Operating and maintenance manual

For RKS plunger valve

Welded construction
 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

1. General Characteristics
1.1. Design
Type RKS plunger valve with variable operator devices as counter
weight for closing and hydraulic cylinder for opening, manual by
gearbox or electric actuator. Welded, manufactured parts with external
equipments to install in water systems. Soft sealing system is for water
application on different pressure rates for normal temperature use.

Design details:
- eccentric driving shaft and crank
- welded construction housing
- welded construction piston
- normally opened position
- pressure balanced isolating and flow-control piston
- piston is guided by double metallic bronze rings
- excellent flow-control or pressure-reducer abilities
- seat ring is plugged into the body and supported by counter
flange
- main sealing element is EPDM / NBR rubber profile sealing
- long lasting and wear-free sealing
- with lever and counterweight - single side /option/
- hydraulic cylinder with end-damping function /option/
- with gearbox and electric actuator /option/
- linear sensor ensure accurate control /option/
- inductive sensors at end positions /option/
- slotted cylinder for water dispersing /option/
- de-aeration and drainage screws

Operating details:

Valve with hydraulic operation device

The valve is normally in closed position by counterweight if there is no
oil pressure supplied into the cylinder. Opening of the valve (piston) is
done by hydraulic cylinder in case there is oil pressure supplied. Min.
oil pressure is 80 bar!
Hydraulic cylinder has end-damping ability when main valve is in
closing phase, at last ~40 mm of stroke. End-damping strength is
adjustable by set-screw on hydraulic cylinder which ensures fine and
smooth closing avoiding damage of valves parts and/or equipments.

Inductive sensors at both end positions open/closed.

Operating and maintenance manual page 2 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

Valve with manual gearbox and/or electric actuator

Valves are equipped by worm and/or spur gearbox combination and a
hand wheel in order to reach low torque values. Mechanical position
indicator placed at side of gearbox is showing the actual position of the
disk. Gearboxes have a protection class of IP67.

Electrical actuator optionally installed and limit switched are adjusted by

factory. Electrical connections that are going to be supply actuators
should be made according to the wiring diagrams that are supplied with
the actuators. Connections should be made before connecting the
valve to the pipeline. Before making electrical connection the valve
should be opened halfway with the emergency hand wheel. After
completion of electrical connections valve should be operated to open
the open button is pressed or vice-versa then the phase connection
should be changed. Actuators with reversing contactors will correct the
phase connection even if they are connected faulty.
Limit switch and torque switch adjustments must never be altered.
These settings are factory made for optimum operation conditions. Any
changes in these adjustments can cause serious damage to the valve
and the actuator.
Valve disk position can easily be checked from the mechanical position
indicator on the valve gearbox and / or electric actuator feedback
system. If valve reaches its full closed position and there is still leakage
from valve, than sealing material on disk should be checked and
replaced if necessary.
There should not be any solid particles in the medium. Solid particles in
the medium can cause serious damage to the sealing.

Warning: Unlike gate valves, sealing can not be provided by

forcing the hand wheel . When the valve reaches its full closed
position adjustment nut inside the gearbox and limit switches in
actuator reaches its end position. Further force applied may
damage operation unit and / or valve.

Piston is all time guided by bronze rings therefore even under heavily
stressed position smooth and “stuck-free” operation assured.

Operating and maintenance manual page 3 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

1.2. Operating and testing conditions

Medium: water
Medium temperature: °C
Design temperature: acc. to drawing

Operating pressure: bar g

Design pressure: acc. to drawing

Hydrostatic testing:
Casing: 1,5 x PN
Seat: 1,1 x PN
2. Description of main parts
2.1. Housing:
Welded design – S235JR carbon steel

2.2. Piston:
Welded design - 1.4301 stainless steel

2.3. Retaining ring:

Stainless steel 1.4301

2.4. Disc sealing ring:

Rubber profile made from EPDM / NBR

2.5. Shaft and shaft bearing:

The shaft is sitting in the bearing pipe with snug fit, fixed by keys and
pivoted. The bearings are assembled into the body with friction-set.
Bushings are maintenance free, DU+PTFE.
Shaft material is 1.4021.

2.6. Shaft sealing:

By NBR O-rings and PU lip gaskets.

2.7. Seat ring:

Stainless steel 1.4301.

For detailed material specification please refer attached parts list.

Operating and maintenance manual page 4 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com
3. Operation mechanism and application

Secure closing of the plunger valve is assured by the force which is

provided by counter weight or actuator. The valve will remain closed
until hydraulic oil pressure is not been provided. In case of emergency
situation, power failure or hydraulic supply unit malfunction the
counterweight will automatically close the valve.
Hydraulic cylinder is furthermore equipped with an additional end
position damping device which is about the last 5 – 10% of the piston
stroke. END DAMPING IS PRE-ADJUSTED!!! DO NOT ADJUST END
DAMPING WITHOUT CONSULTING SUPPLIER!
The lineal magnetic sensor is mounted to the operation system. It is
connecting into the installed switch box and it is supplying the order
signal for control electric unit.
For electrically actuated valve please refer attached documentation
supplied by the producer of electric device.
The valve is suitable for flow-volume regulation, which is depends on
piston’s position.
4. Materials: according to data sheets and/or parts list
5. Coating:
Valve - inside and outside sand blasted SA2.5
zinc primer and epoxy coating

Lever and counter weight - sand blasted SA2.5

zinc primer and epoxy coating
Supporter - sand blasted SA2.5
zinc primer and epoxy coating

6. Main measurements: according to the assembly drawing

7. Maintenance and inspection

The plunger valve is basically maintenance free. No lubricating points

are provided. It is strongly recommended to make following inspections
regularly:
- Make a full visual inspection of valve every month. Check
condition of valve and equipments.
- Make a full operation circle open/closed at least in every 3
months.
- Check for any leakage at the valve and equipments regularly.
- Check tightness of flanges, shaft sealing and hydraulic joints.
- Supervise connections and bolts regularly, if necessary tighten
them.

Operating and maintenance manual page 5 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

Depending on environment, hydraulic piston should be regularly

checked for dirt, sand or similar covers and cleaned with tissue
soaked in degreasing, non aggressive medium.

8. Failure and repair

The valve can be expected to operate reliably and safely provided that
all joints and connections have been made properly. Nevertheless,
accidental events (e.g. occurrences not included in the scope of
delivery) may lead to valve failures.

Mechanical failure
In view of the strict safety margins observed in the valve design,
mechanical failure is liable to occur only in the case of high improper
operation or unforeseeable events. If a mechanical failure should occur
follow these instructions:
1. The valve didn't close / open normally
- It’s possible that something is between the body seat,
slotted cylinder or piston. Check valve inside parts for
solid particles.
- Check if electric actuator is under voltage and working
properly.
- Check if nothing is blocks counterweight of moving and
hydraulic cylinder is connected correctly to oil system.
- Check that operating mechanism (gearbox, supporter,
lever, inside supporters and connecting rods) are not
blocked by some other things (i.e. tools).
2. Electric actuator or gearbox is damaged
- Contact the supplier or change the part by well trained
technical staff.
3. Hydraulic cylinder is damaged
- Contact the supplier for reparation or new hydraulic
cylinder then replace by well trained technical staff.
4. Surface protection is damaged
- Clear damaged surface then repair coating with two
component epoxy.
5. Mechanical damage
- Contact supplier;
6. Leakage
- see point 10 (replacement of seals)

IF PISTON, OPERATOR DEVICE OR HYDRAULIC STUCKED OR

NOT ABLE TO OPERATE SMOOTHLY IN NORMAL WAY, NEVER
TRY TO MOVE OR OPERATE THEM BY FORCE! WARILY CHECK
OPERATION MECHANISM AND FIX PROBLEM BEFORE
STARTING OPERATION!
WE RECOMMEND THAT ANY MAJOR REPAIR SHOULD BE MADE
AT OUR WORKSHOP OR BY OUR TECHNICAL STAFF AT SITE.

Operating and maintenance manual page 6 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

9. Tests

The valve was manufactured and tested acc. DIN 3230 Tail 3. standard
or in compliance with customer’s request.

10. Replacement of seals

10.1 Main sealing replacement (see assembly drawing)

- depressurise the system and deactivate operation device (hydraulic
cylinder, electric actuator), make sure that they will not able to
operate valve during reparation procedure
- disassembly valve from pipeline system
- pull out and remove seat ring (pos.10)
- loosen and remove fixing bolts (pos.37, 38) then retaining ring
(pos.3)
- if necessary place suitable temporary bolts to position of set
screws. They will be used as guides to help detaching retaining ring
(pos. 3) from piston.
- replace main sealing ring (pos.11)
- re-assemble parts in reverse order

10.2 Replacement of piston lip-gaskets

- depressurise the system and deactivate operation device (hydraulic
cylinder, electric actuator), make sure that they will not able to
operate valve during reparation procedure
- disassembly valve from pipeline system
- pull out and remove seat ring (pos. 10)
- remove fixing pin and bridge (pos.13 and 17)
- pull piston (pos.2) out from the body
- replace two lip-gaskets (pos.48) (Take care the positions of two
gaskets when replacing!)
- re-assemble parts in reverse order

10.3 Replacement of shaft sealings

Shaft has double sealing system (primary and secondary) which is

ensure long and reliable operation for long time without having leakage.
Replacement of shaft sealing is require complete dismount of operation
device which can be complicated. In case of leakage is realized please
contact company FALKNER for technical support.

WE RECOMMEND THAT ANY MAJOR REPAIR SHOULD BE MADE

AT OUR WORKSHOP OR BY OUR TECHNICAL STAFF AT SITE.

Operating and maintenance manual page 7 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

11. Mounting instruction

The plunger valve will be delivered in „ready for use” condition. The
installation process is simple. Please keep the following instructions in
prior before assembly:
- Unpack valve and equipments than check condition of all parts. Do
not install valve if you recognized any damaged or missing parts!
- Make sure that pipeline is clear and free from impurities.
- Before installation check if there is enough space for moving
operator device and to have free access all around the valve.
- Keep in priority the correct flow direction marked on assembly
drawings.
- Clean the valve sealing surfaces.
- Counter flanges must be parallel and fit to valve standards.
- Use correct sealing material for flanges according to applicable
medium and temperature.
- Tighten connecting bolts evenly and crosswise.

12. Storage
During storage period the valve has to be protected against impurities,
direct sunlight, rain, frost and other weather circumstance.
If valve is stored for longer than twelve months it is necessary to
replace sealings and gaskets in the valve and hydraulic before
installation.

If valve is going to be kept in stock for a time leave the valve disc in a
slightly open position.
If valve will be stored sitting on its flange connection, make sure that
valve is stored on a wooden pallet to protect flange surface against
mechanical damages.

Never lift valve from hand wheel, gearbox or actuator. This may cause
serious damage and it is extremely dangerous for persons around the
valve.

Operating and maintenance manual page 8 of 9 RKS-

 Falkner Armaturenvertriebs GmbH
A-4320 Perg / Technologiepark 17
Phone: +43 7262 9396 3320
Fax: +43 7262 9396 3329
e-mail: sales@gur-valves.com
Internet: www.gur-valves.com

12. Important safety information

In and outside of valve there are moving parts (lever,

supporter, counterweight, hydraulic, operator device, disc,
shafts etc.). Because of it, every person in valve proximity
has to be careful and should be aware that those parts may
suddenly start to move without any warning. Be careful of
burn injuries; the valve may be hot due to medium inside.
Some parts may have significantly higher temperature than
others (i.e. body). Before starting ANY maintenance or
reparation operation, parts such as hydraulic and pipeline
itself MUST NOT be pressurised and all actuation must be
disabled, so emergency closing or/and opening functions can
not be started.

Valve should not be installed in area which is permanently

accessible by personnel OR area without clearly displayed
warnings for dangerous moving objects!!!

Compensating oil tank should not be exposed to direct

sunlight and it should be protected from it. Max. temperature
of oil inside should not exceed 60°C!

Any repairing has to be performed by skilled personnel.

Never loosen bolts and screws in pressurised pipeline; the

same applies for any existing hydraulic devices.

Counterweight has to be removed or it has to be supported

by beam in case of reparation of valve.

In case of inside repairing, the counterweight has to be

dismounted.

Before any maintenance read this operational and

maintenance manual.

Falkner Armaturenvertriebs GmbH.

AUSTRIA

Operating and maintenance manual page 9 of 9 RKS-