1 Using Kämmer Valves And Actuators Correctly
2 Initial Installation
3. Trim Parts
4 Actuator
5 Identification
6 Spare Parts
7 Technical Tables
8 Trouble Shooting
Kämmer Series 341000 FCD KMENIM4104-01 03/18
1 USING KÄMMER VALVES AND ACTUATORS CORRECTLY
1.1 General
The following instructions are designed to assist in installing and performing maintenance as required on FLOWSERVE
Kämmer products. Product users and maintenance personnel should Thoroughly review this maintenance instruction prior
to installing and prior to performing any maintenance on the product.
DANGER: Please review also the general Installation and Operational Manual (IOM) for general safety instructions.
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: indicates that death, severe personal injury and / or substantial property damage will occur if proper precautions
are not taken.
WARNING: indicates that death, severe personal injury and / or substantial property damage can occur if proper precautions
are not taken.
CAUTION:indicates that minor personal injury and / or property damage can occur if proper precautions are not taken.
NOTE:indicates and provides additional technical information, which may not be very obvious even to qualified personnel.
Compliance with other, not particularly emphasized 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.
2
2 INITIAL INSTALLATION
2.1 Unpacking
2.1.1 Valve and Actuator are delivered separately. This
allows for more compact transport boxes and easier
installation. After unpacking the valve and actuator,
clearly mark the parts for proper assembly. The trim is
installed inside the valve body to avoid damage during
transport. To remove the trim assembly from the valve
please refer to section 3.1
Kämmer Series 341000 FCD KMENIM4104-01 03/18
2.1.2 Marking (figure 1)
Valve components have been marked with the serial
number in order to allow a proper disassembly and
assembly. The valve body is marked on top of the
cover plate (1.1), trim kit at the upper part of the
extension(1.2) and the bonnet on the side (1.3). All
relevant technical data is shown on a stainless steel
nameplate attached to the actuator. See also section 5
Identification.
2.2 Preparation for vacuum box installation (figure 2)
2.2.1 After trim has been removed from the valve body (see
chapter 3.1) mount the installation flange (2:1) on the
bonnet flange thread of the valve.
CAUTION:Please ensure that the mounting flange has
been tightened with the correct torque (see table 7.3).
2.2.2 Attach hoisting equipment of adequate lifting capacity
to the hoisting lug (3:1) and lower the valve body into
the vacuum box. See also table 7.2 for approximate
maximum weights of this subassembly.
1.1
1.3
1.2
Figure 1: Marking
2.1
Figure 2: Mounting Preparation
CAUTION: take care when lowering the valve
subassembly into the vacuum box.
Mounting (figure 3)
Insert the mounting Tool (3.1) between the valve
cover plate (3.2) and the mounting flange (3.3) before
reaching the final position inside the box.
3.2
3.3
3.1
Figure 3: Mounting
3
2.3 Welding
2.3.1 Pipe connections
Position the valve inside the vacuum box and secure it
with the mounting tool. The pipe connections for inlet
and outlet can now be welded.
NOTE:Ensure that the trim internals are removed and
that the mounting flange is the correct size.
For the standard pipe sizes refer to table 7.2 BW (mm).
2.3.2 Welding cover plate (figure 4)
Kämmer Series 341000 FCD KMENIM4104-01 03/18
With the mounting tool (4.1) in position tack weld the
cover plate to the vacuum box to secure it‘s position.
Rotating the mounting tool will provide space for the
tack welding.
NOTE:ensure the valve can move freely and is not
under tension while welding it to the vacuum box.
Damage to trim and trim guiding may occur.
Remove the mounting tool (4:1)and weld the entire
circumference of the cover plate to the vacuum tank.
2.4 Pressure testing
After welding all the valves into the vacuum tank
perform a pressure test with all valves. For this all
valves must be fitted with mounting flanges. This
mounting flange has a dual purpose: firstly it assists
in mounting the valves into the vacuum tank and
secondly to seal the valve at the bonnet connection in
order to pressurize the piping system without the trim
assemblies and actuators mounted.
CAUTION:Ensure all mounting flanges are in place and
properly tightened. A loose mounting flange cannot
sustain the pressure and will result in unwanted or
unsecure leakage.
4.1
Figure 4: Cover Plate Welding
2.5 Cleaning
With the mounting flanges in place, clean and purge the
entire piping system with a cleaning media to remove
dirt and welding residues from the system.
2.6 Remove mounting flanges (Figure 5)
After completing all tests, cleaning and mounting
procedures, remove all mounting flanges (5.1) and
spacer plates (5.2) from the valves. Flowserve Essen
offers a refund system for returning the mounting
flanges and mounting tools after use. For further details
please contact Flowserve Essen Order administration.
4
5.1
5.2
Figure 5: Remove Mounting Flange
3. TRIM PARTS
Kämmer Series 341000 FCD KMENIM4104-01 03/18
3.1 Remove Trim assembly
3.1.1 Remove actuator (See section 4)
3.1.2 Remove bonnet (figure 6)
3.1.3 Unscrew the bonnet (6.1) counter clockwise with a
suitable tool and carefully remove the bonnet from
the stem.
CAUTION:do not rotate the stem in any direction.
Severe damage to the bellows seal and/or the trim
assembly may occur.
3.1.4 Carefully remove the trim assembly (7.1) - consisting
of bellows seal, extension and plug - from the valve
housing (Figure 7)
CAUTION:do not rotate the trim assembly within the
valve body. Remove the trim assembly in an upright
position avoiding any contact of the trim assembly with
the valve housing. Severe damage of the bellows seal
and/or the trim assembly may occur.
6.1
Figure 6: Bonnet
7.1
Figure 7: Trim Assembly
3.2 Install Trim assembly (Figure 8)
3.2.1 Insert body O-Ring seal (8.1)
3.2.2 Carefully insert trim assembly (8.2) into valve housing.
CAUTION:do not rotate the trim assembly within the
valve body in any direction. Insert the trim assembly
in an upright position. Avoid any contact of the trim
assembly with the valve housing. Severe damage of
the bellows seal and/or the trim assembly may occur.
3.2.3 Bonnet assembly
(Figure 9)
Carefully place the bonnet (9.1) over the stem (9.2)
and tighten the bonnet clockwise with the suitable tool
to the correct torque (see table 7.3). Ensure that
the
wiper ring (9.3) seats correctly on the stem
8.2
9.3
8.1
Figure 8: Body O-Ring
9.1
9.2
Figure: 9 Bonnet assembly
5
3.3 Disassemble trim assembly (figure 11)
3.3.1 The trim assembly consists out of 3 parts: the stem
with bellows (11.1), the extension (11.2) and the plug
(11.3). All three components can be disassembled and
replaced individually. These parts are secured with pins
(11.4). To remove the pins carefully drive them out by
a suitable tool. When replacing one or more parts of
the assembly always use new pins (see spare parts
table) and make sure that they are in place and secure.
Kämmer Series 341000 FCD KMENIM4104-01 03/18
Figure 10: Trim Assembly
11.1
11.2
11.4
11.4
11.3
Figure 11: Trim Parts
6
4 ACTUATOR
Kämmer Series 341000 FCD KMENIM4104-01 03/18
4.1 KP Diaphragm Actuator
4.1.1 First Installation after unpacking (figure 12)
ColdFlow Series 341000 will be delivered in two parts:
valve subassembly and actuator. Especially for small
sizes the mounted actuator might cause damage to
the valve. Also for welding the valve into the vacuum
cold box actuator and trim must be removed from the
valve body.
Remove the locknut (12.1) from the valve bonnet.
Place the actuator with the installed yoke plate (12.2 )
onto the valve bonnet. Before connecting the coupling
(12.3) slip the locknut over the valve stem (12.4)
and screw the locknut onto the bonnet thread. For
tightening torques please refer to chapter 7.3
CAUTION:Be careful while placing the yoke plate over
the stem. Damage of the stem and/or the entire trim
assembly may occur.
NOTE: Make sure that the Serial Number of the valve
(engraved at the bonnet) and of the actuator (Tag plate)
correspond to each other.
4.1.2 Removing for repair or maintenance (figure 13)
12.1
12.4
Figure 12: Actuator Mounting
12.3
12.2
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.
4.1.2.1 Shut off air supply
4.1.2.2 Disconnect all air tubing from the actuator
4.1.2.3 Remove and install actuator (figure 14)
Typically for a quick removal of the actuator the 2 yoke
nut screws (14.1) are removed. After this remove the
coupling screws (14.2) from the coupling and take off
both coupling parts.
NOTE:If there are accessories such as positioners and/
or limit switches connected to the coupling, please
carefully disconnect the lever or if necessary the entire
accessory.
NOTE: Ensure that the plug assembly is not rotated
with the plug seated. This may cause irreparable
damage to the seating faces.
Figure 13: Actuator Assembly
14.2
14.1
14.1
Figure 14: Remove and install actuator
7
4.1.3 Install Actuator (figure 15)
The actuator stem must be fully extended:
Kämmer Series 341000 FCD KMENIM4104-01 03/18
Actuators with air-to-open action must be fully vented.
Actuators with air-to close action apply pressure.
Manually depress the plug stem to ensure the plug is
fully seated.
4.1.3.1 Screw coupling insert locknut (15.1) and coupling
insert (15.2) as far as possible onto plug stem (15.3)
4.1.3.2 Place the actuator assembly on the valve engaging the
yoke rod threads in the lower yoke plate (15.4) and
ensuring the actuator faces in the right direction.
4.1.3.3 Unscrew the coupling insert until the lower 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.
4.1.3.4 Refit the coupling (figure 16)
Refit the coupling (16.1), ensuring that the arrows
(16.2 ), embossed on the coupling halves, point upward
towards the actuator, and secure with 2 coupling
screws (16.3).
4.1.3.5 Apply supply pressure respectively vent actuator to
50% stroke and refit and tighten yoke nuts.
4.1.3.6 Connect all tubing.
15.3
Figure 15: Install Actuator
16.1
16.3
15.115.2
15.4
16.2
Figure 16: Refit the Coupling
8
4.2 FlowAct Actuator
4.2.1 First Installation (figure 17)
The FlowAct actuator is equipped with a casted yoke,
for all assembly and disassemble the entire actuator
including the yoke must be installed or removed.
Remove the locknut (17.1) from the valve bonnet. Place
the actuator and yoke assembly (17.2 ) onto the valve
bonnet. Before connecting the coupling (17.3 ) slip
the locknut over the valve stem (17.4 ) and screw the
locknut onto the bonnet thread. For tightening torques
please refer to chapter 7.3
CAUTION: Be careful while putting the yoke plate
through the stem. Damage of the stem and/or the
entire trim assembly may occur.
NOTE: Ensure that the serial sumber of the valve
(engraved at the bonnet) and actuator (Tag plate)
correspond to each other.
4.2.2 Removing for repair or maintenance
Kämmer Series 341000 FCD KMENIM4104-01 03/18
17.2
17.3
17.1
17.4
Figure 17: Actuator Mounting
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.
4.2.2.1 Shut off air supply
4.2.2.2 Disconnect all air tubing from the actuator
4.2.2.3 Remove actuator coupling (figure 18)
NOTE: If there are accessories such as positioners and/
or limit switches connected to the coupling, please
carefully disconnect the lever or if necessary the entire
accessory. Remove four screws (18.1) from the upper
coupling half.
4.2.2.4 Remove locknut (18.2)
NOTE: The lower coupling half is still connected to the
stem and can’t be removed from the actuator at this
stage.
4.2.2.5 Carefully raise the actuator assembly vertically around
40 mm. Be aware that most of the FlowAct actuators
are heavy, please use suitable lifting equipment.
4.2.2.6 Remove the lower coupling half (18.3) counter
clockwise from the stem.
18.1
18.2
18.3
Figure 18: Remove and install actuator
NOTE: Ensure that the plug assembly is not rotated with
the plug seated. This may cause irreparable damage
to the seating faces and/or the bellows seal.
9
4.2.3 Installation
The actuator stem must be fully extended. Actuators
with air-to-open action must be fully vented. Actuators
with air-to close action apply pressure. Manually
depress the plug stem to ensure the plug is fully
seated.
4.2.3.1 Using suitable lifting equipement, carefully place the
actuator onto the valve assembly. Before the actuator
is fully lowered slip the locknut onto the bonnet and
thread on the lower coupling half onto the stem.
4.2.3.2 Tighten the locknut. For tightening torques please refer
to chapter 7.3
4.2.3.3 Reinstall the coupling
4.2.3.4 Connect all tubing
Kämmer Series 341000 FCD KMENIM4104-01 03/18
Figure 19: Actuator Assembly
10
5 IDENTIFICATION
5.1 The complete valve assembly (valve plus actuator) are
clearly marked with the serial number.
CAUTION: Ensure that only parts of the same serial
number are assembled together. Serious damage of
the parts may occur.
Kämmer Series 341000 FCD KMENIM4104-01 03/18
Figure 20: Body Identification
Figure 21: Trim Identification
Figure 22: Bonnet Identification
11
6 SPARE PARTS
6.1 Miscellaneous parts
Kämmer Series 341000 FCD KMENIM4104-01 03/18
DNANSI
40.16“
60.25“
80.31“
100.39“
200.79“
251“
321.25“
401.5“
502“
652.5“
803“
1004“70-341KA0274.00
1255“70-341KA2274.00
1506“70-341KA5284.0070-S46031084ID 175 x 3,55
2008“70-341KB0284.0070-S46031086ID 225 x 4
Stem with bellowsPinO-Ring BellowsO-Ring Bellows Adapter
part #qtypart #part #Dimensionpart #Dimension
270-0100375A2
70-341B20471.00
270-0100376A2150.59“
70-341B50471.00270-0100380A270-S46031165ID 59,92 x 2,62
70-341K80271.00170-0100377A270-S46031024ID 104,37 x 3,53