the actuator is pressurized. Limbs can be crushing or amputating.
– Remove the control air line before dismantling.
– Ensure that the actuator is unpressurized.
WARNING
Risk of injury by pre-stressed pressure spring.
The pneumatic-mechanical actuator is spring-loaded. When disassembling the actuator, compon-
ents that jump out may cause injuries.
– Multiturn actuator are maintenance-free and therefore do not need to be opened!
WARNING
ATEX - Guidelines
If the valve or the plant is operated in a potentially explosive atmosphere, the valid ATEX directive of
the EC and the installation instructions in this operating manual must be observed.
CAUTION
To avoid air leaking, only use pneumatic connection parts that have an O-ring seal facing the even
surface.
CAUTION
Before starting the system, the entire pipeline system must be thoroughly cleaned.

KIESELMANN GmbH | Operating instruction Safety instructions | 2
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CAUTION
Steps should be taken to ensure that no external forces are exerted on the fitting.

Operating instruction | KIESELMANN GmbH3 | Delivery, transport and storage
8 / 19 4x6x_DGKH_EN
3 Delivery, transport and storage
3.1 Delivery
• Immediately after receipt check the delivery for completeness and transport damages.
• Remove the packaging from the product.
• Retain packaging material, or expose of according to local regulations.
3.2 Transport
CAUTION
Risk of injury and damage to the product
During the transport the generally acknowledged rules of technology, the national accident preven-
tion regulationsand company internal work and safety regulations must be observed.
3.3 Storage
NOTICE
Damage to the product due to improper storage!
Observe storage instructions
avoid a prolonged storage
INFORMATION
Recommendation for longer storage
We recommend regularly checking the product and the prevailing storage conditions during long
storage times.
• To avoid damage to seals and bearings,
– products up to DN 125 / OD 5 inch should be stored horizontally for maximum 6 months.
– products larger than DN 125 / 5 inch, should be stored in the upright position with the actu-
ator on top.
• Don't store any objects on the products.
• Protect the products for wetness, dust and dirt.
• The product should be stored in a dry and well ventilated room at a constant temperature (op-
timal indoor temperature: 25 C ±5; indoor humidity data 70% ±5%).
• Protect seals, bearings and plastic parts for UV light and ozone.

KIESELMANN GmbH | Operating instruction Specification | 4
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4 Specification
4.1 Modular system
KI-Top control head Feedback unit
Stainless steel hood: Transparent hood
drive systems
pneumatical electrical
PDA 90/75
Ø 75
PDA 90/100
Ø 100
PDA 90/125
Ø 125
4040
manual
Hand lever Hand lever
with sensor mounting
Valve insert
Seal material
PTFE
Connection flanges
S G K/M Cl Fl Ri

Operating instruction | KIESELMANN GmbH5 | Function and operation
10 / 19 4x6x_DGKH_EN
5 Function and operation
5.1 Description of function
Open or close the valve by turning the pneum. controlled rotary drive by 90°.
Functional description for valves with manual operation
The manually operated lever is positioned at an angle of 90°in transverse direction to the conduit
axis in closed position The lever is positioned in the direction of the conduit axis in open position.
The possible assembly-line ways in dependence of the stop functions linked with it are shown in
the table as valve positions.
Valve positions
Valve position 1
Connection A - B open
Valve position 2
Connection A - B closed
A B A B
90°
Description of function for pneum. valves
The valve opens and closes by way of a pneum. multiturn actuator with a rotary movement of 90°.
normal closed (NC)
• pneum. OPERATED
• not pneum. OPERATED
opens the valve
spring force closes the valve
normal open (NO)
• pneum. OPERATED
• not pneum. OPERATED
closes the valve
spring force opens the valve
double acting (DA)
• pneum. OPERATED the valve opens or closes according to control

KIESELMANN GmbH | Operating instruction Function and operation | 5
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5.2 Control system and position indication
Retrofitting to end position feedback for manually operated valves
By replacing the hand lever and the catch disc the valve can be retrofitted for end position feedback
(proximity switch).
Conversion from manual operation to pneumatic actuation
By a simple retrofitting operation the valve can be converted to pneumatic actuation. The rotary ac-
tuator for this purpose is supplied complete with fitting device. The following actuators are avail-
able, depending on the desired actuating function.
Nominal diameter Pneum. actuator Normally closed (NC)
DN 10 | OD ¼“
DN 15 | OD ½“
PDA 90/75 4262 010 010-022
4262 015 010-022
DN 20 | OD ¾”
DN 25 | OD 1“
DN 32 | OD 1 ¼”
DN 40 | OD 1 ½”
PDA 90/100 4262 020 010-022
4262 025 010-022
4262 032 010-022
4262 040 010-022
DN 50 | OD 2“ PDA 90/125 4262 050 010-022
Position indicator with sensor mounting for feedback signal.
The actuator is equipped with a proximity switch mounting (sensor mounting) and a position indica-
tion. When inductive proximity initiators M 12x1 are installed, the current "Open" or "Shut" position
can be interrogated. By screwing the proximity initiator to the limit position the required switching
gap for the signal transmission is established.. When the valve is closed the position indication is
oriented vertically to the direction of valve passage. When the valve is open it is oriented parallel to
the valve passage.
Feedback unit -optional-
Optionally, modular valve control head systems can be installed to the actuator for reading and ac-
tuating valve positions. The standard version is a closed system with SPS or ASI-bus switch-on
electronics, and integrated 3/2-way solenoid valves. For tough operating conditions we recommend
employing a high-grade steel cover.

Operating instruction | KIESELMANN GmbH6 | Commissioning, service and maintenance
12 / 19 4x6x_DGKH_EN
6 Commissioning, service and maintenance
6.1 Commissioning
6.1.1 Installation instructions
For ball valves without leakage outlet, the installation position is without importance.
Ball valves with leakage outlet must always be installed vertically to ensure that outflow of leakage,
or of cleaning medium, from the valve is such that no residue will remain inside the valve.
For valves which are to be welded in on both sides, a releasable connection has to be fitted into the
pipework to allow dismounting (maintenance).
6.1.2 General 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 (EN ISO 9606-1). Use the TIG
(Tungsten Inert Gas) welding process.
CAUTION
Damage and injuries due to high temperature supply
To avoid a distortion of the components, all welding parts must be welded to stress-relieved.
Allow all components to cool before assembling.
NOTICE
Damage due to impurities
Impurities can cause damage to the seals and seals area.
Clean inside areas prior to assembly.
6.1.3 ATEX - Guidelines
For valves or plants/installations that are operated in the ATEX area, sufficient bonding (grounding)
must be ensured (see valid ATEX Guidelines EG).

KIESELMANN GmbH | Operating instruction Commissioning, service and maintenance | 6
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6.2 Service
RECOMMENDATION
Replacement of seals
To achieve optimal maintenance cycles, the following points must be observed!
– When replacement of seals, all product-contacting seals should be replaced.
– Only original spare parts may be installed.
Maintenance interval
The maintenance intervals depend on the operating conditions "temperature, temperature-intervals,
medium, cleaning medium, pressure and opening frequency". We recommend replacing the seals 2-
year cycle.The user, however should establish appropriate maintenance intervals according to the
condition of the seals.
Lubricant recommendation
EPDM; HNBR; NBR; FKM; k-flex - Klüber Paraliq GTE703*
Silicone - Klüber Sintheso pro AA2*
Thread - Interflon Food*
*) It is only permitted to use approved lubricants, if the respective fitting is used for the produc-
tion of food or drink. Please observe the relevant safety data sheets of the manufacturers of lub-
ricants.
6.3 Cleaning
In order to ensure continuous flawless function 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 dirty-
ing.

Operating instruction | KIESELMANN GmbH7 | Technical data
14 / 19 4x6x_DGKH_EN
7 Technical data
Model: Straight-way ball valve
Valve size: Valves - manual operation
DIN: DN 10 - DN 100
Inch: DN ¼“ - DN 2“
Valve - pneumatical
DIN: DN 10 - DN 50
Inch: DN ¼“ - DN 2“
Connections: Welded end (S) DIN EN 10357
Thread (G) DIN 11851
Liner/nut (K/M) DIN11581
Clamp connection (Cl)
Flange connection (Fl)
Pipe Thread (Ri)
Temperature range: Ambient (air) +4° to +45°C
Operating (medium dependent) +0° to +95°C
Sterilization (SIP 30 min) PTFE +140°C
Pressure range: Operating pressure: 56 bar (at 20°C)
Leak rate: A (DIN EN 12266-1)
Control air: Control air pressure:
5,5 - 8,0 bar
Quality of control air:
ISO 8573-1 : 2001 quality class 3
Materials:
(in product contact)
Stainless steel: 1.4301 / AISI304
1.4404 / AISI316L
1.4408 / AISICF-8M / SCS14
Surfaces: Ra < 0,8µm e-polished
Sealing material: PTFE

KIESELMANN GmbH | Operating instruction Disassembly and assembly | 8
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8 Disassembly and assembly
8.1 Disassembly
NOTICE
All threaded joint have right-hand thread.
Unscrew and remove control air, steam resp. cleaning lines and electrical lines, complete feedback
unit or control head.
Ball valve - pneum. operation - dismount actuator
• Unscrew the nuts (17a) and remove screws (15a).
• Remove the complete actuator (22).
• Remove the square boss (19).
Ball valve manual operation - Dismount hand lever
• Unscrew the screw (8).
• Remove the disc (9) and hand lever (3).
Replacement wear parts
• Unscrew the nuts (17b) and remove screws (15b).
• Remove flanges (2).
• Dismantle the O-rings (14) and thrust collar (6).
• Dismount the ball (7) from the housing (1).
• Remove axle (5).
• Dismount the sealing package (10,11,12,13) from the housing (1).
8.2 Assembly
• Before installation, thoroughly clean and slightly lubricate mounting areas and running sur-
faces.
• Assemble in reverse order.
15b 2
14 6
14
6
1
8
9
3
4
10,11,12,13
5
2
16 17b
7
15a 17a
19
21
20
22
A18

Operating instruction | KIESELMANN GmbH9 | Drawings and dimensions
16 / 19 4x6x_DGKH_EN
9 Drawings and dimensions
9.1 Control units
Control head KI-TOP Position indication
with sensor mounting
Plastic hood
transparent
stainless steel hood
129
Ø 105
25,5
Position indication with sensor mounting (R)
• R1 = dog
• R1.1 = Straight pin
• R2 = Position indication
• R3 = O-ring
• R4 = Screw
• R5 = Sensor mounting
• R6 = Cap
• R7 = Screw
• LA = air supply

KIESELMANN GmbH | Operating instruction Drawings and dimensions | 9
4x6x_DGKH_EN 17 / 19
9.2 Drawings
1 = Housing
2 = Flange
3 = Hand lever
4 = Nut
5 = Axis
6 = Thrust collar
7 = Ball
8 = Nut
9 = Disc
10-13 = Sealing package
14 = O-ring
15 = Screw
16 = Disc
17 = Nut
18 = Cap for hand lever
19 = Square boss
20 = Screw
21 = Holding flange
22 = Actuator
A = Control head
15b 2
14 6
14
6
1
8
9
3
4
10,11,12,13
5
2
16 17b
7
15a 17a
19
21
20
22
A
18

Operating instruction | KIESELMANN GmbH9 | Drawings and dimensions
18 / 19 4x6x_DGKH_EN
9.3 Dimensions
Straight-way ball valve S-S, manual operation DN d1 d4 L1 L2
10 12.5 18.5 63 51
15 16.0 21.5 73 60
20 20.0 26.0 85 63
25 25.0 31.0 94 76
32 32.0 38.5 110 81
40 38.0 45.0 122 93
50 51.0 58.5 142 102
65 65.0 75.0 167 132
80 80.0 92.5 192 143
100 100.0 114 226 174
Straight-way ball valve S-S, pneumatic operation DN d1 L1 L3
10 12.5 63 278
15 16.0 73 286
20 20.0 85 289
25 25.0 94 291
32 32.0 110 302
40 38.0 122 335
50 51.0 142 345
65 - - -
80 - - -
100 - - -
Straight-way ball valve S-S, pneumatic operation OD d1 L1 L3 SW
¼" ¼" 54 51 23
⅜" ⅜" 54 51 23
½" ½" 64 60 28
¾" ¾" 76 63 33
1" 1" 88 76 40
1 ¼" 1 ¼" 88 82 50
1 ½" 1 ½" 120 93 58
2" 2" 134 101 71

KIESELMANN GmbH | Operating instruction Appendix | 10
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10 Appendix
10.1 Declaration of incorporation
Declaration of incorporation
Translation of the original
Manufacturer / authorised representative: KIESELMANN GmbH
Paul-Kieselmann-Str. 4-10
75438 Knittlingen
Germany
Authorised representative: Achim Kauselmann
(for compiling technical documents) Paul-Kieselmann-Str. 4-10
75438 Knittlingen
Germany
Product name Function
pneum. Lift actuators Stroke movement
pneum. Rotary actuators Rotary movement
Ball valves Media cutoff
Butterfly valves Media cutoff
Single seat valves Media cutoff
Flow control valves Control of liquefied media
Throttle valve Control of liquefied media
Overflow valve Definition of fluid pressure
Double seat valve Media separation
Bellow valves Sampling of liquids
Sampling valves Sampling of liquids
Two way valves Media cutoff
Tankdome fitting Prevention of overpressure and vacuum, Tank cleaning
Safety valve Prevention of overpressure
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 in-
tended to be installed into a machine or an incomplete machine. The said product does not yet con-
form 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 must not only carried out if it has been determined that
the respective machine into which the incomplete machine is to be installed conforms to the regu-
lations set out in the Directive on Machinery referred to above.
The above product conforms to the requirements of the directives and harmonized standards spe-
cified below:
• Directive 2014/68/EU
• DIN EN ISO 12100 Safety of machinery
i.V. Uwe Heisswolf
Head of Development
Knittlingen, 21.07.2017