Operating instructions
Contents
1. ing system Through the inlet valve EV the leakage area between the piston seals can be cleaned or steam cleaned in observance of the tech nical data 7 Control system and interrogation system ap Tsy 7 1 Control head optional Optionally modular valve control systems can be installed to the actuator for reading and actuating valve positions The standard version is a closed system with twofold limit position messaging stand ard with SPS Interbus or ASI bus switch on electronics and integrated 3 2 way solenoid valves For tough operating conditions we recommend employing a stainless steel hood 7 2 Sensor mounting set optional For the acquisition of the valve positions over inductive initiators a limit switch support is mounted on the actuation The enquiry takes place over the position of the piston rod KIESELMANN KI DS Double sealing single seat valves Type 552x 6 8 Technical data Model Double sealing single seat valve pneumatic operation Valve size DN 25 DN 100 DN 1 inch DN 4 inch Connections Welding end DIN EN10357 Temperature range e Ambient temperature 4 to 45 C e Product temperature 0 to 95 C medium dependent e Sterilization temperature EPDM 140 C short time 30 min HNBR 130 C short time 30 min Control air pressure DN 25 DN 65 DN 1 DN 2 min 5 5 bar 8 0 bar DN 80 DN 100 DN 1 DN 4 min 6 0 bar 8 0 bar Pressure Nominal bar PN102. 054 5506 050 009 054 5506 050 009 054 HNBR 5506 050 009 050 5506 050 009 050 5506 050 009 050 5506 050 009 050 5506 050 009 050 5506 050 009 050 D4 NBR 2x O ring 2304 030 035 055 D5 HNBR 2x O rin 2304 019 035 171 D6 k flex 2x Seal 2353 021 016 114 Inlet valve EV 5522 150 050 041 Piston 5722 150 055 114 O rin 2304 004 010 054 O ring 2304 007 015 159 O ring 2304 017 030 055 O ring 2304 024 020 055 DN 100 4 Inch DN 50 2 Inch DN 65 2 Inch DN 80 3 Inch 5522 025 990 050 5522 040 990 050 5522 050 990 050 5522 065 990 050 5522 080 990 050 5522 100 990 050 5522 025 990 054 5522 040 990 054 5522 050 990 054 5522 065 990 054 5522 080 990 054 5522 100 990 054 KI DS Double sealing single seat valves Type 552x a 13 14 Manufacturing 14 1 Structure of Article number 5521 050 130 041 Lo Material in product contact Exterior finish Interrogation system Material seals in product contact Construction modifications Valve size Nominal pipe size Housing type Product type gt Product type 552x Double sealing single seat valve gt Housing type Angle housing S S T housing SS S Cross housing SS SS Loop housing S SS Typ 5521 Typ 5522 Typ 5523 Typ 5524 A GN G EA NA gt Valve size DN Nominal diameter DIN 025 DN 25 040 DN 40 050 DN 50 065 DN 65 080 DN 80 100 DN 100 INCH 026 DN 1 038 DN 1 051 DN2 064 DN2 076 DN3 101 DN 4
3. gt Material seal Construction modifications Material seals in product contact EPDM HNBR Modifications Type of actuation air open spring close Pilot valves with Outlet valve 552x DN O30 xxx 552x DN 035 xxx with Outlet valve and Inlet valve 552x DN 130 xxx 552x DN 135 xxx gt Material in product contact Exterior finish 020 1 4301 AISI304 bright turned 040 1 4404 AISI316L bright turned 021 1 4301 AISI304 E polished 041 1 4404 AISI316L E polished 022 1 4301 AISI304 unpolished glass bead blasted 042 1 4404 AISI316L unpolished glass bead blasted gt Interrogation system Article number Control System or Interrogation System A1 A2 55xx DN xxx 041 Valve without control or interrogation system 55xx DN xxx 750 Valve with Sensor mounting set 5630 005 000 020 55xx DN xxx 6xx Control head ASi Bus Typ 5630 55xx DN xxx K6xx Control head ASi Bus Typ 5631 KI Top 55xx DN xxx BXx Control head SPS Typ 5630 55xx DN xxx K5xx Control head SPS Typ 5631 KI Top DN Nominal pipe size e g 572x 050 130 041 a E 1 1 ap p KI DS Double sealing single seat valves Type 552x c LRN EEECCCOOCDM O AGUEEYA A A XX MN KIESELMANN 14 Declaration of incorporation C Translation of the original Manufacturer authorised representative Authorised representative for compiling technical documents Product name pneum Lift actuato
4. head with stainless steel cap 360 flashing light SKtr Control head with plastic cap IG Position indication IG1 Threaded rod IG2 Disc IG3 Nut IG4 Spring M Magnet N north S south SA Sensor mounting SA1 Bracket SA2 Switch cam SA3 Setscrew SA4 Screw SA5 Disc SA6 Sleeve transparent SA7 Cover en jeden Hae Fig 3 p l ap A f DS Double sealing single seat valves Type 552x KIESELMANN FLUID PROCESS GROUP 1 0 10 9 15 11 1 Pilot valves EV and AV V1 Piston V2 Housing V3 Housing cover V4 Screw plug Inlet valve EV V5 Spring V6 Push in connector elbow V7 Push in connector straight V8 Spring V9 Screws D6 Seal D7 Piston D8 O ring D9 O ring D10 O ring D11 O ring Outlet valve AV Fig 4 4 E i i pas A KI DS Double sealing single seat valves Type 552x KIESELMANN FLUID PROCESS GROUP 11 10 9 15 12 Dimensions 12 1 Size measurement table 25 4x1 65 41x1 5 112 38 1x1 65 53x1 5 50 8x1 65 65 70x2 0 215 63 5x1 65 104x2 0 101 6x2 338 350 5 S 64 5 Valves that do not meet the catalogue standards can lead to dimensional Tr 12 2 Dimensioned drawing FLUID PROCESS asp KIESELMANN GROUP Fig 5 KI DS Double sealing single seat valves Type 552x 12 13 Wearing parts 13 1 Valve insert VE 13 2 Pilot valve AV and EV Outlet va
5. system must have the suit able 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 per sonnel to make electrical connections 2 5 Modifications spare parts accessories Unauthorized modifications additions or conversions which affect the safety of the fitting are not per mitted Safety devices must not be bypassed removed or made inactive Only use original spare parts and accessories recommended by the manufacturer 2 6 General instructions The user is obliged to operate the fitting only when it is in good working order In addition to the instruc tions given in the operating manual please observe the following relevant accident prevention regulations e generally accepted safety regulations e regulations effective in the country of installation e working and safety instructions effective in the user s plant ap p Safety informations RR e 3 Safety instructions 3 1 Field of application The single valves are utilised as a pneumatically controlled shut off valve in food and beverage as well as in pharmaceutical biotechnological and chemical industries ATTENTION e To avoid danger and damage the fitting must be used in accordance with the safety instructions and technical data contained in the operating instructions 3 2 General safety instructions DANGER e Dan
6. 10 9 15 English GBR gt RB gb TA CM e KIESELMANN FLUID PROCESS GROUP O perati n g nstru ctio ns Translation of the original KI DS Double sealing single seat valves Type 5521 5522 5523 5524 pneumatic and manual operation KIESELMANN GmbH Paul Kieselmann Str 4 10 D 75438 Knittlingen Ti 49 0 7043 371 0 Fax 49 0 7043 371 125 www kieselmann de sales kieselmann de 1 List of contents Mice TS EON OU RE RE EE EE nears 2 2 General salen INSIMUICHONS widsedccucwenosmazedaetascceuceaindieGedassastene i Aa iaia aenooia 3 2 1 Information for your safety 3 2 2 Marking of security instructions in the operating manual cccseceeceseeeeeeeeeseeeeeeeeeeeeees 3 2 3 Designated use REE EE 3 2 4 Fv 3 2 5 Modifications spare parts accessories rrrrrrnrannrrrannrrrnnnrevnnnnennnnnennnnrernnsnennaneennansennnnssnnnn 3 20 GENENE NER 3 OEY ELLA COS OE EE EE NE AT rOn 4 3 1 Fel Nr 4 32 General s len INSIMICHOMNS sresti ambo CER oU Jesse Eu ase adu quida 4 3 3 EEE SJ S aieea MU RpPR EASAN nin UN CH ENNEN EEEN nian 4 4 Installation NOM IONS 2 aars 4 4 1 installation ISIC HONS sved eden 4 Ae Welding MENE 4avrvvvv444r4v4evrrvrvrrrrvr eee 4 4 3 ATEX guidelines ccccccccccceecccseeceeseeceecaeeecauceecauseeseseessaseecseaeeseeaeeseeaeesseueesesaeesssaeees 4 NNN 5 5 1 FUNCNONA ACSENPUON Lose 5 5 2 Basic position for pneum operation VAI
7. Quality of control air ISO 8573 1 2001 quality class 3 Material in product contact not in product contact Stainless steel 1 4404 AISI316L 1 4301 AISI304 1 4305 AISI303 Surfaces RA x0 8um metallic bright e pol Seal EPDM FDA HNBR HNBR FDA Nominal diameter DIN 25 40 50 65 80 100 Inch 1 1 2 22 3 4 max Operation pressure bar 10 8 8 8 10 6 Tightening moment DIN 25 40 50 65 80 100 Clamp coupling Inch 1 1 2 22 3 4 Torque Nm 15 15 15 15 15 55 9 Pneumatic valve actuation 9 1 Actuator air open spring close NC pneumatic control with pneumatic control with Valve function solenoid valve MV in control unit external solenoid valve MV Fig 1 page 7 Fig 2 page 7 control air feed control air feed Valve OPEN P gt MV1 gt P1 LA LV ext MV gt LA Valve is opening by control air Valve is opening by control air de aeration de aeration Valve CLOSED LA LV P1 gt MV1 gt R LA gt ext MV Valve is closing by spring Valve is closing by spring Control head with MV Sensors MV solenoid valve R de aeration sound absorber P compressed air inlet control unit S slide switch manual control solenoid valves I initiators H angle bracket E de aeration LA air connection AV Outlet valve EV Inlet valve optional Fig 1 Fig 2 _ pe 1 1 ap KI DS Double allt single seat valves Type 552x KIESELMANN 7 10 9 15 10 Disassembly and assem
8. VES ccccseecccceeeceeeeececseeeeeeeeeeesueeeeseeeessuseeesaaees 5 6 Service and maintenance rrrrannrrnnnnrnrnnnnrnnnnrernnnrennnnnennnnsrnnnnnennnnnennnnsennnnnennnnneennnssennnsnennnneennnnne 6 6 1 MN 6 o ESO aoo 6 7 Control system and interrogation system cccccceececceeeeecesececeeceeeceeeecaeceeseeeseuseeeseueessaeeeessaees 6 7 1 Control head optional RR aeceeniesdvact cnsnacosderosenspnetectacseneteoss 6 7 2 Sensor mounting set optional ccccccccccsssccecceeseceecceesececeeesceeecegeeeeeeseueeeesseseeeeesneeeees 6 Be MOC MMIC AI Cle 2 ORRE 7 9 Pneumatic valve actuation sa 7 9 1 Actuator air open spring close NC ccccccssecceceeececeeeeeeeeeeeceueeeseueeeseaeeeeseeeeesaeeeeees 7 10 Disassembly and assembly Lavendel Eea na aa a iaa a 8 DENN 8 ATNA 9 ee NN 10 11 1 Pilot valves EV and AV sccsncienccicccncetncscadasedecancnatanetionadastandanateuctdedvenasdadsccntenceememcceadeceecates 11 12 Sup Io Lavere en 12 12 1 Size measurement table rrrnnnnrrnnnnnrnnnnnrrnnnnrnnnnnrnnnnnrrnnannrnnnnnrnnnnerennnnnennnnnennnnnennnnseennnnn 12 122 Dimensioned AMG m o mmu 12 13 Weanng ANS TT mmm 13 131 VaANeINSETIVE t 13 13 2 Pilot valve AV and EV orrnonnnnnrrnnnnnonnnnnonnnnnennnnnnnnnnnennnnnennnnnennnnnrennnnnennnnnennnnennnnsennnnnee 13 13 3 Seal kits D1 D7 DPI 13 14 WVU ACTIN Ge 14 14 1 Structure of Article number rrannrrnnnnnnnrnnnrnrnnnvr
9. bly NOTE e All threaded joint have right hand thread e Unscrew and remove control air steam resp cleaning lines and electrical lines complete sensor mounting or control head e Don t damage the surfaces onto the piston 10 1 Disassembly gt Remove pneum valve insert A1 c Connect compressed air at the connection LA The valve opens auto matically The piston moves in position OPEN A2 gt e Unscrew the clamp coupling VK Disconnect the compressed air pipe from connection LA from outlet valve LV and inlet valve EV The piston moves back in position CLOSED A3 Dismount the valve insert VE out of the housing VG gt Exchanging seals D1 D6 A3 Unscrew the screw 9 and remove the pilot valves EV and AV Remove seal D6 A4 Unscrew the piston 1 from spindle 6 SW1 SW2 AS Dismantle O rings D1a D1b and D2 NOTE Puncture the O ring D1a and D1b at the centre with a pointed tool and remove them carefully from the groove A6 c Unscrew the insert 2 from the lantern 4 use a hook wrench A7 gt Remove seal D3 NOTE Bearing bush 3 and 5 and the O rings D4 and D5 do not need to be removed for seal change The races are not included in the seal set If they are worn please order them with the seals see wearing parts set A8 gt Unsrew the lantern 4 from the actuator 7 use a hook wrench and remove la
10. espective 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 DIN EN ISO 12100 Safety of machinery Knittlingen 10 09 2015 Klaus Dohle General Director
11. ger of crushing or amputating limbs Do not reach into the valve housing when in pneumatic mode Dismantling the valve or valve assemblies from the plant can cause injuries from fluids or gases flowing out Dismantle the valve or valve assembly only when the plant has been rendered pressure less and free of liquid and gas The spring preloaded valve insert air open spring close may incur serious injuries by jumping out of the housing Pneumatically open the valve before disassembling the clamp coupling so that upstroke the piston in direction X Fig A1 page 8 e For valves or plants installations that are operated in a ATEX area must be considered the valid ATEX Guidelines EG and the Installation instructions see ATEX guidelines on page 4 ATTENTION e To avoid air leaking only use pneumatic connection parts that have an o ring seal facing the even surface When mounting the clamps the max torque must not be exceeded see technical data e Steps should be taken to ensure that no external forces are exerted on the fitting 3 3 General notes NOTE All data are in line with the current state of development Subject to change as a result of technical progress 4 Installation informations 4 1 Installation instructions The single seat valve must be preferable vertically installed with the actuator upwards Liquid must be able to flow freely from the valve housing and the leakage chamber NOTE If instal
12. led horizontally some minor residual liquids will remain in the ball shape of the housing 42 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 EN287 Use the TIG Tung sten Inert Gas welding process NOTE Impurities can cause damage to the seals and seals area Clean inside areas prior to assembly To avoid a distortion of the components all welding parts must be welded to stress relieved 4 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 p l apr KI DS Double sealing single seat valves Type 552x KIESELMANN 4 5 Function 5 1 Functional description PET e Function of The sealing function in the closed position is performed statically Leakage valve which occurs due to damaged valve disc seals is discharged into the atmos phere without pressure via the leakage outlet L at the outlet valve AV h 4 e Operation pneumatic operation by a lift drive air spring e Activation Pneumatically over a 3 2 way solenoid valve see Pneumatic valve actuation on page 7 i i E a s h EA mW TC fel j air open spring close NC Basic position Valve close Fig I IV pneum operated opens the valve not pne
13. lve AV Pos Material Pce 5522 150 060 041 D7 k flex 1x Piston 5522 150 055 114 D8 EPDM 1x O rin 2304 004 010 054 D9 EPDM 1x O ring 2304 007 015 159 D10 Viton 1x O ring 2304 017 030 055 D11 NBR 1x O ring 2304 024 020 055 13 3 Seal kits D1 D7 D9 D14 Material BINS Jet 1 Inch 1 Inch HNBR EPDM Fl p apo dy KIESELMANN Pos Material Pce DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 1 Inch 1 Inch 2 Inch 2 Inch 3 Inch 4 Inch 3 XSM 1x Bearing bush 8050 028 020 156 5 XMS 2x Bearing bush 8500 020 007 156 Dia 1x O ring O ring O rin O rin O ring O ring EPDM 2304 022 035 159 2304 032 035 159 2304 044 053 159 2304 053 053 159 2304 069 053 159 2304 088 053 159 HNBR 2304 022 035 157 2304 032 035 157 2304 044 053 157 2304 053 053 157 2304 069 053 157 2304 088 053 157 1x O ring O ring O ring O ring O ring O ring D1b EPDM 2304 036 035 159 2304 041 035 159 2304 050 053 069 2304 063 053 159 2304 079 053 170 2304 098 053 170 HNBR 2304 036 035 157 2304 041 035 157 2304 050 053 157 2304 063 053 157 2304 079 053 157 2304 098 053 157 D2 1x O ring O ring O ring O ring O ring O ring EPDM 2304 069 026 159 2304 069 026 159 2304 069 026 159 2304 082 026 159 2304 098 035 159 2304 117 035 159 HNBR 2304 069 028 050 2304 069 028 050 2304 069 028 050 2304 082 026 050 2304 098 035 050 2304 117 035 050 D3 1x Seal Seal Seal Seal Seal Seal EPDM 5506 050 009 054 5506 050 009 054 5506 050 009 054 5506 050 009
14. nnnnrrnnnnnrnnnnnenrnnnennnnneennnnsennnneennnnnennnsennnnne 14 15 Declaration of incorporation rrnannrrnnnnnrnnrnnnrnnnnnrnnnnnrnnnnnrnnnnnrnnnanrnnnnnrnnnnnrennnnsennnnnennnnnennnnnnennnn 15 pm i apr E KI DS Double sealing single seat valves Type 552x KIESELMANN 2 General safety instructions KIESELMANN 2 1 Information for your safety We are pleased that you have decided for a high class KIESELMANN 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 dam ages 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 ca
15. ntern from the spindle 6 Unscrew insert 8 from the actu ator 7 use a pin type face wrench A9 e Dismantle O rings D4 and D5 Exchange seals and wear parts Fig A5 Fig A7 Fig A9 p A l ap A KI DS Double sealing single seat valves Type 552x KIESELMANN FLUID PR 10 9 15 ki 10 2 Assembly e Thoroughly clean and slightly lubricate mounting areas and running surfaces Assemble in reverse order NOTE Alternately press and roll the seal D1a and D1b into the groove with round body see Assembly Fig B1 e Check the valve function 1 Piston 2 Insert 3 Bearing bush 4 Lantern 5 Bearing bush 6 Spindle 7 Actuator 8 Lantern insert 9 Screw Dia O ring D1b O ring D2 O ring D3 Seal D4 O ring D5 O ring D6 Seal B Bore K zCap AV Outlet valve EV inlet valve VG Valve housing VK Clamp coupling Assembly Fig B1 SW1 24 SW2 17 SW3 16 Assembly Fig B2 a gt i ap KI DS Double sealing single seat valves Type 552x ESELMANN UID PRO ESS GROUP 10 9 15 11 Drawing K Cap with Outlet valve AV with Inlet valve EV L Leakage connection and Outlet valve AV AV Outlet valve R Cleaning connection EV Inlet valve 0 0 i VE Valve insert pneumatical VK Clamp coupling VG Valve housing SKva Control
16. rry out the maintenance by yourself our KIESELMANN service team will naturally be at your disposal 2 2 Marking of security instructions in the operating manual 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 sym bols have to be read and adhered to by all means Please continue with the text and with the handling at the valve only afterwards Signal word NEN NNEF danger which may cause severe personal injury or death Dangerous situation which may cause slight ATTENTION personal injury or material damages Marks application hints and other infor NOTE mation which is particularly useful 2 3 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 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 inspec tion and maintenance instructions 2 4 Personnel Personnel entrusted with the operation and maintenance of the tank safety
17. rs pneum Rotary actuators Ball valves Butterfly valves Single seat valves Flow control valves Throttle valve Overflow valve Double seat valve Bellow valves Sampling valves Two way valves Tankdome fitting KIESELMANN GmbH Paul Kieselmann Str 4 10 75438 Knittlingen Germany Achim Kauselmann KIESELMANN GmbH Paul Kieselmann Str 4 10 75438 Knittlingen Germany Function Stroke movement Rotary movement Media cutoff Media cutoff Media cutoff Control of liquefied media Control of liquefied media Definition of fluid pressure Media separation Sampling of liquids Sampling of liquids Media cutoff A 4 2 oe apap KIESELMANN FLUID PROCESS GROUP Prevention of overpressure and vacuum Tank cleaning 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 may only be carried out if it has been determined that the r
18. um operated spring force closes the valve 5 2 Basic position for pneum operation valves Angle valve Type 5521 S S air open spring close NC Basic position Valve close Fig T valve Type 5522 SS S air open spring close NC Basic position Valve close Fig II Cross valve Type 5523 SS SS air open spring close NC Basic position Valve close Fig III Loop valve Type 5524 S SS air open spring close NC Basic position Valve close Fig IV p l pa EE KI DS Double sealing single seat valves Type 552x KIESELMANN 6 Service and maintenance 6 1 Maintenance The maintenance intervals depend on the operating conditions e temperature temperature intervals e medium and cleaning medium pressure and opening frequency We recommend replacing the seals every 1 years The user however should establish appropriate maintenance intervals according to the condition of the seals NOTE Lubricant recommendation EPDM Viton k flex NBR HNBR gt Kluber Paraliq GTE703 Silicone gt Kl ber Sintheso pro AA2 Thread Interflon Food 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 gt Actuator The actuator is maintenance free and non removable 6 2 Cleaning The cleaning of the valve housing is performed with the pipe clean
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