Orbinox EX Instruction manual

ORBINOX SPAIN
ORBINOX SPAIN ORBINOX SPAIN
ORBINOX SPAIN Pol.Ind. s/n-20270 ANOETA. Tel:[phone] ax:[phone] e-mail:[e-mail]
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX RANCE,
ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX RANCE, ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX RANCE,
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ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.
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INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL EX
EXEX
EX

.
11-2011 EDITION
EX-2/13
www.orbinox.com
MODEL
EX
INDEX
INDEXINDEX
INDEX Page
0.- Description .........................………................................................................ .. 2
1.- Handling ..................................………....................................………………… 3
2.- Installation .................................……….....................................................….. 4
3.- Actuators .....................................………........................................................ 7
4.- Maintenance .....................................………................................................... 7
4.1.- Gland packing replacement …….………............................................ 8
4.2.- Seal replacement......………....…....……............................................ 9
4.3.- PT E seal replacement ..…....…..........…............................................ 9
4.4.- Lubrication …………………….……………..…………………………..... 10
5.- Storage …………................................…..………............................................. 12
6.- Parts list & drawing ..................................………............................................. 13
0.- DESCRIPTION
The EX model knife gate is a uni-directional wafer valve designed for general industrial service
applications. The design of the body and seat assures non-clogging shut-off with suspended solids.
The EX valve complies with the following European directives:
-DIR 98/37/EC (machines)
DIR 98/37/EC (machines)DIR 98/37/EC (machines)
DIR 98/37/EC (machines)
-DIR 97/23/EC (PED)
DIR 97/23/EC (PED)DIR 97/23/EC (PED)
DIR 97/23/EC (PED) luid: Group 1 (b), 2 (Cat. I, mod.A)
It may also comply with the ATEX d
ATEX dATEX d
ATEX directive
irectiveirective
irective 94/9/EC (Explosive Atmospheres)
94/9/EC (Explosive Atmospheres) 94/9/EC (Explosive Atmospheres)
94/9/EC (Explosive Atmospheres) :
The EX valve may comply with the directive regarding equipment and protective systems for their
use in explosive atmospheres. In these cases, the logotype shall appear on the identification
label of the valve. This label shows the exact classification of the zone where the valve can be
used. The user will be liable for its use in any other zone.
This directive only applies in the following atmospheric conditions:
0,8 bar ≤ P ≤ 1,2 bar
-20ºC < T < 60ºC
Any increase in temperature due to frictional warmth is negligible, since the relative speed of
the moving parts is extremely low.
The risk analysis associated to this directive does not take into account the fluid that goes
through the valve, even when such fluid produces an explosive atmosphere. The user must take
into account the risks that the fluid generates, such as:
• Heating of the valve surface.
• Generation of electrostatic charges caused by displacement of the fluid.
• Shock waves caused by the installation (water hammer), internal crashes generated by the
pellets or the risks due to foreign bodies susceptible of being present in the installation.
1.- HANDLING
The valves are packed according to the appropriate transport standards. If you receive the packing
damaged, please inform the transport company in writing and contact you Orbinox representative.

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11-2011 EDITION
EX-3/13
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MODEL
EX
When handling an Orbinox valve please pay attention to the following points:
• Do NOT
Do NOT Do NOT
Do NOT attach lifting gear to the valve actuators or gate guards
attach lifting gear to the valve actuators or gate guardsattach lifting gear to the valve actuators or gate guards
attach lifting gear to the valve actuators or gate guards. They are not designed to
bear the weight, and could easily be damaged.
• Do NOT lift the valve by the valve bore
Do NOT lift the valve by the valve boreDo NOT lift the valve by the valve bore
Do NOT lift the valve by the valve bore.
This can cause damage to the seating surfaces and seals.
• Check that selected lifting gear is rated to carry the weight of the valve.
• The valve can be handled using eyebolts, soft straps or slings.
• Eyebolts: make sure the eyebolts have the same thread as the boltholes and they are all well
secured. Ideally when using lifting gear to move an Orbinox valve, it should be supported by
two or more eyebolts screwed into the tapped fixing holes in the valve body.
• Soft straps: with the valve in the closed position, the straps should be placed between the
gland area and the bore such that the valve is balanced.
ig. 1
ig. 1 ig. 1
ig. 1 Handling
Handling Handling
Handling with eyebolts
with eyeboltswith eyebolts
with eyebolts
ig. 2 Handling
ig. 2 Handlingig. 2 Handling
ig. 2 Handling with
with with
with soft straps
soft strapssoft straps
soft straps

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11-2011 EDITION
EX-4/13
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EX
2.- INSTALLATION
To avoid personal injury or damage to property from the release of process fluid:
• Those in charge of handling and maintenance of the valve must be qualified and trained in
valve operations.
• Use appropriate personal protection equipment (gloves, safety shoes, etc).
• Shut off all operating lines to the valve and place a warning sign.
• Isolate the valve completely from the process.
• Release process pressure.
• Drain the process fluid from the valve.
• According to EN 13463
EN 13463 EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenance operations, use hand
tools (non electric)
(non electric) (non electric)
(non electric) with Working Allowance.
Before installation, inspect the valve body and components for any damage that may have occurred
during shipping or storage. Make sure the internal cavities within the valve body are clean. Inspect the
pipeline and mating flanges, making sure the pipe is free of foreign material and that the flanges are
clean.
The valve is unidirectional. It should be installed with pressure exerted against the seat. The words
“SEAT SIDE” are marked on the valve body to indicate the position of the valve seat. Installation and
the correct orientation with respect to the direction of the flow is the responsibility of the user.
It should be noted that the direction of flow and differential pressure, do not always coincide.

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11-2011 EDITION
EX-5/13
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MODEL
EX
Special care should be taken to maintain the correct distance between the flanges and to ensure that
they are parallel to the valve body. Incorrect alignment of the valve can cause deformations, which can
lead to difficulties in operation.
The following table gives the maximum torque values for the valve fixing bolts. Also shown is the
maximum depth (T) allowed for the tapped blind boltholes drilled into the valve body.
DN
DNDN
DN 50
5050
50 65
6565
65 80
8080
80 100
100100
100 125
125125
125 150
150150
150 200
200200
200 250
250250
250 300
300300
300 350
350350
350 400
400400
400 450
450450
450 500
500500
500 600
600600
600 700
700700
700 800
800800
800 900
900900
900 1000
10001000
1000 1200
12001200
1200
T (mm)
T (mm)T (mm)
T (mm) 11 11 11 11 11 14 14 18 18 22 24 24 24 24 20 20 20 20 30
Kg.m
Kg.mKg.m
Kg.m 6 6 6 6 7 7 7 11 11 15 15 19 19 23 23 28 28 34 34
The valve can be mounted in any position with regard to the pipe. However, it is advisable to place it
vertically in horizontal pipeline (A) if the installation allows it. (Please consult the technical department
at Orbinox).
With larger diameters (> 300 mm), heavy actuators (pneumatic, electric, etc.), or with the valve
installed horizontally (B) or at an angle (C) on a horizontal pipeline, the installation will require the
construction of suitable supports. (See the following diagram and consult the technical department at
Orbinox).
BB
A
CC
C*
A*
C*
* or these positions please consult Orbinox.
In vertical pipelines, the construction of suitable supports is always required (for further information
please consult the technical department at Orbinox).
Once the valve is installed, test that the flanges have been fastened correctly and that all electrical
and/or pneumatic connections have been properly made.

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11-2011 EDITION
EX-6/13
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MODEL
EX
These instructions must be observed when installing an Orbinox knife gate valve in an ATEX zone:
• Make sure the valve is ATEX marked according to the requested zone and it includes all anti-
static devices.
• Check continuity between the body of the valve and the pipe (test in accordance with EN
12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
• This check must be done every time the valve has been removed from the line, serviced, and
put back to the line.
The operation of automated valves is limited only with fitted gate covers.
irst, operate the valve with no flow in the pipeline. Then test operation and valve seal with flow. It
should be noted that the packing material might settle in shipping/storage, which can cause minor
leakage. This can be solved by tightening the gland follower (5) during installation. The nuts shall be
tightened gradually and crosswise until the leakage stops (see the next figure). Check that there is no
metal contact between the glandfollower (5) and the gate (2).
If the glandfollower nuts are overtorqued, the force needed to operate the valve will increase, the valve
function will be affected and the box packing lifetime will be shortened.
The table below shows the recomemended maximum torques for the glandfollower nuts.
DN
DNDN
DN Torque (N.m)
Torque (N.m)Torque (N.m)
Torque (N.m)
50 - 100 20
125 - 200 30
250 - 1200 35
Once performance has been tested, the valve can be put into operation.
Approximate weight of the handwheel-operated valve (rising stem):
DN
DNDN
DN 50
5050
50 65
6565
65 80
8080
80 100
100100
100 125
125125
125 150
150150
150 200
200200
200 250
250250
250 300
300300
300 350
350350
350 400
400400
400 450
450450
450 500
500500
500 600
600600
600 700
700700
700 800
800800
800 900
900900
900 1000
10001000
1000 1200
12001200
1200
Kg
KgKg
Kg 7 8 9 11 15 18 30 44 58 96 124 168 192 245 405 512 680 865 1055

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11-2011 EDITION
EX-7/13
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MODEL
EX
3.- ACTUATORS
3.1.- Handwheel
Turn the hand wheel (11) anticlockwise to open the valve. Turn the hand wheel clockwise to
close the valve.
3.2.- Lever
To operate the valve with this device, first loosen the locking clamp located on the top of the
yoke (8). Then either open or close the valve by moving the lever in the desired direction.
inally, fix the position of the lever with the locking clamp.
3.3.- Pneumatic
Valves are usually supplied with a double acting pneumatic actuator although, upon request,
we can supply single-acting actuators. In either case the feed pressure can vary between 3,5
and 10 Kg/cm
2
.However, the size of the actuator for each valve has been designed for a feed
pressure of 6 Kg/cm
2
.
It is essential for a good maintenance of the cylinder that air should be well dried, filtered and
lubricated.
It is recommended to actuate the cylinder 3-4 times before the start up, once it is installed in the
pipeline.
3.4.- Electric actuator
Depending on the type or make of the electric actuator, specific instructions (i.e. a manufacturer’s
manual) will be supplied.
• Allowed actuators for ATEX zones: Hand wheel, Chain Wheel, Bevel Gear, Lever, Pneumatic
Actuator (double acting ONLY
ONLYONLY
ONLY) and Electric Motor
• Make sure these actuators are ATEX marked according to the requested zone.
• Maximum travel speed of the gate must equal or below 0,05 m/s
4.- MAINTENANCE
The valve must not undergo any modifications without a previous agreement with ORBINOX.
ORBINOX shall not be liable for any damages that may arise due to the use of non original parts or
components
To avoid personal injury or damage to property from the release of process fluid:
• Those in charge of handling and maintenance of the valve must be qualified and trained in
valve operations.
• Use appropriate personal protection equipment (gloves, safety shoes, etc).
• Shut off all operating lines to the valve and place a warning sign.
• Isolate the valve completely from the process.
• Release process pressure.
• Drain the process fluid from the valve.
• According to EN 13463
EN 13463 EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenance operations, use hand
tools (non electric)
(non electric) (non electric)
(non electric) with Working Allowance.

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11-2011 EDITION
EX-8/13
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MODEL
EX
The only maintenance required is to change the gland packing (4) or the seal (3) if the valve is a
resilient seated type.
The life of these components will depend on the working conditions of the valve such as: pressure,
temperature, abrasion, chemical action, number of operations, etc.
4.1.
4.1. 4.1.
4.1. -
--
- Replacement of the gland packing (4):
Replacement of the gland packing (4): Replacement of the gland packing (4):
Replacement of the gland packing (4):
1) Depressurise the circuit and place the valve in close position.
2) Remove the gate guards (for automatically actuated valves only).
3) - Rising stem valves. Photo 1: Release the spindle or stem (6) from the gate (2).
- Non rising stem. Photo 2: Release the stem nut from the gate (2).
Photo 1 Photo 2
4) Loosen the screws of the yoke (8) and remove it (without loosing the actuator).
5) Loosen the nuts of the gland follower (5) and remove it. (Photo 3)
6) Remove the old packing rings (4) and clean the stuffing box.
7) Insert the new packing rings (4), making sure that the ring joints alternate (the first on one
side of the gate, the next on the other and so on). (Photo 4)
8) Once the necessary packing rings (4) have been inserted, proceed with a steady initial
tightening of the gland follower (5).(Photo 3)
9) Place the yoke (8) (with the actuator) and screw it.
10) ix the stem (6) to the gate (2)( Rising stem valves.Photo 1) or fix the stem nut to the
gate.(Non rising stem. Photo 2).
11) Remount the gate guards.
12) Carry out some operations with a loaded circuit and then re-tighten the gland follower (5)
to prevent leakage.
Photo 3 Photo 4

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11-2011 EDITION
EX-9/13
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MODEL
EX
4.2.
4.2.4.2.
4.2.-
--
- Replacement of the seal (3) (only applicable to resilient seated valves):
Replacement of the seal (3) (only applicable to resilient seated valves): Replacement of the seal (3) (only applicable to resilient seated valves):
Replacement of the seal (3) (only applicable to resilient seated valves):
1) Remove the valve from the pipeline.
2) Remove the gate guards (for automatically actuated valves only).
3) Release the spindle or stem (6) from the gate (2).(Rising stem valves. Photo 1) or release
the stem nut from the gate.(Non rising stem. Photo 2).
4) Loosen the screws of the yoke (8) and remove it (without loosing the actuator).
5) Loosen the nuts of the gland follower (5) and remove it.(Photo 3)
6) Remove the old packing (4) and the gate (2) and clean the stuffing box.
7) Remove the seal retainer ring (10) which support the seals (3).
8) Remove the worn seal (3) and clean the seal housing.
9) Once the new seal (3) is cut according to size, insert it into the seat housing (making sure
that the union of the seal is at the top). (Photos 5 and 6)
If the valve has PT E seal (3), follow the point 4.3.
Seal lengths
DN
DNDN
DN 50
5050
50 65
6565
65 80
8080
80 100
100100
100 125
125125
125 150
150150
150 200
200200
200 250
250250
250 300
300300
300 350
350350
350 400
400400
400 450
450450
450 500
500500
500 600
600600
600 700
700700
700 800
800800
800 900
900900
900 1000
10001000
1000 1200
12001200
1200
L
L L
L
(mm)
(mm)(mm)
(mm) 205 255 295 365 440 510 680 860 1020 1190 1350 1510 1630 2010 2350 2660 2945 3255 3915
Photo 5 Photo 6
10) Insert the seal retainer ring (10) by hammering gently around the edge. (Photos 7 and 8)
Photo 7 Photo 8

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11-2011 EDITION
EX-10/13
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MODEL
EX
11) Remount the gate (2).
12) Once the necessary packing rings (4) have been inserted, proceed with a steady initial
tightening of the gland follower (5).(Photo 3) following the steps of point 4.1.
4.3.
4.3. 4.3.
4.3. -
--
- Replacement of the PT E seal (3):
Replacement of the PT E seal (3): Replacement of the PT E seal (3):
Replacement of the PT E seal (3):
ollow the same procedure as point 4.2 but with following notes:
1. To obtain a tighter shut off in stainless steel valves (C 8M body), the machined housing of
the seat is sealed with plastic glue. This is not necessary in cast iron valves (GG25).
With the seal in this position:
2. Make a circle; joining the ends and making a heart-shaped form (see the following
diagram).
3. Insert both ends of the seal in the upper
side of the machined housing of the seat
(adjacent to the gland follower (5)), and
pushing the arched part with a finger,
insert the seal into the housing.
If the diameter of the valve is small
(DN≤150), a vice can be used.
4.4.
4.4.4.4.
4.4.-
--
- Lubrication:
Lubrication:Lubrication:
Lubrication:
Twice a year, it is recommended to remove the protection cap (12) and fill up the stem
protector (13) halfway with a calcium-based grease with the following characteristics: highly
water resistant, low ash content, and excellent adherence.
Special requirements for ATEX valves
Special requirements for ATEX valvesSpecial requirements for ATEX valves
Special requirements for ATEX valves:
-The maintenance personnel must be made fully aware of the risks of explosion, and it is advisable
that they receive specific training regarding ATEX.
-Periodicity of check and evaluation of graphite packing status and valve electrical conductivity
must be determined by end user according to valve working conditions. In any case, once the
valve is put into operation, the packing area must be revised after the valve has been stroked 100
-times or after 3 months of operation, whatever happens first. After this preliminary check, new
checking periods must be determined by end user based on the results of this first check.
-Clean the valve periodically to prevent dust accumulation. Do not sweep or dump the dust. Always
use a vacuum cleaner system
-Dead en service is not allowed.

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11-2011 EDITION
EX-11/13
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EX
-Do not apply any new coating to the valve. Should it require new coating, please contact our
closest representative.
-Allowed seals: EPDM, VITON, NITRILE, GRAPHITE and METAL (no seal)
-Allowed packing: ST and GRAPHITE packing
-Any other materials but those above are not allowed to be used in ATEX zones.
-In order to keep the ATEX approval, always use original spares from Orbinox.
• Washer  DIN 6798A (This washer guarantees continuity among carbon steel parts, coated
in epoxy, yoke and body and stainless steel guards for coating thicknesses up to
200 microns)
• ST and GR packing 
oORBINOX ST: Synthetic packing impregnated with PT E
oGR: Graphite packing  MONTERO Ecograflex 780R
-After any maintenance of ATEX valves, it is mandatory to check that the valve is earthed through
the pipe, and there is continuity among the different valve components, such as the body, the gate,
the supports, and guards (test in accordance with EN 12266-2 Standard, annex B, points B.2.2.2.
and B.2.3.1).
MAXIMUM LUID TEMPERATURES
MAXIMUM LUID TEMPERATURESMAXIMUM LUID TEMPERATURES
MAXIMUM LUID TEMPERATURES
Atmosphere
AtmosphereAtmosphere
Atmosphere
Gas/air, steam/air, an
Gas/air, steam/air, anGas/air, steam/air, an
Gas/air, steam/air, and mist/air
d mist/aird mist/air
d mist/air Dust/air
Dust/airDust/air
Dust/air
80% of minimum fluid ignition
temperature, minus 10ºK
2/3 of minimum dust cloud ignition
temperature minus 85ºK
Note: these maximum fluid temperatures apply to all categories. The differences between
categories are the consideration of foreseeable malfunction cases and rare malfunctions cases

.
11-2011 EDITION
EX-12/13
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EX
MAXIMUM
MAXIMUM MAXIMUM
MAXIMUM SEAL AND PACKING
SEAL AND PACKINGSEAL AND PACKING
SEAL AND PACKING TEMPERATURES
TEMPERATURES TEMPERATURES
TEMPERATURES
SEAL
SEALSEAL
SEAL
EPDM
EPDM EPDM
EPDM VITON
VITON VITON
VITON NITRILE
NITRILE NITRILE
NITRILE GRAPHITE
GRAPHITE GRAPHITE
GRAPHITE
Max Temperature
Max Temperature Max Temperature
Max Temperature
(
((
(ºC)
C)C)
C) 120 200 120 600
PACKING
PACKINGPACKING
PACKING
ST
ST ST
ST GRAPHITE
GRAPHITE GRAPHITE
GRAPHITE
Max Temperature
Max Temperature Max Temperature
Max Temperature
(
((
(ºC)
C)C)
C) 240 600
Note: Most of the times seals maximum temperature capacity is the key limitation factor when
evaluating valve maximum working temperatures. In ATEX zones these temperatures must be
compared to those above related to limitation of fluids temperatures.
Always consider the most restrictive as maximum valve working temperature.
5.- STORAGE
•or long storage periods keep the valves indoors in a safe and dry place and protect it from any
impact and or vibrations.
•Storing temperatures: -10ºC to +40ºC
•Valves must be stored in either full open or full closed position.
•or any component installed in the valves, electric motors, solenoid valves, etc, please refer to their
own instructions manuals

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11-2011 EDITION
EX-13/13
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MODEL
EX
6.- PARTS LIST & DRAWINGS
1.- BODY 8.- YOKE
2.- GATE 9.- COLLAR
3.- SEAL 10.- SEAL RETAINER RING
4.- PACKING RING 11.- HANDWHEEL
5.- GLAND OLLOWER 12.- CAP
6.- STEM 13.- STEM PROTECTOR
7.- STEM NUT 14.- RICTION WASHER