1 General informations ....................................................................................................................................................4
1.1Informations for your safety ............................................................................................................................................... 4
1.2Marking of security instructions......................................................................................................................................... 4
1.3General designated use ......................................................................................................................................................4
2.1Intended use ........................................................................................................................................................................6
3 Delivery, transport and storage .....................................................................................................................................8
5 Function and operation ...............................................................................................................................................10
5.1Description of function......................................................................................................................................................10
5.2Control system and position indication ...........................................................................................................................11
6 Commissioning, service and maintenance ..................................................................................................................12
7 Technical data ............................................................................................................................................................14
8 Disassembly and assembly .........................................................................................................................................15
9 Drawings and dimensions ...........................................................................................................................................17
9.1Control units ......................................................................................................................................................................17
10 Wearing parts .............................................................................................................................................................20
10.1 Wear parts kit.....................................................................................................................................................................20
10.2 Spare parts list...................................................................................................................................................................21
11.1 Structure of Order Number ...............................................................................................................................................22
12.1 Declaration of incorporation.............................................................................................................................................24
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Operating instruction | KIESELMANN GmbH1 | General informations
1Gener a l i n for m ati o ns
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 advices contained in it. This guarantees reliable and safe operation of this product and your plant respectively. 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, handling 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 warranty. 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 instruction. 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.
SymbolSignal wordMeaning
DANGERImminent danger which will result severe personal injury or
death.
WARNINGImminent danger which may result severe personal injury or
death.
CAUTIONDangerous situation which may cause slight personal injury or
material damages.
NOTICEAn harmful situation which may result in damages of the product
itself or of adjacent vicinity.
INFORMATIONMarks 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 cannot 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 instructions.
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 qualified personnel to make electrical connections.
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 instructions given in the operating manual, please observe the relevant accident prevention regulations, generally accepted safety regulations, regulations effective in the country of installation,
working and safety instructions effective in the user's plant.
Straight-way ball cocks are used as a shut-off valve in units of the beverage and food industry, the
pharmacy, the biotechnology as well as the chemical industry.
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 technical 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, components 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.
Before starting the system, the entire pipeline system must be thoroughly cleaned.
CAUTION
Steps should be taken to ensure that no external forces are exerted on the fitting.
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Page 8
Operating instruction | KIESELMANN GmbH3 | Delivery, transport and storage
3Deliv e ry, tra n spo r t a n d s t ora g e
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 prevention 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 (optimal indoor temperature: 25 C ±5; indoor humidity data 70% ±5%).
• Protect seals, bearings and plastic parts for UV light and ozone.
Operating instruction | KIESELMANN GmbH5 | Function and operation
ABAB
90°
5Funct i on a nd o per a tio n
5.1 Description of function
Straight-way ball cocks are used as a piggable shut-off valve.
Open or close the valve by turning the pneum. controlled rotary drive by 90°.
Functional description for valves with manual operation
When actuating a fitting manually, the respective switching position will be locked in place in the final position. The manually operated lever is positioned at an angle of 90°in transverse direction to
the conduit axis in closed position The lever is positioned in the direction of the conduit axis in
open position.
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. The position of the hand lever indicates whether the valve is
opened or closed. It will be opened, if the valve points in the direction of the pipe axle – it will be
closed, if the valve is positioned crosswise to the pipe axle. The possible assembly-line ways in dependence of the stop functions linked with it are shown in the as valve positions.
Valve positions
Valve position 1
Connection A - B open
Valve position 2
Connection A - B closed
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
normal open (NO)
• pneum. OPERATED
• not pneum. OPERATED
double acting (DA)
• pneum. OPERATEDthe valve opens or closes according to control
opens the valve
spring force closes the valve
closes the valve
spring force opens the valve
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KIESELMANN GmbH | Operating instructionFunction and operation | 5
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 actuator for this purpose is supplied complete with fitting device. The following actuators are available, depending on the desired actuating function.
Nominal diameter
DN25 - DN80
1“ - 3“
DN 100
DN 4“
Pneum. actu-
ator
PDA 90/1004100 080 100-0224200 080 100-022
PDA 90/1254100 100 125-0224200 100 125-022
air open - air close (DA)Normally closed (NC)
Position indicator with sensor mounting for feedback signal.
The actuator is equipped with a proximity switch mounting (sensor mounting) and a position indication. 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 actuating 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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Page 12
Operating instruction | KIESELMANN GmbH6 | Commissioning, service and maintenance
6Commi s sio n ing , se r vic e an d ma i nte n anc e
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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Page 13
KIESELMANN GmbH | Operating instructionCommissioning, service and maintenance | 6
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
half-yearly cycle The user, however should establish appropriate maintenance intervals according
to the condition of the seals.
*) It is only permitted to use approved lubricants, if the respective fitting is used for the production of food or drink. Please observe the relevant safety data sheets of the manufacturers of lubricants.
6.3 Cleaning
In order to ensure continuous hygienic conditions 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 dirtying.
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Page 14
7Techn i cal dat a
Model:Straight-way ball valve
Valve size:DIN: DN 25 - DN 100
Connections:Welded end (S) DIN EN 10357
Temperature range:Ambient (air)+4° to +45°C
Operating instruction | KIESELMANN GmbH7 | Technical data
Inch: DN 1“ - DN 4“
Thread (G) DIN 11851
Flange connection (Fl)
Clamp connection (Cl)
Liner/nut (K/M) DIN11581
Operating (medium dependent)
Sterilization (SIP 30 min)EPDM +140°C
+0° to +95°C
PTFE +130°C
NBR +100°C
FKM +140°C
VMQ +90°C
Pressure range:Working pressure:
Cleaning pressure:
Leak rate:A (DIN EN 12266-1)
Control air:Control air pressure:
5,5 - 8,0 bar
Materials:
(in product contact)
Stainless steel:1.4301 / AISI304
Surfaces:Ra < 0,8µm e-polished
Sealing material:EPDM / PTFE
16 bar
3 bar
Quality of control air:
ISO 8573-1 : 2001 quality class 3
1.4404 / AISI316L
NBR / PTFE
FKM / PTFE
VMQ / PTFE
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Page 15
KIESELMANN GmbH | Operating instructionDisassembly and assembly | 8
M
10
11
9
8
7
8Disas s emb l y a n d a s sem b ly
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 (12), (13), (14)
• Unscrew the flange (2).
• Dismantle the O-rings (13), (14) and thrust collar (12).
• Put the ball cock in the closed position and remove the ball (3) out of the housing (1).
Replacing the sealing package (6) - (10)
Ball valve - manual operation
• Unscrew the screw (18) and remove the hand lever (19).
• Unscrew the screw (16) and remove the locking disc (5).
• Remove the plain bearing (10) and the pressure spring (11) from the axis (4).
• Dismantle the axis (4) with sliding ring (6) out of the housing (1) downwards.
• Take the sealing package (7/8/9) out of the housing (1).
Replacing the sealing package (6) - (10)
Ball valve - pneum. operation
• Unscrew the screws (20) and remove the pneum. actuator (24) with the square boss (23).
• Unscrew the screws (22) and remove the angle bracket (21).
• Remove the plain bearing (10) and the pressure spring (11) from the axis (4).
• Dismantle the axis (4) with sliding ring (6) out of the housing (1) downwards.
• Take the sealing package (7/8/9) out of the housing (1).
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Page 16
Operating instruction | KIESELMANN GmbH8 | Disassembly and assembly
MP
M
10
11
9
8
7
8.2 Assembly
• Before installation, thoroughly clean and slightly lubricate mounting areas and running surfaces.
• Assemble in reverse order.
NOTICE
Instructions d'installation
Mount the sealing package (7/8/9) in the sequence shown under view.
b) Push the bearing ring (7), the V-rings (8) (3x) and the thrust collar (9) with the mounting sleeve
(M) into the limit stop.
c) When mounting the ball (3) and the axis (4), regards for exact match from the marks on the axis
(4) and the position of the ball (3).
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.
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Page 17
KIESELMANN GmbH | Operating instructionDrawings and dimensions | 9
129
Ø 105
25,5
9Drawi n gs a nd d ime n sio n s
9.1 Control units
Control head KI-TOPPosition indication
with sensor mounting
Plastic hood
transparent
Stainless steel hood
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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Page 18
9.2 Drawings
24
18a19a
16
5
A
23
22
21
20
172 13 12a 1414
6
12b1721212a1412b3
15
M
10
11
9
8
7
A
1 = Housing
2 = Flange
3 = Ball
4 = Axis
5 = Locking disc
6 = Sliding ring
7 = Backup ring
8 = V-ring package
9 = Thrust collar
10 = Plain bearing
11 = Pressure spring
12a) = Thrust collar
12b) = Filling element
14 = O-ring
15 = Straight pin
16 = Screw
17 = Screw
18 = Saucer-head screw
19 = Hand lever
20 = Screw
21 = Holding flange
22 = Screw
23 = Square boss
24 = Actuator
Operating instruction | KIESELMANN GmbH9 | Drawings and dimensions
• Example: ball cock with welding end (Standard version)
A = Sealing package
M = Mounting sleeve
18 / 244x2x_SWBV_EN
Page 19
KIESELMANN GmbH | Operating instructionDrawings and dimensions | 9
Tankdome fittingPrevention of overpressure and vacuum, Tank cleaning
Safety valvePrevention of overpressure
The manufacturer hereby states that the above product is considered as an incomplete machine in
the sense defined in the Directive 2006/42/EC on Machinery. The above product is exclusively intended to be installed into a machine or an incomplete machine. The said product does not yet conform to all the relevant requirements defined in the Directive on Machinery referred to above for this
reason.
The specific technical documents listed in Appendix VII, Part B, have been prepared. The Authorized
Agent empowered to compile technical documents may submit the relevant documents if such a
request has been properly justified.
Commissioning of an incomplete machine must not only carried out if it has been determined that
the respective machine into which the incomplete machine is to be installed conforms to the regulations set out in the Directive on Machinery referred to above.
The above product conforms to the requirements of the directives and harmonized standards specified below: