KSB ISORIA 10, ISORIA 16, ISORIA 20, MAMMOUTH 6, MAMMOUTH 10 Operating Instructions Manual

Operating Instructions

8449.8/18--EN

ISORIA 10, 16, 20, 25

MAMMOUTH 6, 10, 16, 20, 25

1. Declaration of conformity 2

2. Declaration of incorporation for partly completed machinery 5

3. General 6

4. Safety 6

5. Transport and interim storage 7

6. Description of valves 8

7. Installation 10

8. Commissioning / Decommissionning 13

9. Maintenance / Repair 13

10. Trouble shooting 15

42 048 658

1. Declaration of conformity

Hereby we, KSB S.A.S.

Zone industrielle Gagnaire Fonsèche
24490 LA ROCHE CHALAIS

Registered Office: 92635 -- Gennevilliers
France

declare that the valves listed below comply:

-- with the requirements of the Pressure Equipment Directive 2014/68/EU.

Description of the valve types: Butterfly valves

-- ISORIA 10 PS 10 bar DN 40--1000

-- ISORIA 16 PS 16 bar DN 40--1000

-- ISORIA 20 PS 20 bar DN 32--600

-- ISORIA 25 PS 25 bar DN 32--1000

-- MAMMOUTH 6, 10 PS 6/10/16/20/25 bar DN 1050--4000
16, 20, 25

As per harmonized European standards: EN 10213; EN 12516--1; EN 12516--2; EN 12516--4
and other standards / directives: EN 1561; EN 1563; ASME B 16.34; ASME B16.42
Conformity Assessment Procedure: Module H

PED classification for each product type:

Butterfly valves ISORIA 10 ISORIA 16 ISORIA 20

Fluid Liquids Gas* Liquids Gas* Liquids Gas*

Dangerous 1) Yes No Yes No Yes No Yes No Yes No Ye s No

Group 1 2 1 2 1 2 1 2 1 2 1 2

Table N° 2)

XV
XA

XC

K
VA
VC
EG
CC
NB
NH
SK

Y
CB

8 9 6 7 8 9 6 7 8 9 6 7

   
   

   











  
  

  

           
       
       
       
       
       
       
       
 
 

 

 

       

   






 
 

 

Butterfly valves ISORIA 25 MAMMOUTH

Fluid Liquids Gas* Liquids Gas*

Dangerous 1) Yes No Yes No Yes No Yes No

Group 1 2 1 2 1 2 1 2

Table N° 2)

XV 
XA 
XC 

K 
VA 
VC 
EG 
CC 
NB 
NH 
SK 

Y 
CB 

8 9 6 7 8 9 6 7















  
  

  

  

  

  

  

  

  

  

  

  

  















 
 

 

 

 

 

 

 

 

 

 

 

 

2

1)

Definition in accordance with PED 2014/68/EU
(from 07/19/2016)



Comply with PED

Configuration not available

*: For unstable gas, consult us.

Production sites :
LA ROCHE CHALAIS / BURGOS

Table in accordance with annex II of PED 2014/68/EU

2)
(from 07/19/2016)



Available on request to comply with PED

Name and address of the notified body
for orders made from 01/10/2011:

Bureau Veritas S.A.
Newtime
52 Boulevard du Parc
Ile de la Jatte
92200 Neuilly sur Seine
FRANCE

Number of notified body: 0062

Production site :
DALIAN

Name and address of the notified body
for orders made from 01/01/2016:

Bureau Veritas S.A.
Newtime
52 Boulevard du Parc
Ile de la Jatte
92200 Neuilly sur Seine
FRANCE

Number of notified body:

0062

S with the requirements of AD 2000 -- AD A4.

Description of the valve types: Butterfly valves

-- ISORIA 10 PS 10 bar DN 40--1000

-- ISORIA 16 PS 16 bar DN 40--1000

-- ISORIA 20 PS 20 bar DN 32--600

As standard:

DIN 3840

and other standard / directive:

EN 1563

Name and address of the inspection body: TÜV Rheinland France

62 bis, Avenue Henri Ginoux
92120 Montrouge
France

Number of certificate:

AF 03.00126

3

S with the requirements of the regulation EC REACH 1907/2006.

Regulation EC 1907/2006 on the registration, evaluation, authorization and restrictions of chemicals
Description of the valve types: Butterfly valves

-- ISORIA 10 PS 10 bar DN 40--1000

-- ISORIA 16 PS 16 bar DN 40--1000

-- ISORIA 20 PS 20 bar DN 32--600

-- ISORIA 25 PS 25 bar DN 32--1000

-- MAMMOUTH 6, 10 PS 6/10/16/20/25 bar DN 1050--4000
16, 20, 25

Article 33/REACH: None of substances included in the candidate list and in Annex XIV

of this regulation are present in our actuators above a
concentration of 0,1% (weight by weight)

Michel Delobel Rev.14 -- 06/17
Quality Assurance

This document was prepared electronically and is valid without signature.
Its implementation in the public domain validates his condition.

4

2. Declaration of incorporation for Partly Completed machinery
Machinery Directive 2006/42/EC

Hereby, we,: KSB S.A.S.

Zone industrielle Gagnaire Fonsèche
24490 LA ROCHE CHALAIS
Registered Office: 92635 -- GennevilliersFrance

Manufacturer of the partly completed machine (PCM) for following product aggregate of type: valve + automatic actuator +
automation

Butterfly valves of type: -- BOAX--B, BOAX--S, BOAX--SF

-- BOAXMAT--S, BOAXMAT--SF, BOAX--B Mat P, BOAX--B Mat E

-- ISORIA 10, ISORIA 16, ISORIA 20, ISORIA 25

-- K E

-- MAMMOUTH 6, 10,16, 20, 25

-- DANAÏS 150, DANAIS MTII, DANAIS TBT

Actuators of type : -- Electric: ACTELEC

-- Pneumatic: ACTAIR, DYNACTAIR, ACTAIR NG and
DYNACTAIR NG

-- Hydraulic: HQ

-- Counterweight: Series R380 and R480

optionally with limit swich or automation boxes
of type:

declare the following essential requirements of the annex I of the Machine Directive 2006/42/EC are applied and fullfilled:

1.1.3, 1.1.5, 1.2.1, 1.3.2, 1.3.4, 1.3.7, 1.3.8, 1.3.8.1, 1.4.1, 1.4.2.1, 1.5.1, 1.5.2, 1.5.3, 1.5.4, 1.5.7, 1.5.8, 1.6.1, 1.7.2,

2.1.1 a, b, e

The relevant technical documentation is compiled in accordance with part B of Annex VII.

This documentation of parts hereof will be transmitted by post or electronically in response to a reasoned request by the
national authorities. The person authorised to compile the relevant thecnical documentation by:

Other EC--Directives to be used: Pressure Equipment Directive -- PED

-- A M T R O B O X -- Al l t y p e s --

-- AMTROBOX R -- All types --

-- AMTROBOX C R1290

-- AMTROBOX S R1195

-- R1077 / R1078 / R1079 / R1158

-- AMTRONIC / SMARTRONIC -- All Types

-- R1011 / R886 / R1007 / R834

Jacques Peterschmitt -- KSB
Parc d’activité Rémora
33170 Gradignan, France

2014/68/EU

from 19 July 2016

Directive ATEX

2014/34/EU

from 20 April 2016

This partly completed machinery must not be put into service until the final machinery into which it is to be incorporated
has been declared in conformity with the provisions of the Machinery Directive 2006/42/EC, where appropriate.

Michel Delobel
Quality Assurance

This document was prepared electronically and is valid without signature.
Its implementation in the public domain validates his condition.

Rev. 6 -- 06/17

5

3. General

These operating instructions apply to KSB rubber lined butterfly
valves (see section 6).

Design, manufacturing and testing of the KSB valves are subject to a
Quality Assurance System according to EN ISO 9001 and to the
European Pressure Equipment Directive 2014/68/EU (PED).
For a specific product configuration as an actuated valve, the
aggregate can be considered as a partly completed machine
according to the machinery directive 2006/42/EC and comply with the
requirements of the directive.
Correct installation and maintenance or repair are mandatory to
ensure trouble free operation of the valves.

The manufacturer cannot be made liable for these valves if operating
instructions are not being observed.

4.1 Safety Symbols in these Operating
Instructions

Safety instructions put forth in this instruction manual, the
nonobservance of which would involve the risk of personal injury, they
are specially marked with the general hazard symbol:

in accordance with ISO 3864--B.3.1.
or with the electric voltage warning sign:

ATTENTION

permissible operating range. The limits are indicated on the name
plate or currently applicable type leaflet. The pressure-temperature
ratings, in particular, must not be exceeded. Operation of the valves
outside the above-mentioned conditions may result in overloads
which may damage the valves.
The type leaflets can be found at www.ksb.com – product catalogue.

Nonobservance of this warning may lead to personal injury or

property damage, e.g.:

-- Injury caused by escaping fluids (cold/hot, toxic,flammable,
corrosive or under pressure)

-- Incorrect operation or destruction of the valve.

The descriptions and instructions in this manual refer to the standard
versions but also apply to the related variants.

These operating instructions do not take into consideration:

-- incidents which may occur during installation, operation and
maintenance.

-- the local safety regulations. lt is the user’s responsibility to ensure
that these are also observed by the installation staff involved.

For actuated valves, the specified connection parameters and the
installation and maintenance instructions -- including the operating
manual for the actuator -- must be observed.

ATTENTION
personnel.
The personnel in charge of operation, maintenance and installation of

this valve must be aware of the interaction between the valve and the
plant.

Operator’s errors concerning the valve may have serious
consequences for the entire plant, e.g.:

-- fluid may escape

-- downtime of the plant/machine

-- adverse effect/reduction/increase of the efficiency/function of a

plant/machine.

For further questions or in case of damage to the valve, please contact
your KSB Sales Office.

For further questions and supplementary orders, especially when
ordering spare parts, please always state the indications of the
marking plate.

The specifications (operating data) of the valves are listed in the technical
documentation & type leaflet of the related valve (see also section 6).

When returning valves to the manufacturer, please refer to section 5.

The v alves must not be operated outside the

Handling a valve requires skilled and experienced

In accordance with ISO 3864--B.3.6.
Safety instructions the nonobservance of which would involve hazard

to the valve and jeopardize its operation have been marked with the
word

ATTENTION

lnstructions directly attached to the valve, (e.g. nominal pressure)
must be complied with and maintained in a legible condition.

4.2 Qualification of personnel and training

The personnel for operation, maintenance, Inspection and installation
must be adequately qualified for the work involved. The personnel
responsibility,competence and supervision must be clearly defined by
the user. lf the personnel in question is not already in possession of the
required know-how, appropriate training and instructions must be
provided. lf deemed necessary,the manufacturer/supplier will provide
such training and instructions at the user’s request. In addition, the
user is responsible for ensuring that the contents of these operating
instructions are fully understood by the personnel involved.

4.3 Danger or nonobservance of the safety
instructions

Nonobservance of the safety instructions may lead to personal injury
and danger for both the environment and the valve itself.
Nonobservance of these safety instructions will also forfeit the user’s
warranty.

Such noncompliance could result in for example :

-- failure of essential functions of the valve/plant

-- failure of prescribed maintenance and repair practices

-- hazard to people by electrical, mechanical or chemical effects

-- hazard to the environment due to leakage of hazardous substances

4.4 Safety Consciousness

The safety instructions contained in this manual, the applicable
national accident prevention regulations and any of the user’s own
applicable internal work, operation or safety instructions must be fully
complied with.

4.5 Safety Instructions for the User/Operator

Any hot or cold parts of the valve (e.g. body or handle or actuator) that
could cause a hazard must be protectedby the user against accidental
contact.

Leakage of hazardous substance (e.g. flammable, corrosive, toxic,
hot) must be drained so as to avoid all danger to people or the
environment. All relevant laws must be observed.

4. Safety

This manual contains basic instructions to be complied with during
operation and maintenance. lt is therefore vital for the fitter and the
operator/user to read this manual before installing/commissioning the
valve. Also, this manual must always be available at the site where the
valve i s installed.

lt is not enough to observe the general instructions listed in the section
”safety”, the specific safety instructions listed in the other sections
should also be observed.

6

Electrical hazards must be effectively prevented. (For details,
please refer to the IEC 364 or equivalent national standard and/or
local utility energy supply regulations).

4.6 Safety lnstructions for Maintenance, Inspection and Installation work

Val

4.6.1 General

On an actuated valve the operating instructions of the valve must be strictly followed as well as those of the operating instructions of
the actuators, the limit switch or automation boxes.
The user is responsible for ensuring that all maintenance, inspection and installation work is carried out by authorized, adequately
qualified staff who are thoroughly familiar with thisinstruction manual.
Any work on a valve may only be performed when the valve is un-pressurized and has cooled down to 60 ° C.
Any work on actuated valves may only be done after that the actuator has been disconnected from its energy supply.
The procedure described in the operating instructions to shut down the actuator must be observed.Valves in contact with
hazardous media must be decontaminated. Immediately following completion of the work, all safety relevant and protective
devices must be reinstalled and/or re-enabled. Prior to recommissioning, refer to the points listed under section 7 Commissioning.

4.6.2 End of line installation

Use as end of line and downstream dismantling at ambient temperature of standard range.
End of line and downstream dismantling not authorized for bodies type 1 (annular shape).
NB: A valve fitted at the end of a pipe with a blind flange downstream is not to be considered as an end of pipe service.

ves

ISORIA 10 All sizes: not authorized

ISORIA 16 All sizes: not authorized

ISORIA 20 All sizes: not authorized

ISORIA 25 non applicable non applicable All sizes: not authorized

MAMMOUTH
6/10/16/20/25

PS: Differential pressure
* Liquids whose vapour pressure at the maximum allowable temperature is greater than 0.5 bar above normal atmospheric pressure (1013 mbar)

Hazardous (Group 1) Non hazardous (Group 2) Hazardous (Group1) Non hazardous (Group 2)

All sizes: not authorized on request

Gaz or liquids * Liquids

Sizes  500:

Liners: XA, XC, XV , K, Y, NH,

VA, VC, CB, EG
PS = 7 bar max.
Liners: CC, SK, NB

PS = 4.5 bar max.

Greater sizes: on request

Sizes  350:

PS = 10 bar max.

Greater sizes: on request

Sizes  125:

PS = 15 bar max.

Greater sizes: on request

All Sizes:

Liners: XA, XC, XV , K, Y,

NH, VA, VC, CB, EG

PS = 7 bar max.
Liners: CC, SK, NB
PS = 4.5 bar max.

All Sizes:

PS = 10 bar max.

Size  125:

PS = 15 bar max.

Greater sizes: on request

All sizes:

PS = 0.7PS limited to10

bar max.

Greater PS: on request

Liners: XA, XC, XV , K, Y, NH, VA,

PS = 0.7PS limited to10 bar

All Sizes:

VC, CB, EG

PS = 7 bar max.
Liners: CC, SK, NB
PS = 4.5 bar max.

All Sizes:

PS = 10 bar max.

All sizes :

PS = 15 bar max.

All sizes:

PS = 17 bar max.

All sizes:

max.

Greater PS: on request

4.7 Unauthorized Modification and Manufacturing of Spare Parts

The equipment shall not be altered or modified in any way prior to consultation with the manufacturer. Genuine spare parts and accessories
authorized by the manufacturer will ensure operational safety. The manufacturer cannot be held responsible for damage resulting from the use
of non-genuine parts or accessories.

4.8 Inadmissible Modes of Operation

Operational safety and reliability of the valve supplied is only warranted for its designated use as defined in section 2 ”General”
of the operating instructions.The limits stated in the technical documentation must not be exceeded under any circumstances.

5 Transport and Interim Storage

5.1 Transport

The valves in the as-supplied condition are ready for operation.

ATTENTION

crate or case with suitable protection (dessicant, thermowelded barrier).

ATTENTION

checked for damage during transit.

5.2 Interim Storage

The valves must be stored in such a way that correct operation is assured even after prolonged storage.
This comprises: -- Storing at 5° from the closed position

For transport and storage, the valves must always be maintained in the semi--closed position and be packed in cardboard,

To prevent damage, do not hang the valve by its handle or actuator.After delivery or prior to installation, the valve should be

-- Suitable measures against contamination, frost and corrosion (e.g. by using thermowelded plastic bags with dessicant,
protection caps and plugs onto threaded holes)

.

7

6 Description of valves

P

S

P

S

The s ectional drawings shown hereafter are examples for the general
design of our valves. For drawings and other information pertaining to
a s pecific valve series, please refer to the relevant type leaflets.

6.1 Marking

The valves are marked to PED 2014/68/EU.

6.2 Drawings and documents

Type DN (mm) PS (bar) Leaflet no.
ISORIA 10 40--1000 10 8444.1
ISORIA 16 40--1000 16 8445.1

DN

01/02

250 300

>300

10

Marking of the identity plate Example

1 -- Valve type model
2 -- Internal material code
3 -- Valve PN /Class designation
4 -- Maximum allowable pressure
5 -- Maximum allowable pressure at end of line or for downstream

dismantling
6 -- Maximum allowable temperature
7 -- Pipe flange drilling pattern (if known)
8 -- Month and year of production
9 -- Equipment serial number
10 -- CE marking with notified body identification number

ISORIA 25

32 40 50 65 80 100 125 150 200

3

10

16

25

Valves for non hazardous fluids (group 2)

according to table 7 of annex II (PED)

310.1

412

100

310.2

310.3

310.4

Type DN (mm) PS (bar) Leaflet no.

ISORIA 20 32--600 20 8446.1

970.1

900.1

413

213

550

210

900.2

916

ISORIA 10, 16, 20 / MAMMOUTH 10, 16, 20, 25

DN

32 40 50 65 80 100 125 150 200

10
16
20
25

Valves for hazardous liquids and gaz (group 1)

according to table 6 of annex II (PED)

8

310.3

100

213

310.2

920

411

970

310.1

413

550

905

210

554

916

Type DN (mm) PS (bar) Leaflet no.

ISORIA 25 32--1000 25 8447.1

970

412.1

901.1

412.2

363

310.1

310.2

414

412.3

901.2

176

904

920.2

Type DN (mm) PS (bar) Leaflet no.

MAMMOUTH
6/10/16/20/25

561

1050--4000 6/10/16/25 8612.12

559

543.1

100

413

213

554

550

905

210

486

310.3

554.1

920.1

543.2

6.3 List of Components

Part No. Name of Parts

100 Body
176 Bottom
210 Shaft
213 Operating shaft

310.* Plain bearing
363 Wedge
411 Gasket

412.* O--ring
413 Liner
414 Disc thrust plate
486 Ball

543.* Spacer bush
550 Disc
553 Lubricating thrust insert
554 Washer
559 Gasket holder
560 Elastic pin
561 Grooved nail

900.* Anti blow--out screw

901.* Hexagon head screw
904 Adjusting screw
905 Tie rod
916 Plug

920.* Nut
932 Self locking ring

940.* Key
970

Identity plate

554

310.1

413

213

550

940.2

310.3

553

901.2

920

901.1

412.1

970

561

100

940.1

210

414

412.2

176

904

*

Repetitive part

6.4 Functioning principle

Description

The v alve consists mainly of a body (100), operating shaft (213), shaft
(210), disc (550) and rubber liner (413).

The in--house designed formulated and manufactured rubber liner
achieves the leak tightness at shaft passages, pipe flanges and
downstream/upstream around the disc.

Disc--shaft connection: The disc (550) is connected to the operating
shaft by key (s), or splines.

Anti blow--out device: Every valve is fitted with an anti blow--out
device which prevents the shaft to burst off the body in case of shaft
failure. This function is achieved by additional parts.

Operation: The valves are quarter--turn operated manually by
handles or gear box or hydraulic, pneumatic or electric actuators
mounted on the valve top plate (as per ISO 5211 standard).

9

6.5 Optional accessories

Body support

Caution: Supporting legs must not be fixed to the ground.They must
remain free to move.

-- Assemble separately, the four identical parts as shown hereunder,

with the screws (900), the nuts (920.2) and the washers (554.2).

-- Assemble the body supports onto the valve.

Depending on lifting means, place the valve either in vertical or
horizontal position, sling with lifting and/or supporting means.
Assemble every support onto the valve using connecting rods
(81.51), eye bolts (81--39) + (920.1) and washers (554.1).

81--39

920.1554.1 81--51

900 191 920.2 554.2

Valves sizes DN  600 may be installed in any position.

Valves sizes DN > 600 have a mountung preferential direction

horizontal shaft following the figure hereafter. This is the most
favourable position because:

--The weight of the disc and shafts is borne by the two bearings,

-- the pivot bearing is relieved,

-- it is a guarantee of long valve life, specially in the c ase of fluids
containing solids, where sold particles tend to accumultate on the
bottom of the pipe (during the closing, the reduction in cross--section
causes a local increase in velocity which results in a “sweeping” or
“cleaning” of the liner).
The mounting, vertical shaft, actuators ace upwards is allowable.

7.2 Installation conditions

7 Installation

7.1 General

ATTENTION

the piping should be laid out in such a way that no thrust or bending
forces act on the valve bodies (Part Nr. 100) when they are installed
and operational.

ATTENTION

undamaged (Ra  25m).

insulation gasket, please consult us) between body and piping
flanges. To insert the valve between flanges, pull apart the two pipes
flanges to obtain sufficient clearance between flange face and valve
seat cheeks. All holes provided in the flanges must be used for the
flange connection.

must be protected against dust, sand and building material etc.(cover
with suitable means).
Do not use valve handles and gear handwheels as footholds!

temperatures must either be fitted with a protective insulation, or there
must be warning signs fitted showing that it is dangerous to touch
these v alves.

To avoid leakage, deformation or rupture of the body,

The sealing faces of the flanges must be clean and

It is prohibited to add any additional gasket (except electric

lf construction work is still in progress, non--mounted valves

Valves and pipes used for high (> 60 ° C) or low (< 0 ° C)

7.2.1 Recommended minimum distances between the
position of the valve and of the T--piece or elbow.

1DN

1 3 5

5--6 DN

3DN

DN

4

1DN

2

DN

Also valid for valve placed at pump dischange.

3DN

3DN

1DN

DNDN

1DN

DNDN

6

lf a valve is used as end-valve in a pipe, this valve should be
protected against unauthorized or unintentional opening to prevent
personal injury or damage to property.

10

7.2.2 Flanging dimensions

f

f

DNNPS

ø

6

DNNPS

ø

6

Connection to the piping.
Piping flanges must match the following dimensions.

Ø2a

Ø6 Ø3

Ø2a: max. allowable diameter on flange face
Ø2b: external diameter of the pipe when fitting loose plate flange with

lapped pipe end
Ø3: allowed minimum diameter on flange face
Ø4: minimum diameter at 10mm from the flange face
Ø5: minimum diameter at 20mm from the flange face
Ø6: allowed minimum diameter of raised face

ISORIA 10, ISORIA 16

DN NPS ø2a ø2b ø3 ø4 ø5 ø6

20
25 1 44 43 64
32
40
50 2 63 61 33 86
65

80 3 93 89 71 50 121
100 4 11 6 115 90 74 40 141
125 5 141,5 140 119 107 87 171
150 6 170,5* 169 144 134 120 196
200 8 222* 220 196 189 178 250
250 10 276,5* 273 249 243 234 306
300 12 327,5* 324 297 291 283 358
350 14 361 356 326 321 314 399
400 16 412 407 370 366 358 452
450 18 463 457 422 416 409 505
500 20 515 508 470 464 457 558
550 22 568 561 522 516 509 625
600 24 617 610 566 560 554 664
650 26 668 620 614 608 723
700 28 718 671 666 660 773
750 30 770 717 711 705 830
800 32 820 769 764 758 880
900 36 924 869 864 859 987

1000 40 1027 970 965 960 1094

* Please check that the body is well centered between the tie--rods

44 43 64

¾

54 49 32 77

1 ¼

54 49 32 77

1 ½

80 77 55 13 107

2 ½

ISORIA 20

DN NPS ø2a ø2b ø3 ø4 ø5 ø6

32

1 ¼

40

1 ½
50 2 63 61 38 89
65

2 ½

80 3 92 89 74 53 124

100 4 117 115 92 77 48 147
125 5 145 140 11 7 107 88 177
150 6 172 169 143 137 123 202
200 8 223 220 191 183 173 251
250 10 278 273 241 234 226 305
300 12 329 324 290 284 276 358
350 14 361 356 326 321 314 399
400 16 412 407 370 366 358 452
450 18 463 457 422 416 409 505
500 20 515 508 470 464 457 558
550 22 568 561 522 516 509 625
600 24 617 610 566 560 554 664

44 43 64
50 49 33 73

78 77 55 104

10 mm
20 mm

Ø2b

Ø5 Ø4

ISORIA 25

DN NPS ø2a ø3 ø4 ø5 ø6

32

1 ¼

40

1 ½
50 2 51 38 89
65

2 ½
80 3 81 74 53 124

100 4 101 92 77 48 147
125 5 126 117 107 88 177
150 6 151 143 137 123 202
200 8 201 191 183 173 251
250 10 251 241 234 226 305
300 12 302 290 284 276 358
350 14 337 326 321 314 399
400 16 387 370 366 358 452
450 18 438 422 416 409 505
500 20 488 470 464 457 558
550 22 549 522 516 509 625
600 24 589 566 560 554 664
700 28 700 683 668 661
800 32 799 782 766 760
900 36 900 880 860 854

1000 40 1000 976 958 952

33 64
41 33 73

66 55 104

Flat

lange

ace

MAMMOUTH 6, 10, 16, 20, 25

ø2a ø3 ø4 ø5

DN NPS

1050 42 1067 1010

1100 44 1117 1063 1058 1053 1187

1200 48 1222 1158 1152 1147 1307

DN NPS

1100 44 1130 1057
1200 48 1226 1152 1148 1143 1320
1300 52 1330 1259
1350 54 1380 1310
1400 56 1430 1430 1361
1500 60 1530 1530 1463
1600 1625 1560 1556 1552 1730

1800 72 1830 1830 1768

2000 2034 2034 1974

2200 2234 2234 2176

2400 96 2440
2500 2540
2600 102 2640

2800 2840

3000 3040

DN 3000 < DN  4000 : please consult us

face to face face to face face to face face to face

ISO ISO ISO ISO

1006

ø2a ø3 ø4 ø5

face to face face to face face to face face to face

280 400 280 400 280 400 280 400

1045

1252

1303
1320 1354
1424 1459

66 1690 1626

78 1990 1990 1930

84 2140 2140 2081

90 2330

108 2740 2665 2658 2654 2890

114 2940

120 3060 2988 2972 2967 3160

1623
1734 1765
1888 1926
1943 1971
2051 2078
2147 2173
2244 2224
2356
2456
2564

2766
2867
2968

1005 1135

1039 1220

1247 1420

1298 1470
1312 1349
1416 1454

1619 1810
1730 1761
1894 1923
1935 1968
2047 2075
2149 2171
2240 2221
2355
2456
2555

2760
2860
2962

ø6

1305
1410

1722
1889
1931
2043
2145
2235
2351
2453
2552

2756
2856
2959

ø6

1530
1630

1930
2090
2130
2240
2340
2430
2540
2640
2740

2940
3040
3140

11

7.2.3 Interface between valve and pipe flanges

Correctfitting except T6 bodies

Metallic intermediate insertion flange

VALVE WITH NECK EXTENSION

CORRECT FORBIDDEN

no gasket

In case of coated pipe (hard rubber, concrete or Teflon for
example), coating hardness and flanges detailed dimensions
shall be given to KSB for acceptance.
In case of fitting between polyethylene flanges:

-- Authorized fitting between flanges with flat faces

-- Not authorized fitting between flanges with grooved faces

no direct contact
with the
expansion j oint

no rubber coated flange

T5 type body T6 type body

7.3 Handling

Handling m eans may be necessary to install large sizes valves.
They must be used as shown.

VALVE WITH MOTORIZATION

CORRECT

FORBIDDEN

HORIZONTAL VALVE

VALVE WITH COUNTERWEIGHT

CORRECT FORBIDDEN

CORRECT FORBIDDEN

Neck extension and body supports may have been
delivered separately from the valve. They must be
mounted onto the valve before fitting it between flanges

12

7.4 Recommendations for installation

Before assembly

-- Verify that pipeline flanges are free from metallic chips and weld
splatter.

-- Verify that pipeline flanges are located on the same c entreline and
are parallel.

-- Verify that inside diameter of pipeline flange is in accordance with
the minimum and maximum diameters given by the manufacturer.

-- Verify that nothing hinders the complete moving of the disc during
opening or closing, in particular at the internal weld seams or at the
pipe ends.

-- Pull apart the pipeline flanges to allow valve insertion without
damaging the elastomer liner of the valve.

During assembly

-- Place the disc as spaced apart as possible from the closing
position, but without that disc protrudes past the valve’s body.

-- Spread the two pipe flanges to obtain sufficient clearance between
flange face and valve seat cheeks.

E + 40 mini

Minimum clearance : E + 40mm
E : Face to face valve

(refer to the type series booklet)

-- Insert valve between pipeflanges and center using several tie--rods.

-- Screw up progressively the nuts until metal to metal contact is
achieved between the valve body and pipeline flanges, by making
sure the good centering of the body compared with the flange is
maintained.

-- Operate the valve several times to ensure no valve disc obstruction.

E

8.1.2 Operation

The position of the disc is indicated by the pointer of the actuator or by
handle lever. The valves are closed by turning in the clockwise
direction (top view) and opened in the counterclockwise direction.

8.1.3 Functional Check

The following functions should be checked:Before commissioning,
the shut-off-function of the valves should be checked by repeated
opening and closing.

8.1.4 Actuated valves

Adjustable end stops and torque limiter are pre--adjusted in factory.
The customer may have to complete the adjustment on site during the
commissioning, if necessary.

8.2 Decommissioning

During extended shutdown periods, liquids liable to change their
condition due to polymerization, crystallization, solidification etc. must
be drained from the piping system. If necessary, the piping system
should be flushed with the valves fully open.

9. Maintenance/Repair

9.1 Safety Instructions

Maintenance and repair work may only be carried out by skilled and
qualified personnel.

For all maintenance and repair work, the safety instructions listed
below and also the general notes in section 2 must be
observed.Always use suitable spare parts and tools, even in case of
emergency, otherwise correct operation of the valves cannot be
assured.

9.2 Valve removal from piping and actuator
disconnecting

Identify the valve by identity plate.

Please c heck what is the relevant spare kit.

Place the disc at 10 ° opening.

7.5 Actuated valves

Electrical cables may only be connected by qualified personnel.

The applicable electrical regulations (e.g. IEC and national
standards), also for equipment in hazardous locations, must be
observed.All electrical equipment such as actuator, switchboard,
magnetic valve drive, limit switch etc. must be installed in floodproof
dry locations.Voltage and frequency must match the valves stated on
the identity plate.

8 Commissioning/Decommissioning

8.1 Commissioning

8.1.1 General

Prior to commissioning the valve, the pressure, temperature and
material data stated on the valve should be compared to the actual
operating conditions in the piping system to check whether the valve
can withstand the loads occurring in the system.

Possible pressure surges (water hammer) must not be exceed
the highest admissible pressure. Adequate precautions should be
taken.In new pipe systems and especially after repair work, the
system should be flushed with the valves fully open to remove solids,
e.g. weld beads, which may damage the seats.

The entire valve must be unpressurized and must have cooled
down sufficiently so that the temperature of the medium is lower than
60 ° C, to prevent scalding.

Opening pressurized valves will cause danger to life and
limb!lf toxic or highly flammable substances or liquids whose residues
may cause corrosion by interaction with the air humidity were handled
by the valve, then the valve should be drained and flushed or vented.lf
necessary, wear safety clothing and a face guard/mask.Depending on
the installation position, any liquid remaining in the valve may have to
be removed.

Prior to possible transport, the valves must be flushed and drained
carefully.lf you have any questions please contact your KSB Sales
Office.

lf actuators powered by an external source of energy (electric,
pneumatic, hydraulic) need to be removed from the valves or
dismantled, the energy supply must be shut down prior to starting any
repair work.

Remove the valve from the piping with its actuator. Do not
damage the liner during removal the valve from the pipe. Therefore,
pull apart the pipe flanges to allow sufficient clearance.

Identify the mounting position of the actuator
Disconnect the actuator and take care of all bolting parts.

13

9.3 Spares, list of tools, Consummables

9.3.1 Spares

Use the relevant spare parts included in the liner kit or disc kit or shaft
kit. Please refer to leaflets.
All constitutive parts of kits must be replaced.

During the mounting /dismantling of the valve, the order of
operations given in § 8.4.1. must be respected to prevent injuries and
material damages.

During the tests, while closing and opening valves, care must be taken
that no operator interferes with the disc travel.

9.3.2 List of tools for mounting/dismantling

Pneumatic screwing machine, open ended spanner,ring spanner, box
spanner, screwdrivers, hammer, pneumatic polisher, wedges, crow
bar and silicon grease if authorized.

9.3.3 Consummables

Use only the silicon grease enclosed in the kit (Molykote type 111).
The use of mechanical grease is strictly prohibited.

9.4 Valve disassembly and re--assembly

9.4.1 Valve disassembly

Remove the plug (916) or bottom (176) , the spring retaining ring (932)
if any.

Remove the anti blow--out screws (900.*) and gasket holder (559) if
any.

Extract the operating shaft (213) and lower shaft (210)
Remove the disc (550) and dismantle the liner (413)

9.5 Test and re--installation

Reassemble the actuator (check the N or M position)
Open the valve at 10 ° opening.
Pull apart the pipeline flanges to allow valve insertion without

damaging the elastomer liner of the valve.
Connect the power supply if necessary.
Check that the valve can be fully operated by the actuator.
Connect the valve to the pipe and follow assembling instructions.

Take care to prevent disc edge, liner and paint from any

damage.
Change O--rings 412.* using silicon grease. Put grease onto the liner

at shaft passages.

9.4.2 Valve re--assembly

Put in place the liner (413) into the body (100) so that shaft passages
are correctly aligned with the bores of the body.

Insert the disc (550) in open position and check correct alignment of
shaft passages.

Mount the shaft (210) with the ball (486) / keys (940.*) or spring
retaining ring (932), the washer (554) and screw (901.*) if any.
ISORIA 10,16 DN 250 to 600 : check that the groove of the shaft and
operating shaft are in front of the anti blow--out screws (900.1) and
(900.2) as shown below:

CORRECT FORBIDDEN

Mount the operating shaft (213) with keys (940.*) if any. Check the
correct indexation with the disc edge (550)

Adjust the anti blow--out screws (900.*)
Mount the plug (916) or bottom (176) and gasket holder (559) if any.
Valves with a bottom(176) must be put in a horizontal position to adjust

screw (904) which is to be locked with nut (920).

14

10 Trouble shooting

10.1 General

All repair and service work must be carried out by qualified personnel using suitable tools and genuine spare parts.
The previous safety instructions must be observed.

10.2 Faults & Remedies

Downstream/Upstream leakage
Shaft leakage

Flange leakage
Over torque
No opening
No closing
Hard point
Vibration / Fluttering

Foreign particles in the valve Actuator on safe position

Broken body Defect due to water hammer

Broken or warped disc Defect due to water hammer

Damaged disc, corroded disc

Adjusting bottom screws
Broken shaft, twisted shaft Analyse the defect / research of causes / replace shaft
Worn out liner Replacement liner (liner kit)
Receding liner, damaged liner If the liner is undamaged : separate the pipe flanges / remove valve /

Wrong flanging Check type and flange bolting torque
Wrong flanging size Follow i nstructions given in KSB technical leaflet
Wrong face to face,

non parallel flanges
Flow conditions

Wrong operating conditions
Damaged actuator Check sizing versus operating conditions (see KSB)

-- Open the valve, line without fluid or flow, remove the particle

-- inspect liner/disc

-- replace liner/disc

Search for the reasons.
Replace / Repair the valve

Search the reasons. Replace / Repair the valve
Disc : check flanging dimensions and replace using the disc kit

Adjust bottom screws

put it back between the pipe flanges / c heck operations.

Flanging has to be modified in accordance with KSB technical leaflet
requirements.

Check the technical offer versus service conditions

15

ISORIA 10, 16, 20, 25 and MAMMOUTH 6, 10, 16, 20, 25

KSB S.A.S.

4, allée des Barbanniers  92635 Gennevilliers Cedex (France)
Tél.:[phone]
www.ksb.com

Subject to technical modification without prior notice.

Legal information/Copyright -- Original operating manual -- all right reserved

Contents provided herein must neither be processed without KSB’express written consent

03.01.20188449.8/18--EN