KLINGER INTEC K210-FS Setup guide

Assembly and Repair Instructions Page 1 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
Assembly and repair instructions or KLINGER SCHÖNEBERG ball valves, Type INTEC K210-FS
Contents
1 Validity ............................................................................................................................................................ 2
2 General information ........................................................................................................................................ 2
3 Construction and component designation INTEC K210-FS ............................................................................ 3
4 Assem ly INTEC K210-FS ............................................................................................................................. 4
4.1 Assem ly preparation ............................................................................................................................ 4
4.2 Assem ly of valves ................................................................................................................................ 4
4.3 Assem ly of hand lever .......................................................................................................................... 5
4.4 Function/strength and leak test .............................................................................................................. 5
4.5 Unauthorised modification and spare parts manufacture ....................................................................... 5
4.6 Unpermitted operating modes ................................................................................................................ 5
5 Deinstallation .................................................................................................................................................. 6
5.1 Precautionary measures ........................................................................................................................ 6
5.2 Deinstallation preparation ...................................................................................................................... 6
5.3 Deinstallation ......................................................................................................................................... 6
5.4 Final cleaning and damage assessment ................................................................................................ 7

Assembly and Repair Instructions Page 2 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
1Validity
These Assem ly and Repair Instructions are valid for the valve series
INTEC K210-FS
2General information
These Assem ly and Repair Instructions provide support during the assem ly, maintenance and repair of INTEC
K210-FS all valves.
The valves may only e deinstalled and dismantled y specialist personnel who are familiar with the
assem ly, the commissioning and the operation of this product.
Specialist personnel in terms of these Assem ly and Repair Instructions are people a le to assess the work dele-
gated to them and to detect possi le hazards ased on their specialist training, their knowledge and their experi-
ence as well as their familiarity with the pertinent standards.
These instructions and the Operating Instructions or KLINGER SCHÖNEBERG ball valves are to e
o served.
KLINGER SCHÖNEBERG Gm H shall ear no lia ility ofr damage or operating malfunctions caused through
incorrect handling or non-o servance of these Repair Instructions.

Assembly and Repair Instructions Page 3 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
3Construction and component designation INTEC K210-FS
INTEC K210-FS
1
10
5
6
4
3
4
5
6
20
1Gehäuse
2Gehäuseteil
3 Kugel
4 Kugelsitz
5
Schaltwelle gelagert
6
Dichtring unten
7
Keilring unten
13
Gehäusedichtung
12
Mutter
11
Keilring oben
Dichtring oben
8
2
21
14
15
16
Kugelsitzaufnahmering mit Dichtring
Spiralfeder
19
18
17
9
8
7
17
9
Sechskantschraube
18
10
19Lager Schaltwelle unten
Lagerzapfen
Lager Lagerzapfen
Lagerzapfendichtung
Pos. BezeichnungBezeichnungPos.
11
12
13
14
15
16
20
21
Fire-Safe-Dichtring
Fire-Safe-Druckring
Fire-Safe-Gleitscheibe
Pos Designation Pos Designation
1 Body 12 Upper cone ring
2 Cap 13 Fire-safe seal
3 Ball 14 Fire-safe thrust collar
4 Seat 15 Fire-safe friction washer
5 Seat thrust collar with seal 16 Nut
6 Ball seat spring 17 Trunnion
7 Bearing-supported stem 18 Trunnion seal
8 Below stem sealing 19 Trunnion earing
9 Below seal 20 Body seal
10 Below cone ring 21 Hex. screw
11 Upper seal

Assembly and Repair Instructions Page 4 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
4Assembly INTEC K210-FS
4.1 Assembly preparation
In order to assem le the all valve, all parts must e prepared, i.e. the parts are carefully cleaned and placed on
a soft underlay (ru er mat or similar).
It must e taken into account that plastic parts are almost always soft and sensitive, and the sealing surfaces in
particular must not e damaged.
4.2 Assembly o valves
The ody (1) of the valves must e clamped firmly and securely; free access to the interior and the stem must e
guaranteed.
The ody (1) and cap (2) in the area of the all seats are to e lightly greased with FDA-approved high tempera-
ture grease (e.g. Q1). Grease the groove of the all seat thrust collar in the same way. Insert the divided graphite
seal ring into the all seat thrust collar groove (5). Then insert the all seat springs (6) into the all seat thrust col-
lars. O serve the installation quantity of the all seat springs in accordance with the specification or resulting
torque.
Insert the all seat thrust collars into the ody or cap; if applica le with the aid of a tool.
Grease the stem (7) lightly in the area of the primary stem seal using FDA-approved high temperature grease.
Only add a light film of grease, which does not overflow during assem ly of the sealing elements. This can for ex-
ample e applied with the aid of a rush.
On valves specified as “oil and grease-free”, the assem ly takes place without grease and other auxil-
iary su stances.
Roll the earing (8) over a cylinder prior to assem ly to adapt the shape to the stem (7). Thread the earing (8)
and primary sealing parts (9)(10) onto the stem (7) and insert the stem from inside through the ody (1). The
sealing and earing parts may not e sheared or damaged. Thread the secondary sealing parts, (11)(12)(13) the
fire-safe support ring (14) and the friction washer (15) from the top onto the stem (7). Screw the nut (16) onto the
switching disk (7).
Tighten the nut with a fork wrench and counter the stem on the dihedron using the hand lever. Tighten the nut
firmly on the lock so that the sealing package can settle. Then turn the nut ack again y half a turn and check
the stem torque. Secure the nut in end position using a gru screw.
The following ta le serves as a reference value:
DN
80
100
150
200
250
300
Torque 12 Nm 17 Nm 25 Nm 35 Nm 35 Nm 50 Nm
Bring the stem (7) into open position (dihedron longitudinal to valve passage). Apply the all (3) with driver slot
onto the stem and swivel it into the ody.
Roll the earing (19) over a cylinder in order to adapt the shape to the trunnions (17). Brush the trunnions (17) on
the thread with high temperature grease (OKS) to avoid cold welding.
Push the trunnion earing (18) and the earing (19) onto the trunnion (17). Press the all with a suita le device
into the ody until the earing orehole of the all (3) aligns with the trunnion orehole in the ody (1).Insert the
trunnion (17) and screw it tight. Sealing and earing parts may not e sheared or damaged. Remove the device
again and check that the all runs smoothly.

Assembly and Repair Instructions Page 5 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
Insert the ody seal (20, in case of com ination ody seal, the PTFE ring in the direction of the stem) into the
ody (1). Insert the cap (2) carefully into the ody (1) without damaging the ody seal (20). Brush the ody
screws (21) on the thread with high temperature grease (OKS) in order to avoid cold welding.
On valves specified as “oil and grease-free”, the assem ly takes place without grease and other auxil-
iary su stances.
Tighten the ody screws (21) crosswise in steps all the way round until the seal is evenly pressed down and the
cap (2) with the ody (1) lies with full metal contact.
4.3 Assembly o hand lever
Attach the lever, insert the clamping screw of the hand lever and tighten. Loosely screw on the stopper plate us-
ing the fixing screws. Bring the all into perfectly-aligned open position. In this position, press the stopper plate
against the hand lever stop and tighten the fixing screws of the stopper plate. In this way, the stopper is perfectly
aligned.
From dome flange F12, the adjustment of the hand lever stop is conducted using eccentric screws. The eccentric
screws are turned until they contact with precisely-aligned hand lever stop. Fix the screws in position with the
counter nuts.
4.4 Function/strength and leak test
After assem ly of the all valve, check whether it can easily e switched and whether the all can turn unhin-
dered. Then the all valve is su jected to a strength and leak test acc. EN12266 -1 No. P10 / P11 / P12.
4.5 Unauthorised modi ication and spare parts manu acture
Conversion or changes to the valves are only permitted in agreement with and written consent from the manufac-
turer. Original spare parts and accessories authorised y the manufacturer are specified for reasons of safety.
In case other spare parts are used, KLINGER SCHÖNEBERG Gm H shall ear no lia ility for the consequences
resulting from their use.
4.6 Unpermitted operating modes
The operating safety of the valve is only guaranteed in case of use in accordance with the Operating Instructions
for KLINGER SCHÖNEBERG all valves. The limit value stated in the technical documentation may not under
any circumstances e exceeded.

Assembly and Repair Instructions Page 6 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
5Deinstallation
5.1 Precautionary measures
In order to ensure that any product residues which may have remained in the interior of the valve cannot endan-
ger the deinstallation personnel, they must wear appropriate fully- ody protective clothing made of chemical and
solvent-resistant material and equally resistant facial protection.
As a precautionary measure, the deinstallation should take place via a collecting vessel. Appropriate drainage
must e ensured so that hazardous gases or vapours cannot reach the deinstallation personnel. This also applies
for the final cleaning after deinstallation has taken place.
The all valves must e put in depressurised condition for repair purposes. To do this, they should e rought in-
to “semi-open” position. Cleaning inside and out is also necessary prior to deinstallation. During interior cleaning,
it is expedient to switch the all several times.
5.2 Deinstallation preparation
Prior to deinstallation, the ody (1), the cap (2) and the all valve parts must e la elled so that their assem ly
positions can e comprehended over the course of the process.
5.3 Deinstallation
Prior to deinstallation, the valve should e clamped tightly and securely in a suita le device. An expedient solu-
tion would e onto the flange of the ody (1) in order to guarantee free access to the intermediate flange, the inte-
rior and the stem. By loosening the middle flange screws (21), the cap (2) can now e removed. Bring the all (3)
into open position (dihedron longitudinal to valve passage). Press the all (3) ack into the ody (1) using a suita-
le device in order to release the prestress on the all seat (4). In this way, the trunnion can e removed. Re-
move the device and the all.
Next, if availa le, the hand lever is removed. To do this, the screw with a hexagon socket must e loosened and
removed completely, as the screw interlocks into the stem recess and thus makes it impossi le to remove the
hand lever. In case it proves hard to move, the hand lever can e spread at the slot using a screwdriver or cone
and thus more easily removed.
Using a fork wrench, the nut(16) can e unscrewed from the stem (7) y turning it to the left. Prior to this, loosen
the threaded pin. In order to ease this process, it is possi le to counter it using the hand lever which has just een
dismantled or a suita le fork wrench on the dihedron. Now the stem can e carefully pressed into the all space.
Secure the stem against falling and eing damaged. The friction washer (15) and the fire-safe support ring (14)
can e removed and the secondary sealing parts (11)(12)(13) removed from the dome.
The primary sealing parts (9)(10) may remain in the ody, making the removal of the stem (7) more difficult at
small nominal widths. These seals can e carefully pressed out using a small screwdriver in the ody in the direc-
tion of the ody or stem collar, and then the stem can e removed more easily. All damage in the sealing area of
the ody (1) must e avoided.
Then the all seat parts (4)(5)(6) can e removed.
Last of all, the ody seal (20) is to e removed. No auxiliary equipment is generally required for this step.

Assembly and Repair Instructions Page 7 of 7
Revision 0
INTEC K210-FS File: Montage-und
Rep.-Anl. K210-FS
Author: Roth Release:
Printed pages are not su ject to Change Management
Date: 09.12.2009
5.4 Final cleaning and damage assessment
Once the product has een deinstalled, all parts are su jected to final cleaning. During this final cleaning process,
the dismantled sealing parts must also e cleaned so that they can e disposed of without pro lems.
Then the damage assessment is conducted.
Here interior and exterior damage to the caps must e o served in particular. The quality of the sealing surfaces
on the all seal, stem passage, ody seal and the flange seals must e inspected.
The caps are now peened inside and outside with glass eads, and, if necessary, su jected to mechanical re-
work. However, for this the sealing surfaces must e covered.
Then the valves must e cleaned once more and are then ready for reinstallation after another visual inspection.
The stem is inspected after the visual inspection for parallelism and pressure marks in the two driver surfaces.
Please focus in particular on the proper conditions of the sealing surfaces. Slight scratches can e removed using
emery cloth. Damaged or twisted stems are to e replaced.
The cleaned alls are first inspected visually. Deep scratches as well as other mechanical damage and chemical
attacks on the sealing surface and the running surface of the seal ring lead to all faults. In the same way, defor-
mations in the area of the all slot are not permitted.
Replace all screws and sealing parts during every repair process.