sks KIESELMANN 403 Series User manual

Operating instruction
Translation of the original
Three-way ball valve
pneumatic und manual operation
Types 403x
413x
423x
GB
ENGLISHPDF • ak • 03/12/2020
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KIESELMANN GmbH
Paul-Kieselmann-Str. 4-10
D - 75438 Knittlingen
( [phone] • 7 [phone]
www.kieselmann.de • [email protected]
Copyright: © KIESELMANN FLUID PROCESS GROUP
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KIESELMANN GmbH Table of contents
4x3x_TWBV_EN 3
Table of contents
1 General informations ....................................................................................................................................................4
1.1 Informations for your safety ...............................................................................................................................................4
1.2 Marking of security instructions.........................................................................................................................................4
1.3 General designated use ......................................................................................................................................................4
1.4 Personnel .............................................................................................................................................................................4
1.5 Modifications, spare parts, accessories ............................................................................................................................5
1.6 General instructions ............................................................................................................................................................5
2 Safety instructions........................................................................................................................................................6
2.1 Intended use ........................................................................................................................................................................6
2.2 General notes.......................................................................................................................................................................6
2.3 General safety instructions.................................................................................................................................................6
3 Delivery, transport and storage .....................................................................................................................................8
3.1 Delivery.................................................................................................................................................................................8
3.2 Transport..............................................................................................................................................................................8
3.3 Storage.................................................................................................................................................................................8
4 Specification.................................................................................................................................................................9
4.1 Modular system...................................................................................................................................................................9
5 Function and operation ...............................................................................................................................................10
5.1 Description of function......................................................................................................................................................10
5.2 Control system and position indication ...........................................................................................................................11
6 Commissioning, service and maintenance ..................................................................................................................12
6.1 Commissioning..................................................................................................................................................................12
6.1.1 Installation instructions....................................................................................................................................... 12
6.1.2 General welding guidelines ................................................................................................................................. 12
6.1.3 ATEX - Guidelines ................................................................................................................................................ 12
6.2 Service................................................................................................................................................................................13
6.3 Cleaning .............................................................................................................................................................................13
7 Technical data ............................................................................................................................................................14
8 Disassembly and assembly .........................................................................................................................................15
8.1 Disassembly.......................................................................................................................................................................15
8.2 Assembly ...........................................................................................................................................................................16
9 Drawings and dimensions ...........................................................................................................................................17
9.1 Control units ......................................................................................................................................................................17
9.2 Drawings ............................................................................................................................................................................18
9.3 Dimensions ........................................................................................................................................................................20
10 Wearing parts .............................................................................................................................................................21
10.1 Wear parts kit.....................................................................................................................................................................21
10.2 Spare parts list...................................................................................................................................................................22
11 Classification..............................................................................................................................................................23
11.1 Structure of Order Number ...............................................................................................................................................23
12 Appendix ....................................................................................................................................................................25
12.1 Declaration of incorporation.............................................................................................................................................25
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Operating instruction | KIESELMANN GmbH1 | General informations
4 / 25 4x3x_TWBV_EN
1 General informations
1.1 Informations for your safety
We are pleased that you have decided for a high-class KIESELMANN GmbH product. With correct
application and adequate maintenance, our products provide long time and reliable operation.
Before installation and initiation, please carefully read this instruction manual and the security ad-
vices contained in it. This guarantees reliable and safe operation of this product and your plant re-
spectively. Please note that an incorrect application of the process components may lead to great
material damages and personal injury.
In case of damages caused by non observance of this instruction manual, incorrect initiation, hand-
ling or external interference, guarantee and warranty will lapse!
Our products are produced, mounted and tested with high diligence. However, if there is still a
reason for complaint, we will naturally try to give you entire satisfaction within the scope of our war-
ranty. We will be at your disposal also after expiration of the warranty. In addition, you will also find
all necessary instructions and spare part data for maintenance in this instruction manual. If you
don't want to carry out the maintenance by yourself, ourKIESELMANN GmbH - service team will
naturally be at your disposal.
1.2 Marking of security instructions
Hints are available in the chapter "safety instructions" or directly before the respective operation in-
struction. The hints are highlighted with a danger symbol and a signal word. Texts beside these
symbols have to be read and adhered to by all means. Please continue with the text and with the
handling at the valve only afterwards.
Symbol Signal word Meaning
DANGER Imminent danger which will result severe personal injury or
death.
WARNING Imminent danger which may result severe personal injury or
death.
CAUTION Dangerous situation which may cause slight personal injury or
material damages.
NOTICE An harmful situation which may result in damages of the product
itself or of adjacent vicinity.
INFORMATION Marks application hints and other information which is particu-
larly useful.
1.3 General designated use
The fitting is designed exclusively for the purposes described below. Using the fitting for purposes
other than those mentioned is considered contrary to its designated use. KIESELMANN GmbH can-
not be held liable for any damage resulting from such use. The risk of such misuse lies entirely with
the user. The prerequisite for the reliable and safe operation of the fitting is proper transportation
and storage as well as competent installation and assembly. Operating the fitting within the limits
of its designated use also involves observing the operating, inspection and maintenance instruc-
tions.
1.4 Personnel
Personnel entrusted with the operation and maintenance of the tank safety system must have the
suitable qualification to carry out their tasks. They must be informed about possible dangers and
must understand and observe the safety instructions given in the relevant manual. Only allow quali-
fied personnel to make electrical connections.
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KIESELMANN GmbH | Operating instruction General informations | 1
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1.5 Modifications, spare parts, accessories
Unauthorized modifications, additions or conversions which affect the safety of the fitting are not
permitted. Safety devices must not be bypassed, removed or made inactive. Only use original spare
parts and accessories recommended by the manufacturer.
1.6 General instructions
The user is obliged to operate the fitting only when it is in good working order. In addition to the in-
structions given in the operating manual, please observe the relevant accident prevention regula-
tions, generally accepted safety regulations, regulations effective in the country of installation,
working and safety instructions effective in the user's plant.
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Operating instruction | KIESELMANN GmbH2 | Safety instructions
6 / 25 4x3x_TWBV_EN
2 Safety instructions
2.1 Intended use
The Three way ball valve can be used as multiple way valve in the drinks and food industry, the
pharmaceuticals and chem. Industry and the bio-technology sector.
2.2 General notes
NOTICE - observe the operating instructions
To avoid danger and damage, the fitting must be used in accordance with the safety instructions
and technical data contained in the operating instructions.
NOTICE
All data are in line with the current state of development. Subject to change as a result of tech-
nical progress.
2.3 General safety instructions
WARNING
Risk of injury by outflowing medium
Dismantling the valve or valve assemblies from the plant can cause injuries.
– Medias flowing through the leakage drain outlet are to be drained off without splashing
into a discharge arrangement.
– Carry the disassembling only if when the plant has been rendered pressure-less and free
of liquid and gas.
WARNING
Risk of injury by moving parts
Do not grab into the valve when the actuator is pressurized. Limbs can be crushing or amputating.
– Remove the control air line before dismantling.
– Ensure that the actuator is unpressurized.
WARNING
Risk of injury by pre-stressed pressure spring.
The pneumatic-mechanical actuator is spring-loaded. When disassembling the actuator, compon-
ents that jump out may cause injuries.
– Multiturn actuator are maintenance-free and therefore do not need to be opened!
WARNING
ATEX - Guidelines
If the valve or the plant is operated in a potentially explosive atmosphere, the valid ATEX directive of
the EC and the installation instructions in this operating manual must be observed.
CAUTION
To avoid air leaking, only use pneumatic connection parts that have an O-ring seal facing the even
surface.
CAUTION
Before starting the system, the entire pipeline system must be thoroughly cleaned.
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KIESELMANN GmbH | Operating instruction Safety instructions | 2
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CAUTION
Steps should be taken to ensure that no external forces are exerted on the fitting.
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Operating instruction | KIESELMANN GmbH3 | Delivery, transport and storage
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3 Delivery, transport and storage
3.1 Delivery
• Immediately after receipt check the delivery for completeness and transport damages.
• Remove the packaging from the product.
• Retain packaging material, or expose of according to local regulations.
3.2 Transport
CAUTION
Risk of injury and damage to the product
During the transport the generally acknowledged rules of technology, the national accident preven-
tion regulationsand company internal work and safety regulations must be observed.
3.3 Storage
NOTICE
Damage to the product due to improper storage!
Observe storage instructions
avoid a prolonged storage
INFORMATION
Recommendation for longer storage
We recommend regularly checking the product and the prevailing storage conditions during long
storage times.
• To avoid damage to seals and bearings,
– products up to DN 125 / OD 5 inch should be stored horizontally for maximum 6 months.
– products larger than DN 125 / 5 inch, should be stored in the upright position with the actu-
ator on top.
• Don't store any objects on the products.
• Protect the products for wetness, dust and dirt.
• The product should be stored in a dry and well ventilated room at a constant temperature (op-
timal indoor temperature: 25 C ±5; indoor humidity data 70% ±5%).
• Protect seals, bearings and plastic parts for UV light and ozone.
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KIESELMANN GmbH | Operating instruction Specification | 4
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4 Specification
4.1 Modular system
KI-Top control head Feedback unit
Stainless steel hood: Transparent hood
drive systems
pneumatical electrical
PDA 90/75
Ø 75
PDA 90/100
Ø 100
PDA 90/125
Ø 125
4040
manual
Hand lever Hand lever
with sensor mounting
Hand lever
stainless steel
Hand lever
continuously adjustable
Model
Standard
PTFE - Thrust collar
Filling element
PTFE - shell
Seal material
EPDM
NBR
FKM
VMQ
Connection flanges
S G K/M Fl Cl -
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Operating instruction | KIESELMANN GmbH5 | Function and operation
10 / 25 4x3x_TWBV_EN
5 Function and operation
5.1 Description of function
The Three way ball valve is a distribution valve with the function of the valve is the opening or clos-
ing of several pipes to divert the flow. The possible assembly-line ways in dependence of the stop
functions linked with it are shown in the table as valve positions.
Valve positions L - ball
Valve position 1
Connection A - C open
Connection B closed
- Basic positon -
Valve position 2
Connection A - B open
Connection C closed
A
CB
A
CB
Valve positions T -ball
Valve position 1
Connection B - C open
Connection A closed
- Basic positon -
Valve position 2
Connection A - C open
Connection B closed
A
CB
A
CB
Valve position 3
Connection A - B - C open
Valve position 4
Connection A - B open
Connection C closed
A
CB
A
CB
Functional description for valves with manual operation
When actuating a fitting manually, the respective switching position will be locked in place in the fi-
nal position. The desired valve position can be positioned in 90° steps by a rotary movement by
means of a hand lever strength in a swivelling angle of 360 °.
Before operation, unlock the final position lock by lifting the notch lever against the hand lever. By
letting go of the notch lever in the respective final position the spring-loaded notch lever will latch
back by itself to the final position lock.
Description of function for pneum. valves
By means of a pneum. multiturn actuator, the valve ball is rotated by a 90° rotary movement.
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KIESELMANN GmbH | Operating instruction Function and operation | 5
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Description of function for pneum. valves
The valve opens and closes by way of a pneum. multiturn actuator with a rotary movement of 90°.
normal closed (NC)
• pneum. OPERATED
• not pneum. OPERATED
opens the valve
spring force closes the valve
normal open (NO)
• pneum. OPERATED
• not pneum. OPERATED
closes the valve
spring force opens the valve
double acting (DA)
• pneum. OPERATED the valve opens or closes according to control
5.2 Control system and position indication
Retrofitting to end position feedback for manually operated valves
By replacing the hand lever and the catch disc the valve can be retrofitted for end position feedback
(proximity switch).
Conversion from manual operation to pneumatic actuation
By a simple retrofitting operation the valve can be converted to pneumatic actuation. The rotary ac-
tuator for this purpose is supplied complete with fitting device. The following actuators are avail-
able, depending on the desired actuating function.
Nominal dia-
meter
Pneum. actu-
ator
air open - air close (DA) Normally closed (NC)
DN25 - DN80
1“ - 3“
PDA 90/100 4100 080 100-022 4200 080 100-022
DN 100
DN 4“
PDA 90/125 4100 100 125-022 4200 100 125-022
Position indicator with sensor mounting for feedback signal.
The actuator is equipped with a proximity switch mounting (sensor mounting) and a position indica-
tion. When inductive proximity initiators M 12x1 are installed, the current "Open" or "Shut" position
can be interrogated. By screwing the proximity initiator to the limit position the required switching
gap for the signal transmission is established.. When the valve is closed the position indication is
oriented vertically to the direction of valve passage. When the valve is open it is oriented parallel to
the valve passage.
Feedback unit -optional-
Optionally, modular valve control head systems can be installed to the actuator for reading and ac-
tuating valve positions. The standard version is a closed system with SPS or ASI-bus switch-on
electronics, and integrated 3/2-way solenoid valves. For tough operating conditions we recommend
employing a high-grade steel cover.
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Operating instruction | KIESELMANN GmbH6 | Commissioning, service and maintenance
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6 Commissioning, service and maintenance
6.1 Commissioning
6.1.1 Installation instructions
For ball valves without leakage outlet, the installation position is without importance.
Ball valves with leakage outlet must always be installed vertically to ensure that outflow of leakage,
or of cleaning medium, from the valve is such that no residue will remain inside the valve.
For valves which are to be welded in on both sides, a releasable connection has to be fitted into the
pipework to allow dismounting (maintenance).
6.1.2 General welding guidelines
Sealing elements integrated in weld components must generally be removed prior to welding. To
prevent damage, welding should be undertaken by certified personnel (EN ISO 9606-1). Use the TIG
(Tungsten Inert Gas) welding process.
CAUTION
Damage and injuries due to high temperature supply
To avoid a distortion of the components, all welding parts must be welded to stress-relieved.
Allow all components to cool before assembling.
NOTICE
Damage due to impurities
Impurities can cause damage to the seals and seals area.
Clean inside areas prior to assembly.
6.1.3 ATEX - Guidelines
For valves or plants/installations that are operated in the ATEX area, sufficient bonding (grounding)
must be ensured (see valid ATEX Guidelines EG).
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KIESELMANN GmbH | Operating instruction Commissioning, service and maintenance | 6
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6.2 Service
RECOMMENDATION
Replacement of seals
To achieve optimal maintenance cycles, the following points must be observed!
– When replacement of seals, all product-contacting seals should be replaced.
– Only original spare parts may be installed.
Maintenance interval
The maintenance intervals depend on the operating conditions "temperature, temperature-intervals,
medium, cleaning medium, pressure and opening frequency". We recommend replacing the seals 2-
year cycle.The user, however should establish appropriate maintenance intervals according to the
condition of the seals.
Lubricant recommendation
EPDM; HNBR; NBR; FKM; k-flex - Klüber Paraliq GTE703*
Silicone - Klüber Sintheso pro AA2*
Thread - Interflon Food*
*) It is only permitted to use approved lubricants, if the respective fitting is used for the produc-
tion of food or drink. Please observe the relevant safety data sheets of the manufacturers of lub-
ricants.
6.3 Cleaning
In order to ensure continuous flawless function during operation, the surfaces between the valve
body and the ball must be cleaned.
Open and close the valve several times from the open position. With an angle of rotation of ≥ 20°,
cleaning fluid flows into the area between the ball and casing. A time-dependent actuation in the
angle of rotation range 20°-45° makes the cleaning process more efficient. The duration and the
number of actuations should be adjusted according to the type of dirtying and the degree of dirty-
ing.
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Operating instruction | KIESELMANN GmbH7 | Technical data
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7 Technical data
Model: Three-way ball valve
Valve size: DIN: DN 25 - DN 80
Inch: DN 1“ - DN 3“
Connections: Welded end (S) DIN EN 10357
Thread (G) DIN 11851
Flange connection (Fl)
Clamp connection (Cl)
Liner/nut (K/M) DIN11581
Temperature range: Ambient (air) +4° to +45°C
Operating (medium dependent) +0° to +95°C
Sterilization (SIP 30 min) EPDM +140°C
PTFE +130°C
NBR +100°C
FKM +140°C
Pressure range: Working pressure:
Cleaning pressure:
10 bar
3 bar
Leak rate: A (DIN EN 12266-1)
Control air: Control air pressure:
5,5 - 8,0 bar
Quality of control air:
ISO 8573-1 : 2001 quality class 3
Materials:
(in product contact)
Stainless steel: 1.4301 / AISI304
1.4404 / AISI316L
Surfaces: Ra < 0,8µm e-polished
Sealing material: EPDM / PTFE
NBR / PTFE
FKM / PTFE
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KIESELMANN GmbH | Operating instruction Disassembly and assembly | 8
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8 Disassembly and assembly
8.1 Disassembly
NOTICE
All threaded joint have right-hand thread.
Unscrew and remove control air, steam resp. cleaning lines and electrical lines, complete feedback
unit or control head.
Remove the ball valve completely from the housing.
Replacing the housing seals (3), (5), (6), (19)
• Unscrew the flange (4) (2x), (17) and (18).
• Dismantle the O-rings (5)(2x), (6)(4x), (19)(2x) and thrust collar (3)(4x).
• Remove the ball (2) out of the housing (1).
Replacing the sealing package (10), (11), (12)
Ball valve - manual operation
M
10
11
9
8
7
• Unscrew the screw (20) and remove the hand lever (21).
• Unscrew the screw (16) and remove the locking disc (8).
• Remove the plain bearing (14) and the pressure spring (13) from the axis (7).
• Dismantle the axis (7) with sliding ring (9) downwards.
• Take the sealing package (10/11/12) out of the housing (1).
Replacing the sealing package (10), (11), (12)
Ball valve - pneum. operation
• Unscrew the screws (22) and remove the pneum. actuator (26) with the square boss (25).
• Unscrew the screws (24) and remove the angle bracket (23).
• Remove the plain bearing (14) and the pressure spring (13) from the axis (7).
• Dismantle the axis (7) with sliding ring (9) downwards.
• Take the sealing package (10/11/12) out of the housing (1).
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Operating instruction | KIESELMANN GmbH8 | Disassembly and assembly
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8.2 Assembly
• Before installation, thoroughly clean and slightly lubricate mounting areas and running sur-
faces.
• Assemble in reverse order.
NOTICE
Instructions d'installation
Mount the sealing package (10/11/12) in the sequence shown under view.
b) Push the bearing ring (10), the V-rings (11) (3x) and the thrust collar (12) with the mounting
sleeve (M) into the limit stop.
c) When mounting the ball (2) and the axis (7), regards for exact match from the marks on the axis
(7) and the position of the ball (2).
d) The mark points (MP) on the switch axis correspond to the respective ball openings.
e) Mount the hand lever or the pneumatic actuator according of the valve functions.
MP
M
10
11
9
8
7
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KIESELMANN GmbH | Operating instruction Drawings and dimensions | 9
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9 Drawings and dimensions
9.1 Control units
Control head KI-TOP Position indication
with sensor mounting
Plastic hood
transparent
stainless steel hood
129
Ø 105
25,5
Position indication with sensor mounting (R)
• R1 = dog
• R1.1 = Straight pin
• R2 = Position indication
• R3 = O-ring
• R4 = Screw
• R5 = Sensor mounting
• R6 = Cap
• R7 = Screw
• LA = air supply
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Operating instruction | KIESELMANN GmbH9 | Drawings and dimensions
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9.2 Drawings
• Example: Ball valve, T-ball with male part flange
1 = Housing
2 = Ball (L,T)
3a = Thrust collar
3b = Filling element
4 = Flange
5 = O-rings
6 = O-rings
7 = Axis
8 = Locking disc
9 = Sliding ring
10 = Backup ring
11 = V-ring package
12 = Thrust collar
13 = Pressure spring
14 = Sliding ring
15 = Straight pin
16 = Screw
17 = Blind flange
18 = Flange
19 = O-ring
20a = Saucer-head screw
20b = Screw
21a = Hand lever GFK
21b = Hand lever stainless
steel
22 = Screws
23 = Holding flange
24 = Screws
25 = Square boss
26 = Actuator
M = Mounting sleeve
S = Control head
R = Sensor mounting
R1 = dog
R2 = Position indication
R3 = O-ring
R4 = Screw
R5 = Sensor mounting
R6 = Cap
R7 = Screws
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KIESELMANN GmbH | Operating instruction Drawings and dimensions | 9
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Exploded drawing
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Operating instruction | KIESELMANN GmbH9 | Drawings and dimensions
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9.3 Dimensions
rinsable heatable Lever Lever with sensor
mounting
DN d1 d2 d3 d4 d5 dLK L1 L2 L3 L4 L5 L6 L7 L8 d■
25
1“
26
22.1
Rd52x1/6 104 50.5
50.5
80 65 303 118 64 75 74.5 77 165 180 10
32
-
32
-
Rd58x1/6 104 50.5
50.5
86 71 314 124 70 84 80.5 83 165 180 10
40
1½“
38
34.8
Rd65x1/6 104 50.5
50.5
92 77 319 129 80 95 90.5 93 165 180 10
50
2“
50
47.5
Rd78x1/6 104 64
64
108 92 328 138 85 103 96.5 99 165 180 10
65
2½“
66
60.2
Rd95x1/6 104 91
77.5
130 110 342 152 100 122 118
-
114 165 180 10
80
3“
81
72.1
Rd110x1/4 129 106
91
146 126 401 194 115 141 132
149
128 - 285 14
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