KIESELMANN GEMBRA 5836 User manual

Angle valve Type: 5836
T-valve Type: 5838
Operating instruction
Translation of the original
GEMBRA Aseptic-Single seat valves
PDF • ak • 14/05/2019
GB
ENGLISH

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

KIESELMANN GmbH Table of contents
583x_GEMBRA_EN III
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
4.1.1 Valve design........................................................................................................................................................... 9
5 Function and operation ...............................................................................................................................................10
5.1 Description of function......................................................................................................................................................10
5.2 Control system and position indicator.............................................................................................................................10
5.3 Valve basic position: .........................................................................................................................................................11
5.4 Pneumatic valve activation...............................................................................................................................................12
6 Commissioning, service and maintenance ..................................................................................................................13
6.1 Commissioning..................................................................................................................................................................13
6.1.1 Installation instructions....................................................................................................................................... 13
6.1.2 General welding guidelines ................................................................................................................................. 13
6.1.3 ATEX - Guidelines ................................................................................................................................................ 13
6.2 Service................................................................................................................................................................................14
6.3 Cleaning .............................................................................................................................................................................14
7 Technical data ............................................................................................................................................................15
7.1 Angle valve 5836, T-valve 5838 ........................................................................................................................................15
7.2 Torques ..............................................................................................................................................................................15
7.3 Valve stroke .......................................................................................................................................................................15
8 Disassembly and assembly .........................................................................................................................................16
8.1 Disassembly.......................................................................................................................................................................16
8.1.1 Assembly valve insert VE .................................................................................................................................... 17
8.1.2 Replacement wear parts ..................................................................................................................................... 17
8.2 Assembly ...........................................................................................................................................................................21
8.2.1 Mounting clamp coupling (VK) ........................................................................................................................... 21
8.2.2 Assembling k-flex Seal (D-1)............................................................................................................................... 22
8.2.3 Mounting k-flex - seal D1..................................................................................................................................... 22
8.2.4 Mounting diaphragm (D2) and valve insert (VE) ............................................................................................... 24
9 Drawings and dimensions ...........................................................................................................................................27
9.1 Drawings ............................................................................................................................................................................27
9.2 Control units ......................................................................................................................................................................28
9.3 Dimensions ........................................................................................................................................................................29
10 Wearing parts .............................................................................................................................................................30
10.1 Wearing parts list...............................................................................................................................................................30
10.2 Wear parts kit.....................................................................................................................................................................32
11 Classification..............................................................................................................................................................33
11.1 Structure of Order Number ...............................................................................................................................................33
12 Appendix ....................................................................................................................................................................35
12.1 Declaration of incorporation.............................................................................................................................................35

Operating instruction | KIESELMANN GmbH1 | General informations
4 / 35 583x_GEMBRA_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.

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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
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2 Safety instructions
2.1 Intended use
The valve is utilised as a pneumatically controlled shut-off valve in food and beverage as well as in
pharmaceutical, biotechnological and chemical industries.
The valve is designed for media characteristics according to DGRL 2014/68/EU for group 2 (media
condition gaseous or liquid).
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 moving parts
Do not grab into the valve when the actuator is pressurized. Limbs can be crushing or amputating.
a) Remove the control air line before dismantling.
b) Ensure that the actuator is unpressurized.
WARNING
Risk of injury by outflowing medium
Dismantling the valve or valve assemblies from the plant can cause injuries.
a) Medias flowing through the leakage drain outlet are to be drained off without splashing into a
discharge arrangement.
b) Carry the disassembling only if when the plant has been rendered pressure-less and free of li-
quid and gas.
WARNING
Risk of injury by pre-stressed pressure spring.
The actuator is spring-loaded. When disassembling the actuator, components that jump out may
cause injuries.
a) For dismantling please observe the separate assembly instructions.
b) We recommend having the manufacturer do the maintenance work required for the actuation.
CAUTION
When mounting the clamps, the max. torque must not be exceeded.
(see technical data)
CAUTION
To avoid air leaking, only use pneumatic connection parts that have an O-ring seal facing the even
surface.

KIESELMANN GmbH | Operating instruction Safety instructions | 2
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CAUTION
Before starting the system, the entire pipeline system must be thoroughly cleaned.
CAUTION
Steps should be taken to ensure that no external forces are exerted on the fitting.

Operating instruction | KIESELMANN GmbH3 | Delivery, transport and storage
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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 Feedback unit with finger guard
(E)
Actuator pneumatical
PTFE / k-flex | PTFE / EPDM
Valve housing
S - S SS - S
4.1.1 Valve design
GEMBRA Aseptic-Single seat valve
Angle valve
S-S
T-valve
SS-S

Operating instruction | KIESELMANN GmbH5 | Function and operation
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5 Function and operation
5.1 Description of function
Valve function: • Shut off fluid media in pipelines
Operation: • pneumatic operation by a lift drive (air/spring or air/air)
Activation: • Pneumatically over a 3/2-way solenoid valve
(Pneumatic valve activation)
Description of function - Lift actuator
Normally closed (NC) Basic position: Valve close
pneum. operated → opens the valve
undivided pneum. operated → spring force closes the valve
normal open (NO) Basic position: Valve open
pneum. operated → valve “CLOSE“
undivided pneum. operated → spring force opens the valve
double acting (DA) Basic position: not defined1
pneum. operated → opens the valve
undivided pneum. operated → valve “CLOSE“
1. The valve position is not defined in case of decrease of pressure in the compressed air line.
L
Leakage drain (L)
Leakage detection takes place via the leakage outlet (L) at the lantern.
5.2 Control system and position indicator
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.
Feedback unit with finger guard -optional-
For the acquisition of the valve positions over inductive initiators (Sensors), a feedback unit is
mounted on the actuation. The enquiry takes place over the position of the piston rod.

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5.3 Valve basic position:
Basic positon:
Kind of actuation:
Valve closed
Normally closed (NC)
Valve open
Normally open (NO)
Type: 5836
S-S
Angle valve
A
B
Line A - B closed
A
B
Line A - B open
Type: 5838
S-S
T-valve
A
B B
Line A - B closed
A
B B
Line A - B open

Operating instruction | KIESELMANN GmbH5 | Function and operation
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5.4 Pneumatic valve activation
Valve function Pneum. activation
via control head with
solenoid valves (MV)
Pneum. activation
via external solenoid valves
(MV external)
Antriebsart: normal closed (NC)
Valve OPEN
by pressurised air
control air feed
P ➟ MV1 ➟ P1/LA2
control air feed
ext. MV ➟ LA2
Valve CLOSED
by spring tension
de-aeration
LA2/P1 ➟ MV1 ➟ R
de-aeration
LA2 ➟ ext. MV
Kind of actuator: normal open (NO)
Valve OPEN
by spring tension
de-aeration
P1/LA1 ➟ MV1 ➟ R
de-aeration
LA1 ➟ ext. MV
Valve CLOSED
by pressurised air
control air feed
P ➟ MV1 ➟ P1/LA1
control air feed
ext. MV ➟ LA1
Kind of actuator: air open - air close (DA)
Valve OPEN
by pressurised air
control air feed
P ➟ MV1 ➟ P1/LA2
control air feed
ext. MV ➟ LA2
Valve CLOSED
by pressurised air
control air feed
P ➟ MV3 ➟ P3/LA1
control air feed
ext. MV ➟ LA1
MV = solenoid valve
R = de-aeration, sound
absorber
P = compressed-air in-
let
LA = air supply
S = Slide switch for
manual operation of the
solenoid valve
Si = Sensor inductive
E = sensor mounting
NC NO DA
MV1
S
P
P1
P3
R
D
LA2
MV1
S
P
P1
P3R
D
LA1
MV1
MV3
S
P
P1
P3R
LA2
LA1
E
D
LA2
Si
E
D
LA1
Si
E
LA2
LA1
Si

KIESELMANN GmbH | Operating instruction Commissioning, service and maintenance | 6
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6 Commissioning, service and maintenance
6.1 Commissioning
6.1.1 Installation instructions
Fitting position
The valve must be installed vertically with the actuator at the upwards. Liquid must be able to flow
freely from the valve housing.
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).

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6.2 Service
RECOMMENDATION
Replacement of seals
To achieve optimal maintenance cycles, the following points must be observed!
a) When replacement of seals, all product-contacting seals should be replaced.
b) 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 1-
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
Cleaning
Ideally, cleaning is carried out with duct cleaning when the valve is open.

KIESELMANN GmbH | Operating instruction Technical data | 7
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7 Technical data
7.1 Angle valve 5836, T-valve 5838
Model: GEMBRA Aseptic-Single seat valve
• Angle valve Type 5836
• T-valve Type 5838
Valve size: DN40 - DN80
Connections: weld-on end DIN EN 10357
Temperature range: Ambient temperature:
Operating temperature:
Sterilization temperature:
+4 to +45°C (air)
+0 to +95°C (medium dependent)
k-flex/PTFE +140°C (SIP 30 min)
Working pressure: DN 40, DN50, DN65 = max.10 bar
DN 80 = max. 8 bar
Pressure resistance: 30 bar
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: Ra < 0,8µm metallic bright, blank
e-polished
Surfaces: Ra < 0,8µm metallic bright, blank
e-polished
Sealing material: k-flex / PTFE (FDA)
EPDM / PTFE (FDA)
7.2 Torques
DN
Inch
25
1
40
1½
50
2
65
2½
80
3
100
4
Clamp coupling (Nm): 15 15 15 25 25 55
7.3 Valve stroke
DN
Inch
25
1
40
1½
50
2
65
2½
80
3
100
4
main lift (mm) 18 18 18 27 27 -

Operating instruction | KIESELMANN GmbH8 | Disassembly and assembly
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8 Disassembly and assembly
8.1 Disassembly
Mounting tools
Tool kit
for GEMBRA Aseptic-Single seat valve
DN40 - DN80
ST4, ST10, ST20,
ST21, ST22, T31,
T10
5820000010-000
T1 Combination wrench-Set SW 8 - SW 24 -
ST20 Spanner SW 30 - 32 8618030032-000
T2 Allen key - Set 1.5 - 10 -
T3 Screwdriver Set Size 2,5 - 10
PH0,PH1
-
T4 Soft-head hammer - -
T10 Joint -pin wrench Pin Ø6 8027000065-000
T31 Round rod ø8 5620065007-020
T30 Needle - -
ST4 Centring ring - valve plate
seal
DN40/50
DN65
DN80
5620050024-020
5620065025-020
5620080025-020
ST11 Mounting wrench A
Mounting wrench B
DN 40 - 65
DN 80
5836000065-000
5836000080-000
NOTICE
All threaded joint have right-hand thread.
Dismantle pneumatic and electrical connections. Unscrew fittings for CIP,discharge and feed lines.

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8.1.1 Assembly valve insert VE
- air open- spring close (NC)
- air open - air close (DA)
• Remove the hood (H) from control head.
• Connect control air to the air connection (P)
and lift the piston (2) by actuating the slide
switch (S).
• Unscrew and remove the Clamp coupling
(VK).
• Remove the completely valve insert (VE)
from the housing (VG).
• Disconnect the air supply (P), the piston
moves back to the basic position.
• the To prevent damage to the control head,
re-install the hood (H).Cap Control head
- air close- spring open (NO)
• Unscrew and remove the Clamp coupling
(VK).
• Remove the completely valve insert (VE)
from the housing (VG).
SP
2
H
VE
VE
VK
VE
VK
VG
8.1.2 Replacement wear parts
• Remove the hood (H) from control head
(bayonet lock).
• Unscrew the screws (S1).
• Remove the control head.
S1
VE
H

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• Unscrew the piston plate (1), hold it against
with a fork wrench at the piston (2).
• Remove seal (D1).
D1 12
• Unscrew the stud bolt (4).
S1
4
H
• Turn the piston (2) 180 ° so that the hole (B)
is in the slot (L) of the lantern (5).
2
3 5
B
180°
L

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• Insert a round rod Ø8 into the hole (B) and
unscrew the piston (2) with a fork wrench
from the upper piston (3).
3
2
B
• Dismount the membrane (D2).
3 2D25
• Unscrew the screws (6).
• Remove lantern (5).
S1
6
5

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• Unscrew piston (3) from piston rod (7).
• Remove the retaining washer (D5).
7
3
B
D5
• Puncture the O-ring (D4) with a needle and
remove them carefully from the groove of
piston.
• Check plain bearing (D3) for wear and re-
place if necessary.
D4
5
T30
D3