Richter KK/F Series User manual

INSTALLATION AND OPERATING MANUAL
Keep for future use!
This operating manual must be strictly observed before
transport, installation, operation and maintenance
Subject to change without notice.
Reproduction is generally permitted with indication of the source.
© Richter Chemie-Technik GmbH.
9520-010-en Revision 15 Edition 11/2018
Series KK/F, KKP/F, KK/FU, KKP/FU
Sandwich Ball Valve

Series KK/F, KKP/F, KK/FU, KKP/FU Page 2
9520-010-en Revision 15
TM 9549 Edition 11/2018
List of Contents
List of Contents ................................................ 2
Relevant documents ........................................ 2
1Technical data............................................. 3
1.1 Type plate, CE and body markings...............3
1.2 Tightening torques........................................... 4
1.3 Pressure-temperature diagram .....................4
1.4 Torques in Nm for ball valves ........................5
2Notes on safety ........................................... 5
2.1 Intended use.....................................................5
2.2 For the customer / operator ........................... 5
2.3 Improper operation ..........................................6
3Safety notes for applications in potentially
explosive areas based on the Directive
2014/34/ EC (ATEX)..................................... 6
3.1 Intended use.....................................................6
4Safety note for valves, certified to Clean
Air Act (TA Luft) .......................................... 7
5Transport, storage and disposal............... 7
5.1 Storage.............................................................. 7
5.2 Return consignments ...................................... 7
5.3 Disposal ............................................................8
6Installation ................................................... 8
6.1 Flange caps and gaskets ............................... 8
6.2 Direction of flow and installation position ..... 8
6.3 Grounding .........................................................8
6.4 Test pressure ................................................... 8
7Operation ..................................................... 9
7.1 Initial commissioning....................................... 9
7.2 Improper operation and their consequences
........................................................................9
7.3 Shutdown..........................................................9
8Malfunctions................................................ 9
9Maintenance .............................................. 10
9.1 Dismantling KK/F, KKP/F .............................10
9.1.1 Dismantling seat ring and ball...........................10
9.1.2 Dismantling of the packing gland and stem DN
25-100 ..................................................................10
9.1.3 Dismantling of the packing gland and stem for
DN 150, lever ......................................................10
9.1.4 Dismantling of packing gland and stem for DN
150, actuator .......................................................10
9.2 Assembly KK/F, KKP/F .................................11
9.2.1 Assembly of packing gland and stem DN 25-100
... .........................................................................11
9.2.2 Assembly of packing gland and stem for DN 150
lever......................................................................11
9.2.3 Assembly of packing gland and stem for DN 150
actuator ................................................................11
9.2.4 Assembly of seat ring and ball..........................11
9.3 Dismantling KK/FU (KHK), KKP/FU............12
9.3.1 Dismantling of seat ring and ball ......................12
9.4 Assembly KK/FU (KHK), KKP/FU ...............12
9.4.1 Assembly of seat ring and ball..........................12
9.5 Conversion from hand lever to actuator .....12
9.5.1 DN 25-100 ...........................................................12
9.5.2 DN 150.................................................................12
10 Drawings .................................................... 13
10.1 Sectional drawing and legend KK/F (DN 25-
100)..................................................................13
10.2 Legend KK/F (DN 150) ................................15
10.3 Sectional drawing KK/F (DN 150) .............16
10.4 Sectional drawing KKP/F (DN 25-100).....17
10.5 Legend KKP/F (DN 25-100)........................18
10.6 Legend KKP/F (DN 150) ...........................18
10.7 Sectional drawing KKP/F (DN150) ..........19
10.8 Legend and sectional drawing KK/FU (KHK)
......................................................................20
10.9 Legend and sectional drawing KKP/FU ....22
10.10 Dimensional drawing KK/F, KK/FU ........24
10.11 Dimensional drawing KKP/F, KKP/FU...25
Relevant documents
♦EG-Declaration of conformity
♦Declaration of conformity FDA & 97/48/EG
♦Manufacturer Declaration ATEX Directive 2014/34/EU
♦Manufacturer Declaration TA-Luft
♦Form for Safety Information Concerning the Contamina-
tion QM 0912-16-2001_en
♦For KKP/F, KKP/FU: Operating manual for actuator
♦Connecting dimensions for actuator 9520-00-4045

Series KK/F, KKP/F, KK/FU, KKP/FU Page 3
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1 Technical data
Manufacturer:
Richter Chemie-Technik GmbH
Otto-Schott-Str. 2
D-47906 Kempen
Telephone: [phone]
Fax: [phone]
E-Mail : [email protected]m
Internet: http://www.richter-ct.com
Designation :
Series:
KK/F Sandwich ball valve, hand actuated
KK/FU (KHK), Sandwich ball valve with universal
connection, hand actuated, for glass lines
KKP/F Sandwich ball valve, version prepared for
pneum., hydr. or elec. actuator to DIN /ISO
5211
KKP/FU Sandwich ball valve with universal connection,
for glass lines, version for pneum., hydr. or elec.
actuator to DIN /ISO 5211
From DN 65 reduced ball passage
Certified to Clean Air Act (TA Luft)
Strength and tightness (P10, P11) of the pressure-bearing
body tested to DIN EN 12266-1.
Gas-tight (P12) in the seat to DIN EN 12266-1,
leak rate A
Face to face: Nominal size (DN) + 50 mm
Flange connecting dimensions
KK/F DIN EN 1092-2, Form B
(ISO 7005-2 Typ B) PN 16.
KK/FU DIN EN 12585
Materials :
Body material: Ductile cast iron EN-JS 1049 /
ASTM A395
Lining material: PFA .../F
On request: antistatic …/F-L
Temperature range :
See pressure-temperature diagram in Section 1.3.
Operating pressure:
KK/F : DN 15 –DN 100 up to max. 16 bar
DN 150 up to max. 10 bar
KK/FU (KHK) : DN 25 –50 up to max. 4 bar
Ball valve sizes in mm:
KK/F: DN 25, 40, 50, 65, 80, 100, 150
KK/FU (KHK): DN 25, 40, 50
Installation position :
arbitrarily, in the case of a ball with relief or drainage
hole, a directional arrow indicates the direction of flow.
See Section 6.2.
Dimensions and individual parts :
See sectional and dimensional drawings in section 10
Wear parts :
♦Seat rings (in pairs)
♦packing gland
♦Stem
♦ball
1.1 Type plate, CE and body markings
The stainless steel name plate is undetachably riveted to the
body.
If the operator attaches his identification, it must be en-
sured that the valve matches the application in question.
Example of name plate with CE marking:
No CE marking is permissible for size 25; the name plate
therefore has no CE marking.
Example: Name plate KK/FU (KHK)

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Body identification:
The following are visible on the body according to DIN EN
19 and AD 2000 A4:
♦Nominal size
♦Rated pressure
♦Body material
♦Manufacturer's identification
♦Melt number/Foundry identification
♦Cast date
1.2 Tightening torques
All screws greased, tighten in diametrically opposite se-
quence!
The tightening torques for pipe screws and body screws
mentioned must not be exceeded. For an exception, see
Section 8, Flange connection valve/pipe is leaking.
Packing nut 920/2
DN
Nm
25
10 Nm
40 - 80
15 Nm
100
20 Nm
150
The following tightening torques are recommended.
Pipe screws for KK/F
Flange
Nominal size
Operating
pressure
screws
Tightening
torque
[mm]
[PN]
[Nm]
25
16
4 x M12
10
40
16
4 x M16
20
50
16
4 x M16
26
65
16
4 x M16
40
80
16
8 x M16
25
100
16
8 x M16
35
150
10
8 x M20
65
Body screws für KK/FU (KHK)
Nominal
size
Rated pressure
screws
Tightening
torque
[mm]
[PN]
[ISO/DIN]
[Nm]
25
4
4 x M8
10
40
4
4 x M8
25
50
4
4 x M8
25
1.3 Pressure-temperature diagram
For PFA-ball
For Al2O3- ball

Series KK/F, KKP/F, KK/FU, KKP/FU Page 5
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1.4 Torques in Nm for ball valves
* Seat rings = PTFE/carbon low-cavity
Torques apply to balls Al2O3or FEP/PFA with metal core.
Test medium water 20 °C; depending on medium - e.g. dry gases or viscous or crystallising fluids - the torques may be higher. If the actuator is to be rated by
Richter, we request detailed information. Observe operating limits acc. to pressure-temperature diagram.
2 Notes on safety
This operating manual contains fundamental information
which is to be observed during installation, operation and
maintenance.
It must be read before installation and commissioning!
For valves which are used in potentially explosive areas, see
Section 3.
Installation and operation are to be performed by qualified
staff.
The area of responsibility, authority and supervision of the
staff must be regulated by the customer.
General hazard symbol!
People may be put at risk.
Safety symbol! The ball valve and its
function may be put at risk if this safety
symbol is not observed.
It is imperative to observe warnings and signs attached di-
rectly to the ball valve and they are to be kept fully legible.
Non-observance of the notes on safety may result in the
loss of any and all claims for damages.
For example, non-observance may involve the following
hazards:
♦Failure of important functions of the valve/plant.
♦Risk to people from electric, mechanical and chemical
effects.
♦Risk to the environment through leaks of hazardous sub-
stances.
2.1 Intended use
Sandwich ball valves of the series KK are flangeless
open/closed valves.
Richter ball valves are pressure containing components in
accordance with the Pressure Equipment Directive (PED) for
the passage and shut-off of fluids. The valves are suitable
for vapours, gases and non-boiling liquids of group 1 accord-
ing to the PED and have a corrosion-resistant plastic lining.
Solids can lead to increased wear, damage to sealing sur-
faces or to a reduction in the service life of the valve.
In case of the valve is intended for operating data other than
those intended, the customer must carefully examine
whether the design of the valve, accessories and materials
are suitable for the new application. (Please consult the
manufacturer).
2.2 For the customer / operator
When using the valve, it must be ensured that
♦actuators which are retrofitted are adapted to suit the
valve
♦hot or cold valve parts are protected by the customer
against being touched
♦the valve has been properly installed in the pipe system
♦the usual flow rates are not exceeded in continuous op-
eration.
This is not the manufacturer's responsibility.
Loads caused by earthquakes were not allowed for in the
design.

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Ball valves at the end of a pipe (end valve)
must be sealed with a blind flange at the free
connection end and appropriately secured
against unauthorised activation.
Fire protection to DIN EN ISO 10497 is not possible (plastic
lining and plastic components).
2.3 Improper operation
The operational safety of the valve supplied is only guaran-
teed if it is used properly in accordance with Section 2.1 of
this operating manual.
The operation limits specified on the name
plate and in the pressure-temperature dia-
gram must under no circumstances be ex-
ceeded.
3 Safety notes for applications in potentially explosive areas based on
the Directive 2014/34/ EC (ATEX)
The valves are intended for use in a potentially explosive
area and are therefore subject to the conformity assess-
ment procedure of the directive 2014/34/EC (ATEX).
As part of this conformity assessment, an ignition hazard
analysis to EN 13463-1 to satisfy the fundamental safety and
health requirements was conducted with the following re-
sult:
♦The valves do not have any ignition source of their own
and can be operated both manually as well as mechan-
ically/electrically.
♦The valves are not covered by the scope of application
of the ATEX directive and therefore do not need to be
identified accordingly.
♦The valves may be used in a potentially explosive area.
Supplementary notes:
♦Electric/mechanical actuators must be subjected to
their own conformity assessment to ATEX.
It is imperative to observe the individual points of
intended use for application in a potentially explosive
area.
3.1 Intended use
Inadmissible modes of operation, even for brief
periods, may result in serious damage to the unit.
In connection with explosion protection, potential
sources of ignition (overheating, electrostatic and
induced charges, mechanical and electric sparks)
may result from these inadmissible modes of
operation; their occurrence can only be prevented
by adhering to the intended use.
Furthermore, reference is made in this connection to the Di-
rective 95/C332/06 (ATEX 118a) which contains the mini-
mum regulations for improving the occupational health and
safety of the workers who may be at risk from an explosive
atmosphere.
A difference is made between two cases for the use of
chargeable liquids (conductivity < 10-8 S/m):
1. Chargeable liquid and non-conductive lining
Charges can occur on the lining surface. As a result, this
can produce discharges inside and outside the valve.
a) Discharges inside the valve
However, these discharges inside the valve cannot cause
ignitions if the valve is completely filled with medium.
If the valve is not completely filled with medium, e.g.
during evacuation and filling, the formation of an explo-
sive atmosphere must be prevented, e.g. by superim-
posing a layer of nitrogen. It is recommended to wait 1
hour before removing the valve from the plant in order
to permit the elimination of static peak charges.
This means that, to safely prevent ignitions, the valve
must be completely filled with medium at all times or
else a potentially explosive atmosphere must be ex-
cluded by superimposing a layer of inert gas.
b) Discharges outside the valve
At the points where the non-conductive lining e.g. pro-
trudes on the sealing surfaces to the outside or gets con-
tact with the atmosphere on the outside, it may lead to
discharges from the lining to nearby valves or attach-
ments.
To safely avoid explosion hazards and accidents, there-
fore, the atmosphere surrounding the valve must not be
explosive.
2. Chargeable liquid and conductive lining
No hazardous charges can occur as charges are dis-
charged direct via the lining and shell (surface resistance
< 109Ohm, leakage resistance < 106Ohm)

Series KK/F, KKP/F, KK/FU, KKP/FU Page 7
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Static discharges of non-conductive linings are only
produced through the interaction with a non-conduc-
tive medium and are therefore the responsibility of the
plant operator.
Static discharges are not sources of ignition which stem
from the valves themselves!
♦The temperature of the medium must not exceed the
temperature of the corresponding temperature class or
the maximum admissible medium temperature as per
the operating manual.
♦If the valve is heated (e.g. heating jacket), it must be en-
sured that the temperature classes prescribed in the An-
nex are observed.
♦For safe and reliable operation, it must be ensured with
regular inspection intervals that the unit is properly ser-
viced and kept in a perfect technical condition.
Increased wear to the valve can be expected with the
conveyance of liquids containing abrasive constituents.
The inspection intervals are to be reduced compared
with the usual times.
♦Actuators and electric peripherals, such as temperature,
pressure and flow sensors etc., must comply with the
valid safety requirements and explosion protection pro-
visions.
♦The valve must be grounded.
This can be achieved in the simplest way via the pipe
screws using tooth lock washers.
Otherwise grounding must be ensured by different
measures e.g. a cable link.
♦Attachments such as actuators, position controllers,
limit switches etc. must satisfy the relevant safety regu-
lations as regards explosion protection and, if required,
be designed in compliance with ATEX.
♦Special attention must be paid to the appropriate safety
and explosion protection notes in the respective operat-
ing manuals.
♦Plastic-lined valves must not be operated with carbon
disulphide.
4 Safety note for valves, certified to Clean Air Act (TA Luft)
Certificate / Manufacturer Declaration Validity is depend-
ent on the operating instructions being read and observed.
♦Carry out regular maintenance intervals and check the
tightness of the screw connections and tighten as nec-
essary.
5 Transport, storage and disposal
It is imperative, for all transport work, to ob-
serve generally accepted engineering practice
and the accident prevention regulations.
The valve is supplied with flange caps. Do not
remove them until just before installation. They
protect the plastic surfaces against dirt and me-
chanical damage.
Handle the goods being transported with care. During
transport the valve must be protected against impacts and
collisions.
Directly after receipt of the goods, the consignment must
be checked for completeness and any in-transit damage.
Do not damage paint protection.
5.1 Storage
If the valve is not installed immediately after delivery, store
them properly.
The valves be stored in a dry, vibration-free and well-venti-
lated room at as constant a temperature as possible.
Protect elastomers against UV light.
In general, a storage period of 10 years should not be ex-
ceeded.
5.2 Return consignments
Valves which have conveyed aggressive or
toxic media must be well rinsed and cleaned
before being returned to the manufacturer's
works.
It is imperative to enclose a safety information sheet / gen-
eral safety certificate on the field of application with the re-
turn consignment.
Pre-printed forms are enclosed with the installation and op-
erating manual.
Safety precautions and decontamination methods are to be
mentioned.

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5.3 Disposal
Parts of the valve may be contaminated with medium which
is detrimental to health and the environment and therefore
cleaning is not sufficient.
Risk of personal injury or damage to the
environment due to the medium!
♦Wear protective clothing when work is performed on
the valve.
♦Prior to the disposal of the valve:
▪Collect any medium, etc. which has escaped and dis-
pose of it in accordance with the local regulations.
▪Neutralise any medium residues in the valve.
♦Separate valve materials (plastics, metals, etc.) and dis-
pose of them in accordance with the local regulations.
6 Installation
♦Examine valve for in-transit damage, damaged ball
valves must not be installed.
♦Before installation the valve and the connecting pipe
must be carefully cleaned to remove any dirt, especially
hard foreign matter.
♦During installation, pay attention to the correct tighten-
ing torque, aligned pipes and tension-free assembly.
Ensure that a remotely actuated actuator
cannot be accidentally switched on.
6.1 Flange caps and
gaskets
♦Leave protective caps on the flanges until just prior to
installation.
KK / F: Can plastic sealing surfaces e.g. with counter flanges
made of metal or enamel, use PTFE-coated gaskets with
metal insert.
These gaskets are available as special accessories in the
Richter range.
6.2 Direction of flow and
installation position
Installation is independent of the direction of flow.
Any fitting position can be chosen.
Exception: with relief or drainage hole, marked with a direc-
tional arrow on the ball valve.
The position of the ball ("open" - "closed") is indicated by
the hand lever or flat pivot point on the stem. (Lever longi-
tudinal to the valve - open; lever at right angles to the valve
- closed. A stud screw serves as an end stop).
For remotely operated valves it is indicated by a red rivet
according to NAMUR on the coupler.
6.3 Grounding
Grounding is provided by the pipe screws.
The valve is grounded by means of a grounding rope 532.
At the customer's request a setscrew M6 with a hex. nut
and washer will be provided at each flange as an additional
grounding connection.
6.4 Test pressure
The test pressure PT of an open valve must not exceed the
value of 1.5 x PN/PS as per the identification of the valve.

Series KK/F, KKP/F, KK/FU, KKP/FU Page 9
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7 Operation
7.1 Initial commissioning
Normally, the valves have been tested for leaks with air or
water. Prior to initial operation check cover screws. For
tightening torques, see Section 1.2.
Unless otherwise agreed there could be resid-
ual amounts of water in the flow section of the
valve. This could result in a possible reaction
with the medium.
To prevent leaks, all connection screws should be
retightened after the initial loading of the valve with
operating pressure and operating temperature. For
tightening torques, see Section 1.2.
7.2 Improper operation and their
consequences
♦The ball valve is an on/off valve and shall not be oper-
ated in an intermediate position.
♦Damage to the seat rings or the stem could occur.
♦Crystallisation may result in damage to the seat rings or
stem . This can be prevented by heating.
In extreme cases this may cause blocking.
♦Increased wear occurs in operation with solids contents.
♦Operation during cavitation leads to increased wear.
♦Non-observance of the pressure-temperature diagram
can lead to damage.
♦Do not subject the lever to heavy loads; the lever or ball
valve may be damaged.
♦Do not use a lever extension as otherwise there is a risk
of damage.
7.3 Shutdown
The local regulations are to be observed when dismantling
the valve.
Prior to undoing the flange connection ensure, that the
plant is depressurised and emptied.
Prior to starting any repair work, the valve is
to be thoroughly cleaned. Medium residue
may be in the valve even if it has been
properly drained and flushed.
After removal, immediately protect the connection surfaces
of the valve against mechanical damage. See also Section
6.1.
8 Malfunctions
♦Flange connection valve/pipe is leaking
Retighten the flange screws to a tightening torque ac-
cording to Section 1.2. If this does not remedy the leak,
the recommended torques may be exceeded by 10%.
If this also fails to stop the leak, dismantle and inspect
the valve.
♦Flange connection body centre piece/transition cover is
leaking
Retighten body screws. See paragraph "Flange connec-
tion ball valve/pipe is leaking".
♦Ball valve does not operate
Is the actuator supplied with power?
Is any directional control valve correctly connected?
Is there foreign matter in the valve?
♦The ball no longer closes completely
Is the stem deformed?
Is the coupling worn?
With a worm gear or actuator, check whether the end
stops can be re-adjusted. The operating manuals of the
gear and actuator manufacturers contain accurate in-
structions.
Never apply force to the lever or use an exten-
sion.
1. Try to get the ball valve working again by moving the
lever to and from.
2. Remove the lever stop and try to switch against the
normal direction of rotation.
3. If actuation is not possible with the max. admissible
actuating torque as per section 1.3, dismantle ball
valve and inspect individual components.

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9 Maintenance
♦All repair work is to be performed by qualified person-
nel using the appropriate tools.
♦For the arrangement, designation and item numbers of
all parts of the valve, see Section 10.
♦Spare parts are to be ordered with all the details in acc.
with the valve identification.
♦Only original spare parts may be installed.
♦To prevent leaks, a regular check of the connection
screws should be made in line with the operating re-
quirements.
For tightening torques, see Section 1.2.
9.1 Dismantling KK/F, KKP/F
9.1.1 Dismantling seat ring and ball
♦See also sectional drawings in Section 10.
♦Place ball valve on a soft, clean surface.
♦Undo cover holder 111.
♦Remove transition cover 109 and seat rings 401.
ATTENTION: Mark the inside and outside of the transi-
tion cover with a felt-tip pen!
♦Move ball 200 into the "closed position" and remove
from the body centre piece 103 by lifting and turning
it.
9.1.2 Dismantling of the packing gland and
stem DN 25-100
See sectional drawings in Section 10.1 and 10.4.
After dismantling the seat rings and ball, as described in
Section 9.1.1, the packing gland and stem are dismantled
as follows:
♦Unscrew hex. nut 920/1.
♦Dismantle lever 203 and actuator 850.
♦Undo hex. screw 901/1 of the grounding rope 532. Un-
screw with the design with actuator.
♦Undo hex. nut 920/2 and remove cup spring cage.
♦Force stem 202 downwards with rubber mallet and re-
move.
♦Remove thrust ring 405 and ring 500.
♦Dismantle packing rings 402/1.
9.1.3 Dismantling of the packing gland and
stem for DN 150, lever
See sectional drawing in Section 10.3.
After dismantling the seat rings and ball, as described in
Section 9.1.1, the packing gland and stem are dismantled
as follows:
♦Undo hex. screws 903/1 and hex. nuts 920/3; as a re-
sult, the cup spring is 950/1 are relieved.
♦Unscrew hex. screws 901/2 and then hex. socket screw
914/1, and remove lever 203, disc 550 and lever stop
577.
♦Undo hex. screw 901/1 of the grounding rope 532.
♦Remove pressure plate 524, cup spring 950/1, plain
bearing 300 and support disc 232.
♦Force stem 202 downwards with rubber mallet and re-
move.
♦Turn profiled sheet 533 to the side.
♦Remove thrust ring 405 and ring 500.
♦Dismantle packing rings 402/1.
9.1.4 Dismantling of packing gland and stem
for DN 150, actuator
See also sectional drawing in Section 10.7.
After dismantling the seat rings and ball, as described in
Section 9.1.1, the packing gland and stem are dismantled
as follows:
♦Dismantle actuator 850 and bracket 510.
♦Undo hex. screws 903/1 and hex. nuts 920/3; as a re-
sult, the cup spring 950/1 is relieved.
♦Undo hex. screws 901/2, force spring-type slotted pins
939/1 out with a rubber mallet, dismantle coupling 804.
♦Undo hex. socket screw 914/1; remove disc 550 and po-
sition indicator 531.
♦Remove pressure plate 524, cup spring 950/1, plain
bearing 300 and support disc 232.
♦Force stem 202 downwards with rubber mallet and re-
move.
♦Turn profiled sheet 533 to the side.
♦Remove thrust ring 405 and ring 500.
♦Dismantle packing rings 402/1.

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9.2 Assembly KK/F, KKP/F
9.2.1 Assembly of packing gland and stem DN
25-100
♦See sectional drawings in Section 10.1 and 10.4.
♦Prior to assembly all parts are to be cleaned and the
plastic-lined parts checked for damage.
♦Insert stem 202 from below into the body centre piece
103.
♦Insert packing rings 402/1.
ATTENTION: Offset overlapping from ring to ring by
60°- 90°.
♦Place ring 500, then the thrust ring 405.
♦Attach cup spring cage 504 with hex. nut 920/2. (Ob-
serve torque data; see Section 1.2).
♦Mount lever 203 and hex. nut 920/1, or with the KKP
first tighten the hex. nut 920/2 and then mount the
coupling.
♦Install hex. screw 901/1 with washer 554/1, grounding
rope 532 and profiled sheet 533 again.
9.2.2 Assembly of packing gland and stem for
DN 150 lever
♦See also sectional drawing in Section 10.3
♦Prior to assembly all parts are to be cleaned and the
plastic-lined parts checked for damage.
♦Insert stem 202 from below into the body centre piece
103.
♦Insert packing rings 402/1.
ATTENTION: Offset overlapping from ring to ring by
60°- 90°.
♦Push ring 500, thrust ring 405 and profiled sheet 533
onto the stem.
♦Push support disc 232, plain bearing 300, cup spring
950/1 and pressure plate 524 onto the stem.
♦Attach lever stop 577 with hex. socket screw 914/1.
♦Pre-tension cup spring 950/1 with hex. screw 903/1
and hex. nut 920/3.
♦Mount lever 203.
♦Install hex. screw 901/1 with washer 554/1, grounding
rope 532 and profiled sheet 533 again.
♦Check whether the lever can be easily activated. Oth-
erwise relieve or tension cup spring slightly (check nut).
9.2.3 Assembly of packing gland and stem for
DN 150 actuator
♦See sectional drawing in Section 10.7.
♦Prior to assembly all parts are to be cleaned and the
plastic-lined parts checked for damage.
♦Insert stem 202 from below into the body centre piece
103.
♦Insert packing rings 402/1.
ATTENTION: Offset overlapping from ring to ring by
60°- 90°.
♦Push ring 500, thrust ring 405 and profiled sheet 533
onto the stem.
♦Push support disc 232, plain bearing 300, cup spring
950/1 and pressure plate 524 onto the stem.
♦Secure disc and position indicator 531 with hex. socket
screw 914/1 to stem 202.
♦Loosely screw coupling 804 onto position indicator 531,
force in spring-type slotted pins 939/1, tighten screws.
♦Pre-tension cup spring 950/1 with hex. screw 903/1 and
hex. nut 920/3.
♦Mount bracket 510 and actuator 850.
♦Install hex. screw 901/1 with washer 554/1, grounding
rope 532 and profiled sheet 533 again.
♦Check actuator to see if it switches. Otherwise relieve or
tension cup spring slightly (check nut).
9.2.4 Assembly of seat ring and ball
♦See also sectional drawings in Section 10.
♦Mount ball 200 on the stem 202 by using the ball slit.
♦In the case of balls with a relief or drain bore install
these opposite the direction of flow.
♦Mount top seat ring 401.
♦Install seat rings 401 and transition cover 109 and at-
tach cover holder 111 again.
ATTENTION: Ensure correct position of the transition
cover! See Section 9.1.1.

Series KK/F, KKP/F, KK/FU, KKP/FU Page 12
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9.3 Dismantling KK/FU (KHK),
KKP/FU
9.3.1 Dismantling of seat ring and ball
♦See sectional drawings in Section 10.8 and 10.9.
♦Place ball valve on a soft, clean surface.
♦Undo screw fittings 918/1, 559/1, 920/3 and remove
transition cover 109.
♦Remove seat rings 401.
♦Move ball 200 into the "closed position" and remove
from the body centre piece 103 by lifting and turning
it.
Further dismantling as described in Section 9.1.2.
9.4 Assembly KK/FU (KHK), KKP/FU
Assembly of packing gland and stem as described in Sec-
tion 9.2.1.
9.4.1 Assembly of seat ring and ball
♦See sectional drawings in Section 10.8 and 10.9.
♦Mount ball 200 on the stem 202 by using the ball slit.
♦In the case of balls with a relief or drain bore install
these opposite the direction of flow.
♦Mount top seat ring 401.
♦Install seat rings 401 and transition cover 109 and se-
cure again with the screw fittings 918/1, 559/1, 920/3.
9.5 Conversion from hand lever to
actuator
9.5.1 DN 25-100
♦Select the actuator in accordance with the instructions
of the actuator manufacturer.
♦Unscrew hex. nut 920/1.
♦Remove lever 203.
♦Remove stud screw 905/1 and sealing plug.
♦The hex. nut 920/2 and cup spring cage 504 do not
need to be removed.
If, however, the cup spring cage has been dismantled,
pay attention during re-assembly to the tightening tor-
ques in Section 1.2 and see Section 9.2.1.
♦Remove hex. screw 901/1 with washer 554/1, ground-
ing rope 532 and distance bushing 530.
♦Check the fits of the coupling, bracket and actuator.
♦Bend the profiled sheet 533 of the cup spring cage 504
upwards.
♦Mount bracket 510 with the opening at right angles to
the direction of flow.
♦Install hex. screw 901/1 with washer 554/1, grounding
rope 532 and profiled sheet 533 again.
With F07 the hex. screw 901/1 is replaced by a hex.
socket screw 914/2.
♦Mount coupling 804 and actuator 850. Observe the ac-
tuator position in accordance with the actuator operat-
ing manual.
♦See also sectional drawings KKP/F and KKP/FU in Sec-
tions 10.4 and 10.9.
9.5.2 DN 150
♦Select the actuator in accordance with the instructions
of the actuator manufacturer.
♦Remove lever 203.
♦Remove stud screw 905/1 and sealing plug.
♦The hex. nut 920/2 and cup spring cage 504 do not need
to be removed.
If the cup spring cage is nevertheless removed, pay at-
tention to the tightening torques in Section 1.2 for re-
assembly.
♦Remove hex. screw 901/1 with washer 554/1, ground-
ing rope 532 and distance bushing 530.
♦Check the fits of the coupling, bracket and actuator.
♦Bend the profiled sheet 533 of the cup spring cage 504
upwards.
♦Mount bracket 510 with the opening at right angles to
the direction of flow.
♦Install hex. screw 901/1 with washer 554/1, grounding
rope 532 and profiled sheet 533 again.
♦With F07 the hex. screw 901/1 is replaced by a hex.
socket screw 914/2.
♦Mount coupling 804 and actuator 850. Observe the ac-
tuator position in accordance with the actuator operat-
ing manual.
♦See also sectional drawings KKP/F in Section 9.5.

Series KK/F, KKP/F, KK/FU, KKP/FU Page 13
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10 Drawings
10.1 Sectional drawing and legend KK/F (DN 25-100)
103 body centre piece
109 transition cover
200 ball
202 stem
203 Lever
401 seat ring
402/1 packing ring
405 thrust ring
500 Ring
504 cup spring cage
includes:
232 support disc
300 plain bearing
533 profiled sheet
950/1 cup spring
530 distance bushing
532 grounding rope
554/1 washer
901/1 hex. screw
905/1 headless screw
920/x hex. nut

Series KK/F, KKP/F, KK/FU, KKP/FU Page 14
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Self adjusting, maintenance-free packing

Series KK/F, KKP/F, KK/FU, KKP/FU Page 15
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10.2 Legend KK/F (DN 150)
103 body centre piece
109 transition cover
111 cover holder
200 ball
202 stem
203 Lever
232 support disc
300 plain bearing
401 seat ring
402/1 packing ring
405 thrust ring
500 Ring
524 pressure plate
530 distance bushing
532 grounding rope
533 profiled sheet
550 disc
554/1 washer
562/1 parallel pin
577 lever stop
901/x hex. screw
901/5 hex. screw DIN 564
914/1 hex. socket screw
920/x hex. nut
950/1 cup spring
980/1 round head grooved pin

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10.3 Sectional drawing KK/F (DN 150)

Series KK/F, KKP/F, KK/FU, KKP/FU Page 17
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10.4 Sectional drawing KKP/F (DN 25-100)

Series KK/F, KKP/F, KK/FU, KKP/FU Page 18
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10.5 Legend KKP/F (DN 25-100)
103 body centre piece
109 transition cover
111 cover holder
200 ball
202 stem
401 seat ring
402/1 packing ring
405 thrust ring
500 Ring
504 cup spring cage
includes:
232 support disc
300 plain bearing
533 profiled sheet
950/1 cup spring
510 bracket
532 grounding rope
554/1 washer
804 coupling
includes:
952/1 pressure spring
980/1 round head grooved pin
850 Actuator
901/x hex. screw
914/2 hex. socket screw
920/2 hex. nut
10.6 Legend KKP/F (DN 150)
103 body centre piece
109 transition cover
111 cover holder
200 ball
202 stem
232 support disc
300 plain bearing
401 seat ring
402/1 packing ring
405 thrust ring
500 Ring
510 bracket
524 Pressure plate
531 position indication
532 grounding rope
533 profiled sheet
550 disc
554/1 washer
804 coupling
850 Actuator
901/x hex. screw
901/5 hex. screw DIN 564
914/1 hex. socket screw
920/x hex. nut
936/3 toothed lock washer
939/1 Spring-type pin
950/1 Cup spring
980/1 round head grooved pin

Series KK/F, KKP/F, KK/FU, KKP/FU Page 19
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10.7 Sectional drawing KKP/F (DN150)
Detail X
View A

Series KK/F, KKP/F, KK/FU, KKP/FU Page 20
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10.8 Legend and sectional drawing KK/FU (KHK)
103 body centre piece
109 transition cover
200 ball
202 stem
203 Lever
401 seat ring
402/1 packing ring
405 thrust ring
500 Ring
504 cup spring cage
includes:
232 support disc
300 plain bearing
533 profiled sheet
950/1 cup spring
530 distance bushing
532 grounding rope
554/1 washer
901/1 hex. screw
905/1 headless screw
918/1 threaded rod
920/x hex. nut
936/1 toothed lock washer