KUGELHAHN MÜLLER KM-O Series Manual

KUGELHAHN-MUELLER.DE YOUR SPECIALIST FOR BALL VALVES
as per EC Pressure Equipment Directive 2014/68/EU
and as (incomplete machine)
as per EC Machinery Directive 2006/42/EC
SERIES: KM-O(ST) & KM-T(ST)
FLANGED BALL VALVE
Operating and maintenance instructions

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
1. PRODUCT INFORMATION 4
1.1 Bill of Material · Teflon® design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Bill of Material · O-ring design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. GENERAL 6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Pressure + temperature Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Safety notes on installation, operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Ball valve marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. INSTALLATION INTO THE PIPE 12
3.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Pressure test and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Additional information: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Valve disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4. NORMAL OPERATION 15
4.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. ASSESSMENT OF BALL VALVE AS PER DIRECTIVE 94/9/EC (ATEX)
INFORMATION FROM MANUFACTURER
You can download the mentioned (data sheets) and other data and information
– also in English – at kugelhahn-mueller.de
or contact us at:
KUGELHAHN MÜLLER GMBH
Subsidiary of Bray International, Inc.
Kölner Straße 686 · D-47807 Krefeld
E: [email protected] · T: [phone] · F: [phone]
CONTENTS
DECLARATION OF CONFORMITY AS PER EC DIRECTIVES

KUGELHAHN MÜLLER GMBH
Subsidiary of Bray International, Inc.
Kölner Str. 686 · D-47807 Krefeld
T: [phone] · F: [phone]
[email protected] · www.kugelhahn-mueller.de
Management
Craig C. Brown
George Crooks
Register court
District court Krefeld · HRB 1747
VAT-ID-No.: DE 811 302 631
National Bank AG Duisburg
SWIFT-BIC: NBAG DE 3 E
IBAN: DE20 3602 0030 0005 0039 11
DECLARATION OF CONFORMITY AS PER DIRECTIVE 2014/68/EC AND
MANUFACTURER'S DECLARATION AS PER DIRECTIVE 2006/42/EC
The manufacturer Kugelhahn Müller GmbH, D-47807 Krefeld, Kölner Straße 686, declares that the valves:
Flanged ball valves with Teflon® and O-ring seal at the shaft of Series KM-O and KM-T
> with lever or gear with handwheel
> with pneumatic, electric or hydraulic actuator
> with bare shaft for subsequent actuator assembly
comply with the directives mentioned below as follows:
Pressure Equipment Directive 2014/68/EC (PED): [only if Art. 3 Clause 1.3 or Art. 3 Clause 3 applies]:
The valves are conform with this directive. The conformity assessment procedure applied as per Annex III of the Pressure Equipment Directive 2014/68/EC is for
category I to III, module H1. - Category IV does not apply to isolation valves.
The valves can be used for various fluids within the permissible pressure and temperature limits, taking the respective influences on the pressure equipment into
consideration. Use in fluid group 1 and 2 is permitted.
The fluid resistance of the valve incl. the components shall be checked for the operating conditions prior to use.
Machinery Directive 2006/42 EC (MD) [applies only if the valve is operated other than by hand]:
The vale is an "incomplete machine" within the meaning of Art. 1 and is intended for installation in a pipe system as complete machine. The listing of conformity with
the clauses of the Machine Directive as per page 2 and 3 of this declaration and the provided (original installation instructions OM-KM-OST/TST) shall be observed by
the planner / user.
In relation to the directives above, the following applies:
1. The user shall follow the "intended use" as defined in the above instructions (OM-KM-OST/TST) included with the delivery and observe all safety-relevant notes in
these instructions. Disregard of these instructions can release manufacturer from his product liability.
2. The commissioning of the valve (and, where applicable, of the attached actuator) is not permitted until the conformity of the system into which the valve is
installed, with all relevant European Directives, is declared by the person responsible and risk of injury is thus ruled out.
The manufacturer Kugelhahn Müller GmbH has performed and documented all necessary risk analyses. For the carbon steel used, a corrosion allowance is neither
required nor taken into account for the calculation.
Standards and rules applied:
DIN EN 12516, AD2000 regulations, DIN EN ISO 9001, DIN EN ISO 12100:2009, DIN EN ISO 5211, DIN EN 1983, DIN EN 12266
Type description
KM-OXST-F1/F27
KM-OX-F1/F27
KM-OAST-F1/F27
KM-OA-F1/F27
KM-TXST-F1/F27
KM-TX-F1/F27
KM-TAST-F1/F27
KM-TA-F1/F27
Dimension sheets no special tools required for replacement of wear parts
MB 015-065-KM-OST.00,
MB 080-200-KM-OST.00,
MB 015-065-KM-O.00,
MB 080-100-KM-O.00,
MB 015-065-KM-TST.00,
MB 080-200-KM-TST.00,
MB 015-065-KM-T.00,
MB 080-100-KM-T.00,
Conformity assessment procedures applied:
according to Annex III of Pressure Equipment Directive 2014/68/EC; Module
H1
Changes to ball valves and/or components that impact the technical data
of the ball valve, the (intended use) as per section 1 of these instructions
and significantly modify the valve or a provided component make this
declaration null and void.
Name of notified body:
TÜV Rheinland Industrie Service GmbH Am Grauen Stein, 51105 Köln
ID-number of notified body:
0035
Signature:
Name: George Crooks
Position: Managing Director
Date: 23 March 2018

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
DECLARATION AS PER EC-DIRECTIVES
Requirement as per Annex I MD 2006/42/EC The following applies to ball valves as per list on page 2 if supplied with actuator:
1.1.1. g) Intended use See installation and operating instructions
1.1.2. c) Foreseeable misuse See installation and operating instructions
1.1.2. c) Required protective equipment Same as for pipe section into which the valve is installed.
1.1.2. e) Accessories No special tools required for replacement of wear parts
1.1.3 Wetted parts The materials of the wetted parts are specified in the type data sheet as well as in the order confirmation
issued by Kugelhahn Müller. It is assumed that the user carries out a respective risk analysis concerning the
resistance to the operating fluid.
1.1.5. Handling Satisfied by the notes in the installation and operating instructions
1.2 and 6.2.11 Control system Is the responsibility of the user in accordance with the documentation of the actuator
1.3.2 Preventing breakage For parts under pressure:
See Declaration of Conformity to PED 2014/68EC.
For functional parts: Ensured when actuator is used as intended
1.3.4. Sharp edges or angles Requirements fulfilled.
1.3.7./.8 Risks related to moving parts Requirements are fulfilled when used as intended.
1.5.1. – 1.5.3 .Energy supply Is the responsibility of the user. Also refer to documentation of the actuator.
1.5.5. Operating temperature Warnings against unauthorized exceedance: see installation and operating instructions, sections (intended
use) and (safety notes).
1.5.7 Explosion When used in potentially explosive atmosphere:
-Protection required for actuator. Must be explicitly agreed on in purchase contract.
1.5.13. Emission of dangerous substances Not applicable.
1.6.1. Maintenance See operating instructions. Clarify storage of wear parts with manufacturer.
1.7.3. Marking Valve: As per section 3 of installation and operating instructions.
Actuator: See documentation of actuator manufacturer.
1.7.4. Operating instructions The installation and operating instructions contains notes on the operation of the valve during regular
industrial use as per section 1 of these instructions.
Any additions required to the operating instructions of the (complete machine) in case of special application
are the responsibility of the planner / user.
Annex III The valve is not a (complete machine):
Therefore, there is no CE marking for conformity with the machinery directive.
Annexes IV, VIII-XI Not applicable.
Requirements as per EN 12100 -
1. Scope Basis for the analysis is the Product Standard EN1983: (Metallic ball valves) with actuator.
The basis is also formed by the long-standing experience in the use of the valve types mentioned on page 2.
Note: It must be assumed that the user carries out a risk analysis specifically adapted to the operating
conditions as per clauses 4 to 6 of EN 12100 for the pipe section, including the valves installed therein.
Kugelhahn Müller cannot carry out such an analysis for standard valves.
3.20, 6.1 Inherently safe design The valves are designed in accordance with the principle of (inherently safe design).
Analysis as per clauses 4, 5 and 6 Experiences with malfunctions and misuse documented at the manufacturer within the scope of claims
(documentation as per ISO 9001) served as basis.
5.3 Limits of the machine The limits of the (incomplete machine) were defined as per the (intended use) on both the valve and the
actuator.
5.4 Decommissioning, disposal Not the responsibility of the manufacturer Kugelhahn Müller.
6.2.2 Geometrical factors This section does not apply since valve and actuator are enclosed by the movable functional parts during
intended use..
6.3 Technical protective devices If applicable, only required for accessories - see order confirmation.
6.4.5. Operating instructions Since actuated valves operate "automatically" according to the commands from the control system, the
operating instructions describe aspects that are (typical for valves)..
7 Risk analysis The risk analysis has been carried out and documented as per MD Annex VII, B) by manufacturer Kugelhahn
Müller.

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
1. PRODUCT INFORMATION
1.1 BILL OF MATERIAL · TEFLON® DESIGN
DN 15 – DN 200
PN 10/16 – PN 40
Item Qty Designation Materials
1 1 Valve body 1.4408/1.0619
2 1 Counter flange F1/F27 1.4408/1.0619
3 1 Ball 1.4404/1.4408
4 2 Ball seat PTFE/25% Glass
5 1 Shaft 1.4571/1.4404
6 1 Spring 1.4401
7 1 Guide bushing PTFE-P
8 1 Stung box 1.4571/1.4404
9 3 Belleville spring 1.4310
10 1 Pressure piece 1.4571/1.4404
Item Qty Designation Materials
11 3 Package PTFE
12 1 Slide ring PTFE
13 1 Valve body seal PTFE
14 Hexagon screws A4-70
15 1 Stop pin 1.4305
16 1 Hand lever 1.4308
17 1 Disk Stainless steel
18 1 Spring washer DIN 127 A4-70
19 1 Cylinder screws DIN
912 A4-70
TYPE KM-TXST-F1/F27 STAINLESS STEEL
TYPE KM-TAST-F1/F27 STEEL

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Operating and maintenance instructions
1.2 BILL OF MATERIAL · O-RING DESIGN
DN 15 – DN 200
PN 10/16 – PN 40
Item Qty Designation Materials
1 1 Valve body 1.4408/1.0619
2 1 Counter flange
F1/F27 1.4408/1.0619
3 1 Ball 1.4404/1.4408
4 2 Ball seat PTFE/25% Glass
5 1 Shaft 1.4571/1.4404
6 1 Spring 1.4401
7 1 Guide bushing PTFE-P
8 1 Slide ring PTFE
9 3 O-ring Viton
10 1 Valve body seal PTFE
Item Qty Designation Materials
11 Hexagon screw A4-70
12 1 Stop pin 1.4305
13 1 Hand lever 1.4308
14 1 Disk Stainless steel
15 1 Spring washer DIN 127 A4-70
16 1 Cylinder screws DIN
912 A4-70
PRODUCT INFORMATION
TYP KM-OXST-F1/F27 STAINLESS STEEL
TYP KM-OAST-F1/F27 STEEL

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Operating and maintenance instructions
2. GENERAL
These instructions are intended to assist the user during
installation, operation and maintenance of ball valves. The
instructions also require the observation of all pipe-specific
rules that apply to the ball valves. If an actuator is attached,
the relevant manufacturer’s instructions shall be observed in
addition.
2.1 INTENDED USE
After installation into a pipe system, these ball valves are
exclusively intended to shut off or transport fluids within
the approved pressure and temperature limits. During
installation, operation and maintenance observe the safety
notes contained in section 2.
These ball valves are operated either by lever, gear with
handwheel or pneumatic / electrical / hydraulic actuator.
The table (Pressure and temperature applications for KM
flanged ball valves) contains a description of the approved
pressure and temperature limits for the ball valves.
When using the valve, the information on the valve - see
section 3 - shall be observed, particularly in regard to the
valve body material.
The ball valves can be used as end valve. During normal
operation at nominal pressure, especially when using
gaseous, hot and/or dangerous fluids, a blind flange should
be installed at the open end of the connection piece for
safety reasons.
Ball valves are only suited for ON or OFF position.
Intermediate positions are not allowed.

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
2.2 PRESSURE + TEMPERATURE LIMITS
BALL VALVES (F1/F27) MADE OF STEEL (1.0619)1
BALL SEAT PTFE/25% glass fiber reinforced2PTFE/50% stainless steel3
SIZE RANGE TEMPERATURE
KM-
OAST
O-ring
KM-
TAST
Teflon®
KM-
OAST
O-ring
KM-
TAST
Teflon®
KM-
OAST
O-ring
KM-
TAST
Teflon®
KM-
OAST
O-ring
KM-
TAST
Teflon®
PN 40 PN 40
PN 16 PN 16
DN 15 - 50
-10°C 38 bar 36 bar
50°C 40 bar 40 bar
100°C 37.1 bar 37.1 bar
125°C 34 bar 34 bar
150°C 30 bar 30 bar
180°C 22 bar 28 bar
200°C 12 bar 24 bar
220°C – 20 bar
DN 65 - 150
-10°C 16 bar 38 bar 16 bar 36 bar
50°C 16 bar 40 bar 16 bar 40 bar
100°C 14.8 bar 37.1 bar 14.8 bar 37.1 bar
125°C 14.5 bar 34 bar 14.5 bar 34 bar
150°C 14 bar 30 bar 14 bar 30 bar
180°C 13.58 bar 20 bar 13.58 bar 25 bar
200°C 10 bar 10 bar 13.3 bar 21 bar
220°C – – 12.82 bar 16 bar
1 Min. temp. for 1.0619: -10°C, according to AD2000, W5
2 Max. temp: Seat material PTFE/25% stainless steel or 3E0 EN 1092
3Max. temp: Seat material PTFE/50% stainless steel or 3E0 EN 1092
DT-KM-STAKH.2018-04-03.R8.EN
Legend:
KM Kugelhahn Müller
OO-ring
TTeflon®
ASteel (1.0619)
ST Standard valve
F1/F27 Face-to-Face dimension

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Operating and maintenance instructions
PRESSURE + TEMPERATURE LIMITS
BALL VALVES (F1/F27) MADE OF STAINLESS STEEL (1.4408)
BALL SEAT PTFE/25% glass fiber reinforced1PTFE/50% stainless steel2
SIZE RANGE TEMPERATURE
KM-
OXST
O-ring
KM-
TXST
Teflon®
KM-
OXST
O-ring
KM-
TXST
Teflon®
KM-
OXST
O-ring
KM-
TXST
Teflon®
KM-
OXST
O-ring
KM-
TXST
Teflon®
PN 16 PN 40 PN 16 PN 40
-60°C – 40 bar – 40 bar – 40 bar – 40 bar
DN 15 - 50
-25°C 40 bar 40 bar
50°C 40 bar 40 bar
100°C 40 bar 40 bar
125°C 38.15 bar 38.15 bar
150°C 30 bar 30 bar
180°C 22 bar 28 bar
200°C 12 bar 24 bar
220°C – 20 bar
DN 65 - 150
-60°C – 16 bar – 40 bar – 16 bar – 40 bar
-25°C 16 bar 40 bar 16 bar 40 bar
50°C 16 bar 40 bar 16 bar 40 bar
100°C 16 bar 40 bar 16 bar 40 bar
125°C 15.25 bar 38.15 bar 15.25 bar 38.15 bar
150°C 14.5 bar 30 bar 14.5 bar 30 bar
180°C 13.84 bar 20 bar 13.84 bar 25 bar
200°C 10 bar 10 bar 13.4 bar 20.5 bar
220°C – – 13.12 bar 16 bar
Note:
1Restriction of temperature data (min/max) due to seat material used, PTFE/25% glass or EN 1092. 14E0
2Restriction of temperature data (min/max) due to seat material used, PTFE/50% glass or EN 1092. 14E0
DT-KM-STXKH.2018-04-03.R8.EN
Legend:
KM Kugelhahn Müller
OO-ring
TTeflon®
XStainless steel (1.4408)
ST Standard valve
F1/F27 Face-To-Face dimension
FDA DESIGN · SEAT: PURE PTFE
SIZE RANGE TEMPERATURE
KM-TXST
Teflon®
KM-TXST
Teflon®
PN 16** PN 40*
*DN 15 - 150 -60°C 16 bar 40 bar
125°C 15.25 bar 38.15 bar
**DN 65 - 150 200°C 8 bar 10 bar
Note:
Temperature data (min/max) due to seat material used, pure PTFE or EN 1092. 14E0

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
2.3 SAFETY NOTES ON INSTALLATION,
OPERATION AND MAINTENANCE
DANGER
Failure to observe the following cautions and warnings
may result in danger, invalidating manufacturer's warranty.
In case of any questions please contact the manufacturer.
See back for addresses.
Ball valves are subject to the same safety regulations as the
pipe system into which they are installed and the control
system to which the actuator is connected. Additional
safety notes may also be included in the instructions of the
actuator assembly.
The manufacturer is not responsible and therefore, before
using the ball valve, it must be ensured that
> after installation into a pipe system, these ball valves are
exclusively used to shut off or transport fluids within the
approved pressure and temperature limits.
DANGER TO LIFE
It is not allowed to install a valve whose approved
pressure/temperature range (= "rating") is not sufficient
for the operating condition.
The approved range is described in the planning
document > Pressure and temperature applications.
See last page for reference address
Failure to observe this regulation may present a danger.
> the valve is only installed by personnel qualified to
perform work on pipes under pressure. (Qualified
personnel within the meaning of these instructions are
persons who are able to properly assess and perform
any task associated with the valve and anticipate or
recognize any possible dangers and eliminate them as
quickly as possible)
DANGER
Protection against incorrect use of ball valve:
In particular, it must be ensured that the selected materials
of the wetted ball valve parts are suitable for the fluids in
the pipe section. Failure to observe these precautions may
present a danger to the user and cause damage to the pipe
system.
> the ball valve is installed and operated in such a way
as supplied by the manufacturer Kugelhahn Müller.
Any changes performed without the approval of the
manufacturer (except the retrofitting of an actuator)
are not allowed and relieve manufacturer of his product
liability.
> an actuator unit subsequently attached to a ball valve
is adapted to the ball valve and correctly adjusted in its
end positions, particularly in open position,
> the pipe system and control system for the actuator
(if any) have been properly installed and are
subject to regular checks. The design of the wall
thickness of the ball valve body takes the usual
additional pipe load Fz into account for such a
properly laid pipe system (Fz = π/4*DN²*PS).
(PS = maximum permissible design pressure – see type
plate in section 3).
> the usual flow rates in this pipe system are not
exceeded during continuous operation and abnormal
operating conditions such as vibrations, water
hammers, cavitation, decomposition of unstable fluids,
earthquake and increased content of solids in the fluid,
particularly abrasive solids, have been clarified with the
manufacturer Kugelhahn Müller.
> the valve is correctly connected to this system,
> the pipe system has the required free space for operation
and for disassembly/assembly for the purpose of
inspection or maintenance.

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Operating and maintenance instructions
> the use of a ball valve actuator in an ambient atmosphere
that is other than normal - particularly in potentially
explosive environment - has been clarified with the
manufacturer Kugelhahn Müller,
> ball valves installed in pipe systems with operating
temperatures > +50°C or < –20°C are protected against
contact, together with the pipe section. Such thermal
insulation is not the responsibility of Kugelhahn Müller
GmbH.
> Make sure that the pressure of the ball valve corresponds
to the operating conditions of the pipe. Size and
pressure range are indicated in more detail on our ball
valves. Before installation, open and close valve while
simultaneously checking whether any problems occur
during opening/closing and whether the ball is in the
correct position.
PARTICULAR DANGERS
DANGER TO LIFE
Before disassembly of the ball valve from the pipe, the
pipe must be completely decompressed to prevent
leakage of the fluid to outside.
DANGER
The bolting on the connection of the valve body parts
shall be loosened only after disassembly of the valve. A
detailed description of reassembly is contained in the
Kugelhahn-Müller assembly instructions.
Ball valves used as end valve:
During normal operation, especially when using gaseous,
hot and/or dangerous fluids, install a blind flange at the
open end of the valve or securely and permanently lock
the ball valve in "CLOSED" position.
When disassembling a valve from the pipe, fluid may leak
from the pipe or the ball valve. When using harmful or
dangerous fluids, the pipe must be completely drained
before disassembling the ball valve. Use caution with
residues that still flow out of the pipe or have remained in
the dead spots of the ball valve.
If a ball valve that is used as end valve in a pipe section
under pressure must be opened, use greatest care and
do it in such a way that any fluid splashing out does not
cause damage.
Risk of crushing hand or fingers:
Do not operate an actuated valve as long as the valve is
not yet installed. Do not operate a valve installed at the
open end of a pipe section.

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Operating and maintenance instructions
2.4 BALL VALVE MARKING
for Marking Note
Manufacturer KM KM = Kugelhahn Müller, see back for address
Valve type e.g.: KM-OXST, KM-TXST
OXST = Type KM-OXST-F1 see Kugelhahn Müller
catalogue. The 2nd letter indicates the valve body
material: X = 1.4408 / A = 1.0619
Valve body material e.g.: 1.4408 Material number (valve body marking)
Size DN (and number) Number in mm, e.g. DN100 (valve body marking)
Design pressure PN (and number)
PN = Standard for flange connection
Number = maximum permissible pressure [bar]
at 120°C
Year of manufacture e.g.: 11/1234 1st + 2nd number = year of manufacture, e.g. 11 =
2011 / 1234 = consecutive serial number
Heat No. e.g.: 022E Batch no./melt no. of primary material
Conformity CE The conformity is certified separately by
manufacturer
ID number 0035 "Notified body" as per EC Directive = TÜV
Rheinland
customer-specific e.g.: 02ZS1637 Special marking as requested by customer
2.5 TRANSPORT AND STORAGE
Ball valves shall be handled, transported and stored with
care:
> The valve shall be stored in its protective packaging
and/or with the protective caps at the connection ends.
Ball valves that are heavier than approx. 10 kg should be
stored and transported on a pallet (or similar support)
(up to the place of installation).
> During storage prior to installation, protect valve
and actuator from harmful influences such as dirt or
humidity, usually in an enclosed space.
> Ensure that particularly an actuated ball valve and the
ball valve flanges for connection to the pipe are not
subject to damage by mechanical or other influences.
> To protect the internal parts, the ball valves are usually
supplied in fully open position. The ball valve shall be
transported/stored in the same position as delivered.
Markings shall not be damaged to ensure identifiability of valve.

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Operating and maintenance instructions
3. INSTALLATION INTO THE PIPE
Accurate piping is of utmost importance. Stresses and
displacements in the pipe system can result in an increased
torque and leakage between valve body and connection
ends. The distance between the pipe ends should correspond
precisely to the dimensions of the ball valve.
3.1 NOTES
The installation of ball valves into a pipe is subject to the same
instructions as the flange connection of pipes and similar pipe
elements. In addition, the following instructions apply to ball
valves. For transport to place of installation, section 2.5 shall
also be observed.
WARNINGS AND NOTES
If retrofitting an actuator unit on site, ensure that the
torque, direction of rotation, angle of activation and
the setting of the end stops "OPEN" and CLOSED" are
adapted to the ball valve. It is of particular importance that
retrofitted connection parts (bracket and adapter) are
precisely aligned with the ball valve shaft, thus ensuring a
plane-parallel mounting of the actuator to the ball valve.
Failure to observe this precaution may present a danger
to the user and cause damage to the pipe system or ball
valve.
An actuator supplied together with the ball valve is
adjusted to the operating data indicated in the order.
The setting of the end stops "OPEN" and "CLOSED"
shall not be changed without the permission of the
manufacturer.
Applies only to ball valves with electric actuator:
Make sure that actuator in end positions is switched off
by thesignal of the limit switch. If switch-off takes place
via the signal of the torque switch, then this signal shall
also be used as failure signal. The fault must be eliminated
as quickly as possible, see section 4.2 (Troubleshooting)
For additional notes see instructions for the electric
actuator
Closing/opening times for pneumatic piston actuators:
Adapt compressed air supply/decompression to the
valve in such a way that - unless otherwise specified -
the closing time of a ball valve equals the guide value:
t [sec] = DN [mm] / 25.
FOR ACTUATORS, OBSERVE THE FOLLOWING:
WARNINGS AND NOTES
For actuators, observe the following:
Do not use valve (and actuator) as "ladder" - Do not
apply external loads to valve (and actuator); this may
damage or destroy the ball valve.
Actuators whose weight exceeds the weight of the ball
valve: They shall be supported if the weight and/or
actuator position result in a permanent deformation of
the valve body.
Risk of crushing hand or fingers:
Do not operate an actuated valve as long as the valve is
not yet installed. Do not operate a valve installed at the
open end of a pipe section.

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
3.2 INSTALLATION STEPS
>Transport the ball valve in its protective packaging to the
place of installation; to protect valve against contamination,
do not unpack until it is ready to be inserted into the pipe
. Remove protective caps at the connection ends of the
valve immediately prior to the installation.
> Check valve (and actuator) for transport damage. Do not
install damaged ball valves or actuators.
>Ensure that only ball vales are installed whose pressure
class, materials of wetted parts, connection type and
flange dimensions are in compliance with the operating
conditions. See relevant ball valve markings.
>The connection data for the actuator unit shall correspond
to the data of the control system. See type plate on actuator
unit. The pipe flanges shall be aligned with the ball valve
flanges and have plane-parallel ends.
>Even if the ball valves were transported in a clean
environment, make sure to check the ball valve and
connecting pipe for contamination or foreign matter prior
to installation. In case of a negative result, thoroughly
clean the valve and, most importantly, remove any hard
foreign matter.
>Use water or compressed air to clean the valves. Place
opening of valve perpendicular to the floor and clean
it. Ensure that the dust is completely removed from the
opening. Next, check and clean the pipe opening and the
connection place. There shall be no joints, rust spots and
foreign matter in order to prevent blocking and leakiness.
>The valve can be installed in any position. An actuator,
however, should not be located directly below the ball
valve: A leakage at the shaft may damage the actuator.
When installing a valve with horizontal actuator shaft and
the actuator dimension exceeds the valve dimension, the
plant supervisor shall decide whether the actuator requires
a support on site.
>When sliding the ball valve (and the necessary seals) into
an already existing pipe, ensure that the space between
the pipe flanges is sucient to prevent damage to the
flange connection surfaces and the seals. However, in
order to prevent any additional stresses in the pipe, this
space should not be larger than required.
INFO
As a rule, flange seals and flange screws are not included:
The torque of the flange screws shall be specified by the
supplier of the flange seal.
> To connect an actuator unit to the control unit, the relevant
instructions apply.
>After installation is finished, perform a functional test:
A ball valve with lever or gear/handwheel shall be easy
to OPEN and CLOSE.
>The following applies to an actuated ball valve: The
valve must properly close and open according to the
control commands. Any obvious malfunctions must be
eliminated prior to commissioning. See also section 4.2
(Troubleshooting).
Incorrectly executed control commands could cause a
danger to life and damage to the pipe system.

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Operating and maintenance instructions
3.4 ADDITIONAL INFORMATION:
VALVE DISASSEMBLY
Observe the same safety rules as for the pipe system and the
(electrical/pneumatic) supply system/control system.
>(if applicable) Securely interrupt the energy supply
>Open valve and drain pipe section.
WARNING
In completely open/closed position, fluid remains in the
ball valve:
To drain the valve body completely, place ball in
intermediate position directly prior to removal.
>Loosen valve/pipe section connection and disassemble
valve. Make sure that ball surface is bare and free from
damage.
>To store valve, observe section 2.5 (Transport and storage).
3.3 PRESSURE TEST AND COMMISSIONING
INFO
Prior to commissioning, flush the system to remove dirt.
Ensure that ball valve is open during the entire flushing
process; do not operate ball valve until cleaning is finished.
The manufacturer Kugelhahn Müller has already performed
the required tests on every finished valve as per the European
Standard EN 12266.
The following restrictions and notes apply if a pressure test of
the pipe section is required together with the installed ball valve:
> To remove all foreign matter, carefully flush newly installed
pipe systems before closing them for the first time.
> When valve is in open position, the test pressures shall
not exceed the value 1.5 x design pressure (PN or PS) as
per valve marking.
>When ball valve is in closed position, the maximum
test pressure to be applied = 1.1 x (PN or PS).
If the valve is marked with "Class" only, limit the test
pressure [bar] to 0.077 x Class. (PS = maximum permissible
operating pressure)
>If a leakage occurs in a valve, observe the notes in section
4.2 (Troubleshooting).
DANGER
Ball valves have a cavity between ball and valve body in
which small amounts of water collect from the pressure
test:
To remove this water, e.g. by drying the pipe section, the
ball valve must remain in an intermediate position (z.B.
half-open) while the pipe section dries.

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
4. NORMAL OPERATION
Normal manual force is sucient to operate ball valves designed
for manual operation. The use of lever extensions to increase
the actuating torque is not permitted.
Note: In EN 12570: Manual forces, standard values are defined
according to lever length or handwheel-Ø.
Operate actuated ball valves via the control system signals.
Ball valves supplied with actuator by manufacturer Kugelhahn
Müller are precisely adjusted and shall not be changed as long
as the valve functions correctly.
Ball valves do not require regular maintenance. However, when
checking the pipe section at suitable intervals make sure that
there is no leakage at the flange and screw connections of
the valve body and at the shaft seal. Concerning leakage and
repairs, see section 4.2 (Troubleshooting).
It is recommended to operate ball valves that permanently
remain in the same position once or twice per year.
4.1 MAINTENANCE
Subject to regular visual inspection of the pipe section, the
valve does not require special maintenance.
If an actuator is available, observe the respective manufacturer's
instructions.
If valve is used in corrosive/abrasive fluids and/or at the
threshold of the pressure/temperature limits and/or subject to
(very) frequent operation, the ball valve should be inspected
at suitable intervals, but at least once or twice per year.
In case of faults, see section 4.2 (Troubleshooting).

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
4.2 TROUBLESHOOTING
When troubleshooting as per the following table, observe section (Safety notes on installation, operation and
maintenance).
Note 1:
Install only original Kugelhahn-Müller parts.
Note 2:
If, after disassembly, it is determined that the valve body and/or internal parts are not suciently resistant to the fluid, a
more suitable material should be selected in consultation with Kugelhahn Müller.
Note 3:
It is essential to correctly reassemble a ball valve after disassembly for reasons of maintenance/repair and to perform a
subsequent pressure test with water as per section 3.3.
The instructions provided by Kugelhahn-Müller include detailed information for reassembly.
Send e-mail request to: [email protected]
Leakage at flange connection to
pipe
When a leakage occurs in this area, first retighten flange connection. If this does not eliminate the
leakage, disassemble the valve.
Observe warnings under (Particular dangers) and replace flange seal.
Leakage at the connection of the
valve body parts
Use a torque wrench to retighten screws as indicated in the Kugelhahn-Müller assembly
instructions. If this does not eliminate the leakage, disassemble the valve.
Observe warnings under (Particular dangers) and replace flange seal.
Observe section 3.4 (Valve disassembly) and replace valve body seal. Request spare parts and
respective instructions from manufacturer.
Assembly as per Kugelhahn-Müller assembly instructions
Leakage at shaft seal (applies only
to type KM-T)
The ball valve type KM-T has an adjustable stuffing box with Belleville spring preload: If leakage
occurs at the shaft seal, use the following steps to retighten the Belleville spring. Observe warnings
under (Particular dangers):
1. Unscrew lever or actuator unit from connection flange to valve body.
2. Retighten stuffing box (=item 8 in sectional drawing).
Observe the following tightening torques:
DN15–32 = 40 Nm, DN40–65 = 70 Nm, DN80-100 = 100 Nm, DN150 = 140 Nm
3. Rotate shaft several times to check proper operation.
4. Check tightness of stuffing box with operating pressure in the valve:
Observe warnings under (Particular dangers)!
Then reattach lever or actuator unit.
Leakage at shaft seal (applies only
to type KM-O) or excessive leakage
in CLOSED position
Repair is required.
Request spare parts and respective assembly instructions from manufacturer Kugelhahn Müller.
Disassembly as per section 3.4, assembly as per Kugelhahn-Müller assembly instructions. Observe
notes under (Particular dangers).
Malfunction Check actuator unit and control commands.
If actuator and control are OK, disassemble valve. Observe notes under(Particular dangers) and
check valve.
Repair is required if ball valve is damaged - see above.
Request spare parts and respective instructions from manufacturer.
For malfunctions concerning the actuator unit, see actuator instructions.

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SERIES: KM-O(ST) & KM-T(ST)
Operating and maintenance instructions
5. ASSESSMENT OF BALL VALVE AS
PER DIRECTIVE 94/9/EC (ATEX)
An Ignition Hazard Assessment as per DIN EN 13643 Part 1 has
been performed for ball valves type KM-O and KM-T. However,
in case of an actuator/valve combination, this only applies to
the ball valve itself.
No potential ignition source was found. Thus, the ball valves
fall outside the scope of Directive 94/9/EC and therefore shall
not be marked according to this Directive.
DANGER
A valve/actuator combination has the same ignition
hazard as identified by the actuator manufacturer in the
Ignition Hazard Assessment. The operator shall observe
the respective operating instructions.
Thus, the use of actuated ball valves in areas with
potentially explosive atmosphere is permitted within the
scope of intended use. It is however necessary to ensure
on site that
> ball valves used in such a way have been included
in the potential equalization measures of the system
section,
> der Verwender einer Kombination Antrieb/Armatur
eine Zündgefahrenbewertung des Systemabschnitts
durchführt.

All statements, technical information and recommendations related to this brochure are only intended for general use.
If you have specific requirements and questions concerning material selection for your desired application, please contact us.
We reserve the right to change or modify the design or the product without prior notification.
Patented worldwide and patents applied worldwide.
Kugelhahn Müller GmbH is a subsidiary of Bray International, Inc.
Bray® is a registered trademark of Bray International, Inc.
© 2018 Bray International, Inc. All rights reserved.
OM_KM_OST-TST_EU-EN_2018-03-27 KUGELHAHN-MUELLER.DE
KUGELHAHN MÜLLER GMBH · Subsidiary of Bray International, Inc.
Kölner Str. 686 ·D-47807 Krefeld ·T. +49 (0) 21 51. 30 80 41 · F. +49 (0) 21 51. 30 80 39 ·[email protected]
YOUR SPECIALIST FOR BALL VALVES