BROEN BALLOMAX Manuale utente

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

BROEN BALLOMAX®

USER MANUAL

STANDARD BALL VALVES VERSION 2.0

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

2 - BROEN Valves User Manual

www.broen.com

Read more in the chapter “General information” on page 4.

Warning! Media can be hot and cause burning.

Do use safety goggles and gloves.

Read more in the chapter “Installation and welding” on page 7.

Warning! Wrong installation can result in severel damage or that the

valve is not functioning correctly. These general instructions

do not cover all possible operating scenarios.

For a more specic guidance about the usage of the valve

or its qualication at the desired use, please contact BROEN.

Read more in the chapter “Change of gasket set” on page 31.

Warning! Media can be hot and cause burns.

Use safety goggles and gloves.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

BROEN Valves User Manual - 3

www.broen.com

Content

BROEN valves user manual

1. General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2. Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3. Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4. Instructions and precautions before installation and operation. . . . . . . . . . .7

5. Installation and welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6. Commissioning and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

7. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9. Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

10. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BROEN Ballomax® – further useful information

11. Mounting and disassembly of gears on a valve as well adjustment . . . . 13

12. User Manual for BROEN Ballomax® hot tapping tool. . . . . . . . . . . . . . . . . . . . . 17

13. User Manual for BROEN Ballomax® branching valve . . . . . . . . . . . . . . . . . . . . . 21

14. Instructions for transportable gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

15. Flexible extensions and planetary gear for underground valves. . . . . . . 26

16. Change of gasket sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

4 - BROEN Valves User Manual

www.broen.com

1. General information

BROEN Ballomax®Steel ball valves

BROEN Ballomax® is designed with highest possible safety and functionality in mind,

but we recommend reading this manual thoroughly.

The technical data is not binding and can be changed without any notice. Please

see our general terms and conditions. Further information can be obtained upon

request. It is the responsibility of the project owner and installer to choose products

suitable for the intended purpose and secure that pressure data and performance

data is not exceeded. Updated installation manuals apply.

The entire system should be depressurized and emptied before any kind of removal,

change or repair of a single component – no matter if the components are defective

or not.

BROEN ball valves are intended for installation in heating-, cooling- and district

heating- installations with treated water, that does not corrode neither carbon steel

nor materials in the O-rings or seals.

The valve house is made in carbon steel and the stem and ball are made in stainless

steel.

The ball seats are made of carbon reinforced Teon (PTFE). The stem stung box is

done with FPM- (Viton) and EPDM- O-rings.

The valve is tight in both directions and can be mounted in both directions.

Local legislation must always be observed.

Approvals

BROEN Ballomax® ball valves in steel are approved according to the demands in

(PED) 2014/68/EU for pressurized equipment, module H. Module H is the module for

complete quality control.

Quality management

BROEN A/S has been ISO 9001 certied since 2001:2015.

The ISO certicate has been approved by Bureau Veritas Quality International Ltd.,

London, one of the leading international authorities in the eld of ISO certication.

Bureau Veritas conducts regular audits to check the operation of the system.

ISO 9001 covers all processes of production ow and customer service - from the

rst idea to the product, through drawings, materials, production, as well as control

and testing procedures, packaging, shipping, personnel training, contracts and

technical documentation, maintenance and claims handling.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

BROEN Valves User Manual - 5

www.broen.com

2. Marking

Each product is marked with a self-adhesive label, based on aluminum foil,

resistant to weather conditions, on which all relevant information about the

product are given.

Label example:

• BALLOMAX® - trade name: BALLOMAX, DZT, AH30 FITTINGS,

• DN 50 - nominal size,

• PN 40 - pressure class,

• Material: P235GH - valve body material,

• Temp. - minimum and maximum medium temperature for the valve used,

• Fluid Group 2 - group of liquids according to 2014/68 / EU or information

on the medium (eg steam)

• Date - month and year of the valve’s production and test,

• BROEN POLAND sp. O.o. 58-200 DZIERŻONIÓW - name and address of the

manufacturer,

• CE 0062 - CE mark number of the Bureau Veritas notication

• www.broen.com - manufacturer’s website

• 100331 - label number

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

6 - BROEN Valves User Manual

www.broen.com

3. Transportation and storage

It is important to check if the valve or its parts has been damaged during

transportation. If there are any transportation damages BROEN recommends

receiving the delivery and then immediately contacting BROEN.

BROEN recommends to control that the delivery is as agreed – number, size, type

and equipment and etc.

Information about damages, defects or irregularities according to the agreement

should immediately be informed to BROEN.

Store the valve in a clean and dry place before installation. Do not remove the

protection caps before immediate installation.

Use lifting straps when lifting larger valves. Do not lift the valve in its

actuator, stem or handle (Fig. 1, 2 & 3).

If in doubt about the weight of the valve to be lifted, you can see its weight in the

Ballomax® catalogue or on BROEN’s homepage – www.broen.com.

Fig. 2.



Fig. 3.



Fig. 1.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

BROEN Valves User Manual - 7

www.broen.com

Fig. 4.

4. Instructions and precautions before

installation and operation

Present instructions should be carefully reviewed before mounting and operation of

Ballomax®ball valves:

• The entire system should be depressurized and emptied before any type of

disassembly, replacement or repair of a single element, regardless of whether

the elements are damaged or not.

• Control that the valve is suitable and approved for the used media and the

desired application. The valve is not suitable for steam! Here a valve suitable for

high temperatures is to be used.

• Operate the valve, if possible, to ensure that the valve is not defective from

storage or transportation.

• If the valve is used as an end valve in the pipeline, there has to be installed a

pressure tight ending or blind ange after the valve and the valve is to be left in

the open position (Figure 4).

• In order to ensure safe operation the manual gear or actuator cannot be

removed or dismantled, without special precautions are taken, if the valve is

under pressure and/or there is a ow.

• BROEN recommends, that the valve is installed in the pipeline with minimal

vibrations. In the installation it is recommended to avoid stress and to relieve

the valve for exposed longitudinally pressure and tensile load.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

8 - BROEN Valves User Manual

www.broen.com

Fig. 5.

Fig. 7.

Fig. 6.

5. Installation and welding

Welding

The pipe line is to be cleaned thoroughly before the installation of the valves, as any

impurities can damage the surface of the valve and seals.

Do not remove the manual gear or actuator from the valve unless it is absolutely

necessary. In the event the manual gear or actuator is to be removed during or after

the installation, then contact BROEN customer service or see instructions in the

chapter “Instruction for mounted gear”.

Electric welding (TIG, MIG) is recommended for all BROEN Ballomax® ball valves in

steel. Valves larger than DN150 should always be welded in the pipe line by means

of electric welding.

Do not overheat the valve during the welding – there is a risk for damage of the

seals. It is recommended, that the welding is done by qualied personnel.

Cool the valve (after welding) before normal use. The valve should only be operated,

when the valve is cooled suciently.

The welding is only to be done on the ends of the valve and not on the body of the

valve, as this will damage the seals in the valve.

For further information refer to the guidance on the valve.

The valve can be placed in both vertical and horizontal position, and during the

entire welding process it should be noticed, that the valve must be in open position.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

BROEN Valves User Manual - 9

www.broen.com

Welding of larger valves ≥ DN 200 full port / DN 250 reduced port.

The valve must remain open during welding to protect the ball.

At risk of overheating there should a pause in the welding process.

The ground connection must not be connected to the valve.

Flange mounting: The valve should only be mounted by qualied personnel and

follow valid norms and standards. The valve should be in open position during

mounting in order to ensure, that dirt and coatings do not ruin the surface of

the seals. The mating surface of the ange on the pipe should be parallel to the

mating surface of the valve. The centerline of the valve and the pipeline should

also be correctly aligned. The length of the valve should be the same as the length

between the anges in the pipeline also taking account the thickness of the gaskets.

The anges of the pipeline should be compatible with the anges on the valve. For

detailed information, please see standard EN 1092-1.

6. Commissioning and operation

After installation of the valve the pipe line should be ushed thoroughly. During this

process the valve is to be open.

Testpressure at commissioning

If a pressure test of the system is needed, the following procautions are to be

considered:

• The building of pressure is to be done slowly and gradually in order to prevent

pressure surge and hammering.

• During the pressure test of the pipeline (1,5 x PN) the valve is to be in the open

position.

• BROEN Ballomax® ball valves are designed to be fully open or fully closed.

Control that the valve is either fully open or fully closed position against the

endstop.

• Take care that the maximum and minimum temperatures, of the valve, is not

exceeded! The maximum operating pressure and minimum-/maximum-

temperatures are shown on the label of the valve. Graphs with allowable

pressures in given temperatures can be found in the technical catalog.

Ballomax

ENERGY EFFICIENCY - DESIGNED TO LAST

10 - BROEN Valves User Manual

www.broen.com

7. Operation

Handle operated valves

When the valve is open the handle ush the pipeline. Fig. A.

Gear mounted valves

The valve opens when the gear is turned clockwise. Valves prepared for installation

of gear/actuator. The position indicator at the end of the stem indicates the position

of the ball in relation to the stem.

The opening and closing of the valves are to be done slowly and carefully in order to

prevent pressure surge in the pipe line.

8. Maintenance

The valves do not demand extra service under normal conditions, but to ensure

correct function of the valves, it is recommended to open and close the valves once

yearly.

Correct functionallity of the valve demands correct quality of the water and

installation. The valve house is made in carbon steel and is as such not resistant to

corrosion.

Corrosion from the outside can be avoided be either installing the valve in dry

environment or equip the valve with a watertight insulation or another surface

protection (not oil).

The stung box in the stem is designed to last for the lifetime of the valve.

In specially unfavorable conditions minor leakages can occur. This can be solved

with a change of the o-ring, which can be done without draining the valve of

pressure or media.

Be aware of all special conditions and contact BROEN if necessary.

If it is necessary to change O-rings on the stem, BROEN should be consulted for

guidance and safety instructions. More information can be found under chapter 15 –

“Change of gasket sets”.

Fig. A.

Altri manuali per BALLOMAX

Indice

Altri manuali BROEN Unità di controllo

BROEN

BROEN BALLOMAX Manuale utente

Manuali Unità di controllo popolari di altre marche

Festo

Festo Compact Performance CP-FB6-E Manuale elenco delle parti

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Manuale utente

JS Automation

JS Automation MPC3034A Manuale utente

JAUDT

JAUDT SW GII 6406 Series Guida rapida

Spektrum

Spektrum Air Module System Manuale utente

BOC Edwards

BOC Edwards Q Series Manuale utente

KHADAS

KHADAS BT Magic Manuale utente

Etherma

Etherma eNEXHO-IL Manuale utente

PMFoundations

PMFoundations Attenuverter Manuale utente

GEA

GEA VARIVENT Manuale utente

Walther Systemtechnik

Walther Systemtechnik VMS-05 Manuale utente

Altronix

Altronix LINQ8PD Istruzioni per il montaggio

Eaton

Eaton Powerware Series Manuale utente

WAGO

WAGO 750-407/040-000 Manuale utente

Sony

Sony CCU-590 Manuale utente

Graco

Graco 25D614 Manuale utente

Task Force Tips

Task Force Tips YE-RF-900 Manuale di programmazione

Shini

Shini SPV-U Series Manuale utente