Installation, Operation, Maintenance Instructions
Standard Valves
Series 035 000 Globe Valves
Series 031 000 Angle Valves
Flow Control Division
Kammer Control Valves
Index
1 Using Kämmer valves and actuators correctly.
2 Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Disassemble and assemble valve
8Trouble-shooting chart
1 USING KÄMMER VALVES AND ACTUATORS
CORRECTLY
1.1 General
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Kämmer products. Product users and
maintenance personnel should thoroughly review this
bulletin prior to installing, operating or performing
any maintenance.
DANGER:
are designed for specific applications (e.g. with regard
to medium, pressure, temperature). For this reason
they should not be used in other applications without
first contacting the manufacturer.
1.2 Terms concerning safety
The safety terms DANGER, WARNING, CAUTION and
NOTE are used in these instructions to highlight
particular dangers and/or to provide additional
information on aspects that may not be readily
apparent.
DANGER:
and/or substantial property damage will occur if
proper precautions are not taken.
STOP!
WARNING:
and/or substantial property damage can occur if
proper precautions are not taken.
CAUTION:
or property damage can occur if proper precautions
are not taken.
In most cases Kämmer valves and actuators
indicates that death, severe personal injury
indicates that death, severe personal injury
indicates that minor personal injury and/
NOTE:
information, which may not be very obvious even to
qualified personnel. Compliance with other, not
particularly emphasised notes, with regard to
transport, assembly, operation and maintenance and
with regard to technical documentation (e.g. in the
operating instruction, product documentation or on
the product itself) is essential, in order to avoid faults,
which in themselves might directly or indirectly cause
severe personal injury or property damage.
1.3 Protective clothing
Kämmer products are often used in problematic
applications (e.g. extremely high pressures, dangerous, toxic or corrosive mediums). In particular
valves with bellows seals point to such applications.
When performing service, inspection or repair
operations always ensure, that the valve and actuator
are depressurised and that the valve has been cleaned
and is free from harmful substances. In such cases
pay particular attention to personal protection
(protective clothing, gloves, glasses etc.).
1.4 Qualified personnel
Qualified personnel are people who, on account of
their training, experience and instruction and their
knowledge of relevant standards, specifications,
accident prevention regulations and operating
conditions, have been authorised by those responsible
for the safety of the plant to perform the necessary
work and who can recognise and avoid possible
dangers.
1.5 Installation
DANGER:
serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.
Do not insulate extensions that are provided for hot
or cold services.
Pipelines must be correctly aligned to ensure that the
valve is not fitted under tension.
indicates and provides additional technical
Before installation check the order-no,
KMEIM3501-00 - 08.03
1
Flow Control Division
Kammer Control Valves
1.6 Spare parts
Use only Kämmer original spare parts. Kämmer
cannot accept responsibility for any damages that
occur from using spare parts or fastening materials
from other manufactures. If Kämmer products
(especially sealing materials) have been on store for
longer periods check these for corrosion or deterioration before using these products. Fire protection for
Kämmer products must be provided by the end user.
1.7 Service / repair
To avoid possible injury to personnel or damage to
products, safety terms must be strictly adhered to.
Modifying this product, substituting nonfactory parts,
or using maintenance procedures other than outlined
in this instruction could drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties. Between actuator and
valve there are moving parts. To avoid injury
Flowserve provides pinch-point-protection in the form
of cover plates, especially where side-mounted
positioners are fitted. If these plates are removed for
inspection, service or repair special attention is
required. After completing work the cover plates must
be refitted.
Apart from the operating instructions and the
obligatory accident prevention directives valid in the
country of use, all recognised regulations for safety
and good engineering practices must be followed.
WARNING:
STOP!
for repair or service Kämmer must be provided with
Before products are returned to Kämmer
a certificate which confirms that the product has been
decontaminated and is clean. Kämmer will not accept
deliveries if a certificate has not been provided (a form
can be obtained from Kämmer).
1.8 Storage
In most cases Kämmer Products are manufactured
from stainless steel. Products not manufactured from
stainless steel are provided with an epoxy resin
coating. This means that Kämmer products are well
protected from corrosion. Nevertheless Kämmer
products must be stored adequately in a clean, dry
environment. Plastic caps are fitted to protect the
flange faces to prevent the ingress of foreign
materials. These caps should not be removed until
the valve is actually mounted into the system.
1.9 Valve and actuator variations
These instructions cannot claim to cover all details
of all possible product variations, nor in particular
can they provide information for every possible
example of installation, operation or maintenance.
This means that the instructions normally include only
the directions to be followed by qualified personal
where the product is being used for is defined
purpose. If there are any uncertainties in this respect
particularly in the event of missing product-related
information, clarification must be obtained via the
appropriate FLOWSERVE sales office.
2 UNPACKING
2.1 Each delivery includes a packing slip. When unpacking, check all delivered valves and accessories using
this packing slip.
2.2 Larger valves can be lifted using slings on the yoke
rods or, if present, on the lugs provided for this purpose. If slings are used, attach them so that the outer
tubing or attaching parts are not damaged.
WARNING:
of gravity of the valve may be above the lifting point.
STOP!
If slings are used, be aware that the centre
In this case, secure or support the valve against rotating, to prevent damage or personnel injury.
2.3 Report transport damage to the carrier immediately.
2.4 In case of discrepancies, contact your nearest
FLOWSERVE sales office.
3 INSTALLATION
3.1 Clean tubing prior to installing.
3.2 If possible, install the valve in an upright position (actuator on top), to ease maintenance. An upright installation position is important with low-temperature
applications, in order to keep the distance between
the packing material and the medium as large as possible. The packing material then retains the ambient
temperature as much as possible.
NOTE:
Do not insulate extension bonnets that are pro-
vided for hot or cold services
3.3 Make sure that sufficient overhead clearance above
the actuator is maintained, to allow for disassembly
of plug from the valve body (see following table).
Actuator Clearance Actuator Clearance
size (mm) size (mm)
37/47 95 P2 140
38/48 140 P3 140
39/49 140 P4 140
39D/49D 140 P5 140
3.4 After installing, check direction of flow again. The direction of flow is shown by the arrow on the housing.
3.5 If the valve is to be welded into the line, make sure
that the valve is shielded from excessive heat.
3.6 Connect supply pressure and signal lines. Control
valves are supplied with a positioner. The end connections for supply pressure and signal are clearly
marked. Actuator and positioner are suitable for max.
4.2 bar (60 psi) supply pressure. If the supply pres-
2
Flow Control Division
Kammer Control Valves
sure exceeds the pressure specified on the nameplate,
a pressure reducing station is required. If instrument
air is not available, install an oil separator/air filter in
the air inlet line. All connections must be leak free.
4 QUICK CHECK:
Before operating, check the valve as follows:
4.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.
4.2 Check for maximum stroke through change of signal
(for pneumatic positioners, 0.2 - 1.0 bar or corresponding split-range values; for IP positioners, 4-20
or 0-20 mA).
4.3 Check all air connections for leaks.
4.4 Tighten packing nut (see table 1).
Torque
Thread PTFE Grafoil
M20 x 1,5 1 3
M30 x 1,5 6 15
M38 x 1,5 15 35
M45 x 1,5 17 40
Table 1
NOTE:
An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
5.2 Check bellows gasket and test connection - if present - for
external leaks.
5.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
5.4 Clean valves and repaint as necessary.
Warning:
STOP!
clean the actuator/valve with a damp cloth only.
To prevent a buildup of electrostatic charge
5.5 Check gland nut for correct torque (see table 1)..
NOTE:
An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
5.6 If possible, open and close valve and check for maximum stroke and smooth movement of the plug stem.
Irregular movement of the plug stem may indicate
internal defects.
NOTE: With graphite packing, irregular movement of
the plug stem is normal.
WARNING:
STOP!
all moving parts. Failure to do so can lead to serious
Keep hands, hair, clothing, etc. away from
injury.
5.7 Check all accessories for firm seating.
5.8 If possible, close supply pressure and check the failsafe position.
5.10 Check stem boot for wear.
4.5 Check fail-safe position. To do this, close supply pressure and observe whether the valve opens or closes
as defined.
4.6 After use at fluctuating temperatures, re-tighten all
bolt connections and check for leaks.
5 MAINTENANCE
Check valves for correct functioning at regular
intervals (at least once every 6 months) as follows.
This check can be made when installed and in many
cases without interrupting production. If internal
defects are suspected, see section „Disassembly and
Assembly of Valve“.
5.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).
5.11 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
5.12 Clean plug stem.
5.13 Check air filter, if present, and if necessary replace
insert.
Note:
For further information regarding service and
maintenance please contact your nearest
FLOWSERVE office.
DANGER:
On actuators with aluminium cases the
actuator springs must be renewed with original spare
parts every 10 years or after 50.000 operating hours
which ever occurs first.
3
Flow Control Division
Kammer Control Valves
Cap
Travel indicator
Yoke plate
Yoke nuts
Zero adjustment locknut
Actuator stem
Locknuts
Gland nut
Clamping nut
Plug stem
Actuator series 4
Fig. 1
Coupling
Coupling screws
Coupling insert
Locknut
Yoke plate
Yoke nuts
Actuator series 2
Fig. 1a
4
6 REMOVE AND INSTALL ACTUATOR
Flow Control Division
Kammer Control Valves
General Information
We recommend separating the actuator from the
valve during all repair work. However, many maintenance and adjusting operations can be carried out
in an installed condition.
6.1 Remove series 4 actuator
(see Fig 1 + 2)
For series 2 actuator see 3.3
6.1.1 Shut off air supply.
DANGER:
Depressurise the line to atmospheric
pressure and drain all fluids from the valve before
working on the actuator. Failure to do so can cause
serious injury.
6.1.2 As required remove any outside tubing.
For actuators with spring-to-close, go to 3.1.1
For actuators with spring-to-open, go to 3.1.2
6.1.3 Remove cap and nameplate. Tighten zero adjusting
nut until it just touches the surface of the spring housing. This relieves the plug from actuator spring pressure. If the actuator is fitted with a handwheel this
can be used to relieve the plug from actuator spring
pressure.
6.1.4 Using a wrench, secure the actuator stem against turning and using a second wrench loosen the stem locknuts. If the actuator is fitted with a coupling refer to
the procedure described in the maintenance instructions for the I/P actuator.
NOTE: T
he actuator stem must not be rotated, as this
will cause damage to the diaphragm.
6.1.5 Loosen gland and clamp nuts.
6.1.6 Secure plug stem against turning and unscrew actuator from plug stem by rotating counter-clockwise.
NOTE:
Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable damage to the seating faces.
6.1.7 Remove actuator and remove at the same time locknut, travel indicator disc, gland nut and clamp nut.
6.2 Install series 4 actuator
Information:
• Before the actuator is installed, it must be calibrated according to section 8 of the instructions
„Pneumatic and Electro-pneumatic Actuators“.
• All worn or damaged parts must be replaced.
Reusable parts must be clean.
6.2.1 Position actuator with clamp nut, gland nut, locknuts
and travel indicator disc on the valve.
6.2.2.1 Only for „spring-to-close“ actuators:
Screw actuator onto plug stem by rotating clockwise,
until the yoke plate just touches the valve housing and
the actuator is aligned forward. If the actuator is fitted with a coupling refer to the procedure described
in the maintenance instructions for the I/P actuator.
NOTE:
Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable damage to the seating faces.
6.2.2.2 Only for „spring-to-open“ actuators:
Lift plug stem and screw it into the lower coupling
half until the distance between „plug in seat“ and
„plug raised“ approximately corresponds to the specified stroke.
6.2.3 Tighten clamp nut and gland nut.
6.2.4 Adjust seat tightness by screwing/unscrewing the
plug stem in/out of the actuator stem.
NOTE:
Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable damage to the seating faces. Open valve, make adjustment, close valve and check for leaks. If the valve is
fitted with a bellows seal the plug stem may NOT be
rotated at all. In the case of a bellows seal adjustments are made with the coupling.
6.2.5 After adjusting, secure the locknuts and the travel
indicator disc lying between them against actuator
stem and align the travel indicator on the yoke rod.
6.3 Remove series 2 actuator
(see Fig. 1a)
For series 4 actuator see 3.1
6.3.1 Shut off air supply.
DANGER:
Depressurise the line to atmospheric
pressure and drain all fluids from the valve before
working on the actuator. Failure to do so can cause
serious injury.
6.3.2 Disconnect all tubing.
6.3.3 Remove 2 screws and remove coupling.
6.3.4 Remove yoke rod retaining nuts and lift actuator
assembly from the valve.
6.3.5 Remove coupling insert and it’s locknut from plug
stem.
NOTE:
Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable
damage to the seating faces.
6.4 Install series 2 actuator
(see Fig. 1a)
The actuator stem must be fully extended:
Actuators with air-to-open action must be fully
vented. Actuators with air-to-close action apply
supply pressure.
Manually depress the plug stem to ensure the plug
is fully seated.
6.4.1 Screw coupling insert locknut and coupling insert as
far as possible onto plug stem.
6.4.2 Place the actuator assembly on the valve engaging
the yoke rod threads in the lower yoke plate and
ensuring the actuator faces in the correct direction.
5
Locknut
Gland nut
Packing follower
Clamping nut
Nut
Bonnet
Bolt/stud
(depends on design)
Flow Control Division
Kammer Control Valves
Packing kit see
spare parts list
Gasket
Body
Trim see
spare parts list
Fig. 2
Bore for
hooked spanner
Bore for adjustable
face pin tool
Fig. 3
6
Flow Control Division
Kammer Control Valves
6.4.3 Unscrew the coupling insert until the yoke rods are
raised from the lower yoke plate by around 2 mm.
NOTE:
Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable
damage to the seating faces.
6.4.4 Refit the coupling, ensuring that the arrows,
embossed on the coupling halves, point upward
towards the actuator, and secure with 2 retaining
screws.
6.4.5 Apply supply pressure resp. vent actuator to half stroke
and refit and tighten yoke rod retaining nuts (15).
6.4.6 Connect all tubing.
7 DISASSEMBLE AND ASSEMBLE VALVE
7.1 Disassemble Valve
(see Fig. 2)
7.1.1 Remove bonnet flange bolting and raise bonnet and
plug assembly.
NOTE:
heavy assemblies may require a hoist
7.1.2 Unscrew seat ring using seat ring tool and carefully
press plug stem evenly out of the upper body.
7.1.3 With valves DN 80 / kv 63 and larger, the plug head
can be unscrewed (see Fig. 3). Remove plug head
from stem by securing valve stem against rotation
with a hooked spanner and turning plug head with
an adjustable face pin tool.
7.1.3 Check seating faces of seat ring and plug for dam-
age. Gasket surfaces must be clean and free of damage.
7.1.4 Press guides, packing and packing follower from
below using a drift (the drift must have a slightly
larger diameter than the plug stem).
NOTE:
To prevent damage to the plug or plug stem,
follow the above instructions precisely.
7.1.5 If a seat surfaces need re-machining, seat and plug
seating surfaces must be reworked. The seat angle
on the plug is 30°, on the seat ring 25°. If the valve is
correctly assembled, lapping is not required.
NOTE:
When re-machining the plug, protect plug
stem from damage. The seat surface must be concentric to the plug stem. When re-finishing the seat,
the seat surface must be concentric to the seat outer
diameter.
7.2 Assemble Valve
(see Fig. 2)
7.2.1 All worn or damaged parts must be replaced. Reusable parts must be clean. Expendable parts such as
gaskets, packing and O-rings should always be replaced.
7.2.2 Insert seat ring and tighten. For torques, see following table:
Size Body Torque
material
DN 15/25 (1/2 /1") 1.4581 cast 125 Nm
1.4571 forged 125 Nm
DN 40/50 (1 1/2 /2") 1.4581 200 Nm
1.4571 255 Nm
DN 80 (3") 1.4581 230 Nm
1.4571 270 Nm
DN 100 (4") 1.4581 400 Nm
1.4571 500 Nm
DN 150 (6") 1.4581 450 Nm
1.4571 600 Nm
7.2.3 If necessary, screw plug head back on to stem and
carefully guide plug stem through the bonnet, to avoid
damage.
7.2.4 Insert new bonnet gasket.
7.2.5 Position bonnet slowly and absolutely upright on
body, to avoid damage to seat/plug.
7.2.6 Tighten bonnet flange bolts alternating crosswise finger-tight and then tighten with a wrench. For torques,
see following table:
Hex bolt. Waisted bolt Studs
Thread DIN 933 DIN 2510 DIN 939
A2-70 1.7709 1.7258 CK 35
M 8 20 Nm – – –
M 10 35 Nm – – 20 Nm
M 12 60 Nm 44 Nm 36 Nm 35 Nm
M 16 145 Nm 115 Nm 92 Nm 80 Nm
M 20 280 Nm – – –
M 24 250 Nm – – 270 Nm
7.2.7 Replace packing by inserting packing rings one at a
time tapping each one down with a suitable bushing.
NOTE:
ensure that the gaps in the packing rings are
distributed evenly around the circumference in the
packing box (gaps not in line).
Different packings and fitting sequencess are shown
in the spare parts list.
7.2.8 Insert packing follower. Fit gland nut for transport
purposes only. Gland nut to be fitted correctly and
tightened down when actuator is mounted (see table
1).
7
8 Trouble-shooting Chart
Fault Possible Cause Remedy
Stem motion 1. Packing excessively tightened 1. Tighten gland nut slightly more than „finger-tight“
impeded 2. Operating temperature too 2. Note operating data and contact dealer
high for selected trim
3. Supply pressure inadiquate 3. Check system for leaks in the supply pressure or signal lines. Retighten the connections, if necessary replace leaky lines
4. Positioner defective 4. See operating instructions for positioner
Excessive 1. Bonnet loose 1. See step 7.2.6 for correct tightening of bonnet.
leakage 2. Worn or damaged 2. Re-machine or replace seat ring/plug.
seat ring/plug
3. Gaskets damaged 3. Replace gaskets
4. Inadiquate actuator thrust 4. Check air feed. If air feed is OK, contact dealer.
5. Plug incorrectly adjusted 5. Correctly adjust plug according to step 6.2.4
6. Incorrect direction of flow 6. Check specification. Contact dealer
7. Handwheel incorrectly 7. Adjust handwheel
adjusted (acts like end stop)
Flow Control Division
Kammer Control Valves
Inadiquate flow 1. Plug incorrectly adjusted 1. Correctly adjust plug according to step 6.2.4
(short stroke)
2. Positioner defective 2. See operating instructions for positioner
3. Operating requirements 3. Check operating data. Contact dealer
too high
Plug slams 1. Plug adjustment incorrect 1. Correctly adjust plug according to step 6.2.4
2. Inadiquate supply pressure 2. Check supply pressure, seal leaks, remove blockage
3. Trim too large for 3. Replace trim
flow rate
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8
©09.2003 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation
All data subject to change without notice
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