Gate Valve DN500 Instruction Manual 404896A - LK - Valves - DN500 - INM

Instruction Manual
Gate Valve DN500 Soft Seal

Supplier: LK Valves
Reference: Manual
Version: 1
404896/A
Operation and installation manual
Gate Valve Soft Seal DN500
Article no: 74525 Revision: 1 Page 1 of 56

Revision table
Revision Description Revised by Responsible Date
Rev. 1 2019-01-16

Table of contents
1 General information ............................................................................................................................................... 5
2 Safety precautions .................................................................................................................................................. 6
3 Technical data .......................................................................................................................................................... 7
3.1 Specification ......................................................................................................................................................... 7
3.2 Gate Valve Soft Seal DN500, manual version .......................................................................................... 8
3.2.1 Dimensions [mm] ...................................................................................................................................... 8
3.2.2 Specification ................................................................................................................................................ 9
3.3 Gate Valve Soft Seal DN500, hydraulic actuator .................................................................................. 10
3.3.1 Dimensions [mm] .................................................................................................................................... 10
3.3.2 Specification .............................................................................................................................................. 11
3.4 Inductive sensor (limit switch) ..................................................................................................................... 12
3.5 Hydraulic system (Power pack) ................................................................................................................... 13
3.5.1 System description ................................................................................................................................. 13
3.5.2 Technical specification .......................................................................................................................... 14
3.5.3 Hand pump ............................................................................................................................................... 15
3.5.4 Heat dissipation ....................................................................................................................................... 15
4 Control unit ............................................................................................................................................................. 16
4.1 Description of gate valve control unit ...................................................................................................... 16
4.2 Automatic control ............................................................................................................................................ 16
4.3 Dimensions and layout of control unit ........................................................................................................... 17
4.4 Electrical diagrams of control unit ................................................................................................................... 19
4.5 Equipment list for control unit........................................................................................................................... 23
5 Storage and handling.......................................................................................................................................... 24
6 Marking .................................................................................................................................................................... 25
7 Installation ............................................................................................................................................................... 26
7.1 General installation notes ............................................................................................................................. 26
7.2 Hydraulic system notes .................................................................................................................................. 26
7.2.1 Start procedure hydraulic system ..................................................................................................... 26
7.3 Installation manual for hydraulic actuator.............................................................................................. 27
8 Maintenance instructions .................................................................................................................................. 34
8.1 Repair – dismantling the actuator ............................................................................................................. 34
8.2 Putting the valve into operation after repair ......................................................................................... 34
8.3 Space requirements for opening of valve............................................................................................... 35
9 Spare parts .............................................................................................................................................................. 37
9.1 Spare parts for Gate Valve Soft Seal DN500 .......................................................................................... 37
9.1.1 Sealing kit................................................................................................................................................... 38
9.1.2 Indicator replacement kit ..................................................................................................................... 39
9.1.3 Handwheel replacement kit ................................................................................................................ 40
9.1.4 Stem replacement kit............................................................................................................................. 41
9.1.5 Disc replacement kit .............................................................................................................................. 42
9.1.6 Disc and stem replacement kit .......................................................................................................... 43
9.1.7 Inductive indication kit – manual valve .......................................................................................... 44
9.1.8 Inductive sensor....................................................................................................................................... 45
9.1.9 Indicator and bracket replacement kit ............................................................................................ 46
9.1.10 Hydraulic actuator .................................................................................................................................. 47
9.1.11 Hydraulic motor kit ................................................................................................................................ 48
9.1.12 Gear replacement kit ............................................................................................................................. 49
9.1.13 Service kit – hydraulic motor .............................................................................................................. 50
9.1.14 BOM spare part kits ............................................................................................................................... 51
9.2 Spare parts for power pack .......................................................................................................................... 53
9.3 Spare parts for control unit .......................................................................................................................... 54
10 List of figures .......................................................................................................................................................... 55
11 List of tables ............................................................................................................................................................ 56

1 General information
This manual contains instructions on installation of the Gate Valve Soft Seal DN500 for manual and
hydraulic operation as well as maintenance recommendations. It is to be read carefully before
installation is started.
It is the responsibility of the installer to ensure that the work is carried out in a satisfactorily
manner. Only approved materials should be used and the installation must comply with applicable
rules and regulations. Regional safety requirements must be applied and observed both at
installation and maintenance work.
It is the installers responsibility to define competence of personnel for the installation and
maintenance of the valve. In case of problems which cannot be solved from information in this
manual, the supplier of the valve should be contacted. The notes and warnings defined in the
following chapters must be followed as this information concerns your safety.
The manufacturer reserves the right to introduce technical modifications at any time.

2 Safety precautions
In this Operation and installation manual, dangers, risks and items of safety information are
highlighted to attract special attention.
Information marked with the below symbol and "Attention!" describes practices, to which a failure
to comply with can result in serious injury, danger of death for users and third parties or in material
damage to the system or the environment. It is vital to comply with these practices and to monitor
compliance.
All other information not specifically emphasized such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product
documentation and on the device itself) must also be complied with to the fullest extent in order to
avoid faults which in turn can cause serious injury to persons or damage to property.
Attention!
Warning of general danger.

3 Technical data
3.1 Specification
Size DN500
Pressure class PN6
Flange drilling PN10
Painting specification According to ISO 12944 C3
Painting – primer Hempel 45141 Grey
Painting – top coating Hempel 55210 Red RAL3011
Max temperature for wedge rubber 80°C
Table 1. Technical data for Gate Valve Soft Seal DN500.
Body Ductile iron EN-JS1030 (GGG40)

Bonnet Ductile iron EN-JS1030 (GGG40)
Wedge Ductile iron EN-JS1030 (GGG40)
Wedge lining NBR 70 shore A
Stem AISI316L
Table 2. Material data for Gate Valve Soft Seal DN500.
The sealing surface of the valve is painted with Hempel antifouling paint. The availability of the
antifouling series varies based on region:
- Europe: Hempel Antifouling Globic 9000
- America: Hempel Antifouling Globic 9000
- Asia: Hempel Antifouling Dynamic 79580

3.2 Gate Valve Soft Seal DN500, manual version
3.2.1 Dimensions [mm]
Figure 1. Outline dimensions for Gate Valve Soft Seal DN500, manual version.

Figure 2. Detailed view A of Gate Valve Soft Seal DN500, manual version.
3.2.2 Specification
Actuation Manual
Weight 363 kg
Indication brackets material AISI304
Table 3. Technical data for manually actuated valve.

3.3 Gate Valve Soft Seal DN500, hydraulic actuator
3.3.1 Dimensions [mm]
Figure 3. Outline dimensions for Gate Valve Soft Seal DN500 with hydraulic actuator.

Figure 4. Detailed view A of Gate Valve Soft Seal DN500 with hydraulic actuator.
3.3.2 Specification
Actuation Hydraulic actuator
Weight 370 kg
Output torque (required torque) 325Nm @ 120 bar (300Nm)
Recommended chain oil ISO VG 46-460
Recommended chain oil lubrication 2 times/year (or every 200h)
Recommended union fittings GE 15L R1/2 – LK art.no. 95272
Actuator gearbox material AISI304
Table 4. Technical data for hydraulically actuated valve.
Observe:
No hoses, piping or fittings for the hydraulic motor are included.
Note:
Follow the recommended working pressure as stated above. Uncontrolled output torque may
result in damage to valve stem.
• Before the valve is put into operation check that it is the right valve for the application
(material, pressure, temperature and direction of flow).
• Residues in piping and valve (dirt, weld beads etc.) inevitably leads to leakage.
• Regional safety instruction must be adhered to.

3.4 Inductive sensor (limit switch)
Manufacturer: Telemecanique
Type: XS612B1NAL5
Sensing distance: 0..3,2 mm
Figure 5. Inductive sensor
The sensors use a three-wire cable (5 m) with a normally open (NO) NPN output function
according to the wiring schema in figure 6.
Figure 6. Wiring schema for inductive sensor.

3.5 Hydraulic system (Power pack)
3.5.1 System description
Figure 7. Selector for manual operation.
1 Steel tank 45 liter

2 Pump 10 l/min
3 Junction element
4 Electric motor
5 Central manifold 80-250 bar
6 Pressure gauge 0-250 bar
7 Pressure gauge valve
8 Directional solenoid valve – 24VDC, 31W
9 ¼” test connector
10 Suction strainer 90µ
11 Hand pump 45 cm3
12 Tank level gauge
13 Filler / breather cap
14 Hydraulic motor (not included in power pack)
Table 5. BOM Power Pack

3.5.2 Technical specification
B – Open
Oil filler
A – Close
Figure 8. Power Pack layout and dimensions.
Power supply 3x400VAC 50Hz / 3x440VAC 60Hz

Optional power supply 1 3x690VAC 50Hz / 3x830VAC 60Hz
Optional power supply 2 3x230VAC 50Hz / 3x280VAC 60Hz
Tank capacity 45 liter
Weight (empty) 65 kg
Weight motor 27 kg
Fittings Pipe 15mm
Recommended hoses ½” (13mm) for 30.0 MPa
Recommended hydraulic oil ISO VG 16-46
Min/Max operating temperature -10°C to +55°C
Recommended operating temperature +20°C to +55°C
Storage temperature +5°C to +60°C
Humidity 15% - 85% (non condensing)
Table 6. Technical specification for Power Pack

3.5.3 Hand pump
In case of emergency use the hand pump to manually open and close the gate valve.
When operating the lever manually, there are three functions. Note that these functions
corresponds to recommended solenoid function:
B. Open valve manually
Normal operation
A. Close valve manually
Figure 9. Selector for manual operation.
3.5.4 Heat dissipation

The maximum heat dissipation for the power pack is approximately 730W. Assuming an ambient
temperature of 20°C and a runtime of five minutes, the rise in temperature of the power pack tank
will be approximately 2,8°C.

4 Control unit
4.1 Description of gate valve control unit

The control equipment consists of a control cabinet; a control unit for local control of a hydraulic
power pack.
The main power for the power pack is 3-phase 230/400/690VAC 50Hz, depending on the power
pack. 60Hz (280/440/830VAC) is applicable to all configurations. 24VDC for the automatic
equipment in the gate valve control unit is generated from the main power.
Automatic equipment is controlled by a LOGO PLC from Siemens which is mounted in the gate
valve control unit. It consists of a basic module and an additional module with a total capacity of 12
inputs and 8 outputs. For the control, 9 digital inputs and 8 digital outputs are used. Programming
is normally done using software on a computer but can also be done directly on the PLC. The PLC-
program can be transferred directly to the PLC from a computer or be saved on a PROM mounted
on the front of the PLC.
4.2 Automatic control

The power pack/gate valve can be operated locally by push buttons at the front of the valve
control unit or remotely via ethernet from APOS operating station (see APOS online help). An
ethernet cable is normally connected to the ethernet switch in the HiPAP transceiver. The gate
valve is opened and closed by electrically controlled solenoid valves mounted on the power pack.
A timer is set so that the power pack will develop a pressure before allowing operation of the valve.
The valve opens, closes and stops by pulse switches in the gate valve control unit. When the valve
has reached the requested position, it is automatically stopped by limit switches.
The power pack will not start unless the control unit receives a signal from the hoist control unit
that the hull unit is in the upper position. If an error causes both limit switches to be activated at
the same time, the power pack will not start.
The valve can, if necessary, be operated or stopped in any position. If the valve does not activate a
limit switch during a set time, the power pack will automatically stop. If no new command is given
to the valve, the power pack will automatically stop within five minutes. The hoist control unit
cannot be run before it has received a voltage-free signal which indicates that the valve is
completely open. All timers can be adjusted on the PLC display. For added security, a password can
be programmed.

4.3 Dimensions and layout of control unit
Figure 10. Front and mounting dimensions for control unit.

Figure 11. Bottom of control unit.
Figure 12. Inside of control unit.

4.4 Electrical diagrams of control unit
Figure 13. Electrical block diagram of control unit.

Figure 14. Main circuit diagram of control unit.

Figure 15. Circuit diagram for NPN limit switches.

Figure 16. Circuit diagram for ADAM I/O-Relay.

4.5 Equipment list for control unit
ID on drawings Description Manufacturer Part.no. Qty.
L1 LOGO 24/24RC logic module Siemens 6ED1052-1MD00-0BA6 1
L2 LOGO DM8 12/24 digital I/O-module Siemens 6ED1055-1MB00-0BA1 1
LOGO memory card 32kB Siemens 6ED1056-1DA00-0BA0 1
Main cabinet Steel cabinet 600x380x210 IP54 Rittal AE 1038750 EMC, RAL7035 1
S1 / H1 Illuminated push button – green Schneider ZB4BW0B31 + ZB4BW333 1
S2 / H2 Illuminated push button – yellow Schneider ZB4BW0B51 + ZB4BW353 1
S3 Push button – red Schneider ZB4BZ101 + ZB4BA4 1
S4 / H4 Multi-function push button Schneider XB4BW84B5 1
S5 2-position knob selector switch Schneider XB4BD21 1
H3 Pilot lamp – green Schneider XB4BVB3 1
H7 Pilot lamp – red Schneider XB4BVB4 1
Nameplate 18x27mm Schneider ZBZ33 6
RJ-45 ethernet chassi contact Amphenol RJF544-21 1
RJ-45 ethernet cable house Amphenol RJF544-6 1
T1 Power supply 440VAC/24VDC 3,1A/75W Noratel 34RC75C400 1
K1 Contactor 24VDC 5,5kW/440V Siemens 3RT2017-1BB41 1
F1 Overload relay 4,5-6,3A Siemens 3RU2116-1GB0 1
D1-D8 Mini relay with socket MRZ 24VDC 1CO Weidmüller 4323308 8
X1-X3 Termination list ZDU 2,5/3AN Weidmüller - 35
Q1 Mini Circuit Breaker 6A/2P Siemens BB2P 5SY4 206-6 1
ADAM I/O module 6 channel I/O-relay Advantech ADAM-6066-A 1
Ethernet cable F/FTP CAT.6A 1M Excel - 1
APN wire rope isolator Vibratec A040127-045/8MM 4
Absorber bracket OSWO 394517/A 2
Absorber bracket OSWO 394518/A 2
Table 7. Equipment list for control unit.

5 Storage and handling
• Store the valve indoors in a clean and dry place. Corrosion that occurs during storage will
significantly reduce the life span of the valve.
• Protect the valve and other equipment against external forces.
• Lifting is to be carried out using suitable handling equipment.
• Be careful when lifting the valve. Never lift by the actuator or the indicator assembly.
• Do not damage the external coating during transport and storing.
• Keep inlet/outlets covered using e.g. plywood as long as possible to avoid damage to the
disc. Only remove the covers immediately prior to installation.

6 Marking
Marking of class cerification number is placed on either the flange edge or the body rib.
On the side of the valve body are the following markings:

- Valve size: DN500
- Pressure rating: PN6
- Valve material: GGG40
On the disc are the following markings:

- Disc size: DN500
- Disc material: NBR
- Production date: Year, month and week.

7 Installation
7.1 General installation notes
Attention!
• Protect the valve and actuator from dirt during the installation procedure.
• Check for dirt and foreign particles in the valve.
• Only use counter flanges and screws with correct dimensions.
• Avoid damaging forces on the valve and actuator during installation.
• Lifting is to be carried out using suitable handling equipment.
• Weights of equipment to be taken from section 3.1.2 and section 3.2.2.
• Keep stem threads and shaft free from paint.
7.2 Hydraulic system notes

• Power pack should be outside of watertight trunk to facilitate closing of gate valve in case of
flooding of trunk.
• Make sure power pack is located in such a way that the handle for manual pumping is
unobstructed and the tank gauge is accessible.
• Flexible tubes must be installed between the hydraulic motor/Power Pack and the hydraulic
pipelines.
7.2.1 Start procedure hydraulic system

• Verify that the mechanical and hydraulic installation is OK.
• Fill the hydraulic tank and system with recommended hydraulic oil until the check glass is full.
• Check the rotation direction of the electric motor (arrow on motor).
• Start the pumping station.
• The system is now ready for use.

7.3 Installation manual for hydraulic actuator
1. Remove the hand wheel and brackets from the valve. Make sure that the valve is fully
opened before removing the hand wheel.
2. Fit the bottom plate of the actuator against the ISO-top on the valve using 4 pcs M16x45
screws and 4 pcs M16 nuts.
3. Attach the hydraulic motor to the bottom plate using 2 pcs M12x40 screws and 2 pcs M12
nuts. Do not tighten the screws, the motor should still be able to move slightly.

4. Fit the two keys to the keyways on the stem.
5. Fit the larger sprocket to the stem and the smaller one to the shaft of the motor, making
sure they are in line. Use the set screws to fasten the sprockets in their right positions.

6. Mount the open chain around the sprockets and lock it in place.
7. Tighten the screws connecting the hydraulic motor the bottom plate.

8. Mount the top plate of the actuator, without attaching any screws.
9. Screw the indicator nut on to the stem until a few threads are visible above it.

10. Attach the indicator rod to the top plate using 2 pcs low profile M16 nuts.
11. Use 2 pcs M6x10 screws and 2 pcs M6 locking nuts to connect the sensor bracket to the top
plate.

12. Fasten the top plate to the bottom plate using 10 pcs M6x10 screws.
13. Attach the two inductive sensors to the sensor bracket.

14. The actuator should now look like the picture below.
Adjustments
1. After the hydraulic system has been connected, use the hand pump on the power pack to
close the valve slightly (three revolutions on the stem).
2. Adjust the indicator rod so that the upper slot is in line with the indicator nut. Adjust the
upper sensor so that it is in line with the indicator nut and gives a signal that the valve is
fully opened. The distance between the sensors and the indicator nut has to be less than
3,2mm. The recommended mounting distance is 1,5 mm from the sensor when pushing the
indicator nut up towards the sensor.
3. Close the valve completely.
4. Open the valve slightly (three revolutions on the stem).
5. Adjust the lower sensor so that it gives a signal.
6. With everything connected, open the valve approximately halfway and then close it using
the automatic control. If the valve does not fully close, adjust the Stop Valve Closing timer
in the control cabinet (for instructions on changing settings in the control cabinet, please
contact Kongsberg Maritime). Repeat this cycle until a satisfactory result is achieved.
7. Repeat the procedure in point 6 for the open position, if necessary adjust the Stop Valve
Opening timer in the control cabinet.

8 Maintenance instructions
1. Check your system regularly to prevent any unforeseen breakdowns. Check for leakage or
any unusual noises and check the operating temperature.
2. Change the hydraulic oil according to the instructions from your supplier. The oil should also
be checked for remaining operating hours at least once a year.
3. It is recommended to operate the valve (open and close) at least once every two weeks.
4. Maintenance of stem support with grease through grease nipple at least three times per year.
5. Check the oil level in the power pack through the oil level glass on a regular basis.
6. For hydraulic actuators, recommended chain oil lubrication is 2 times/year (or every 200h)
8.1 Repair – dismantling the actuator
Attention!
The following points must be observed before dismantling the actuator:
• Pressureless pipe system.
• Medium and valve must cool.
• Clean the area around the actuator from dirt.
• Check the actuator and the valve for damages.
8.2 Putting the valve into operation after repair
Attention!
• Before the valve is put into operation check that it is the right valve for the application
(material, pressure, temperature and direction of flow).
• Residues in piping and valve (dirt, weld beads etc.) inevitably leads to leakage.
• Regional safety instruction must be adhered to.
• Touching valve operating at high media temperatures >50°C can cause injury.
• Affix warning notice or protective insulation as appropriate.
Before putting a new valve into operation or restarting after repairs or modifications, always make
sure that all work has been completed for the valve, the actuator and for other depending systems.

8.3 Space requirements for opening of valve
To be able to open the valve, e.g. for changing the disc or the stem, the free space needed around
the valve is described below.
After disconnecting the bonnet from the body and the stem from the disc, the bonnet can be
pulled straight out in the direction of the stem. The necessary space for this operation is 1600 mm
as illustrated in figure 17.
1600 mm
Figure 17. Dismantling the valve for service.
If the space in the direction of the stem is limited, the bonnet can be removed by rotating it as
described in figure 18 to 20. This operation requires that the valve is fully closed. The necessary
space in the direction of the stem is 1400 mm for this operation and in the direction perpendicular
to the stem 1100 mm.
1400 mm
1100 mm

Figure 18. Dismantling the valve for service, step 1.
1400 mm
1100 mm
1400 mm
1100 mm

9 Spare parts
9.1 Spare parts for Gate Valve Soft Seal DN500
Figure 21. Components in spare part kits for Gate Valve Soft Seal DN500.

9.1.1 Sealing kit
LK no: 96431
KM no: 424565
Figure 22. Sealing kit.

9.1.2 Indicator replacement kit
LK no: 96432
KM no: 424566
Figure 23. Indicator replacement kit.

9.1.3 Handwheel replacement kit
LK no: 96433
KM no: 424567
Figure 24. Handwheel replacement kit.

9.1.4 Stem replacement kit
LK no: 96434
KM no: 424568
Figure 25. Stem replacement kit.

9.1.5 Disc replacement kit
LK no: 96435
KM no: 424569
Figure 26. Disc replacement kit.

9.1.6 Disc and stem replacement kit
LK no: 96459
KM no: 424561
Figure 27. Disc and stem replacement kit.

9.1.7 Inductive indication kit – manual valve
LK no: 96436
KM no: 424570
Figure 28. Inductive indication kit – manual valve.

9.1.8 Inductive sensor
LK no: 96437
KM no: 424571
Figure 29. Inductive sensor.

9.1.9 Indicator and bracket replacement kit
LK no: 96441
KM no: 424575
Figure 30. Indicator and bracket replacement kit.

9.1.10 Hydraulic actuator
LK no: 96438
KM no: 424572
Figure 31. Hydraulic actuator.

9.1.11 Hydraulic motor kit
LK no: 96439
KM no: 424573
Figure 32. Hydraulic motor kit.

9.1.12 Gear replacement kit
LK no: 96440
KM no: 424574
Figure 33. Gear replacement kit.

9.1.13 Service kit – hydraulic motor
LK no: 96442
KM no: 424576
Figure 34. Service kit – hydraulic motor.
37

9.1.14 BOM spare part kits
Indicator Handwheel Stem Disc Disc and stem Inductive

Sealing
replacement replacement replacement replacement replacement indication kit -
kit
kit kit kit kit kit manual valve
LK art.no. kit 96431 96432 96433 96434 96435 96459 96436
KM art.no. kit 424565 424566 424567 424568 424569 424561 424570
No. Description
1 Wiper seal 2 2 2 2
2 Bushing 1 1 1 1
3 Axial bearing 2 2 2 2
4 Rotating key 2 2 2 2
5 O-ring 1 1 1 1
6 Grease fitting 1 1 1 1
7 O-ring 1 1 1 1
8 O-ring 2 2 2 2
9 Bonnet gasket 1 1 1 1
10 Indicator nut 1 1 1
11 Indicator rod 1 1 1 1
12 Nut M16 ML6M 2 2 2 2
13 Bolt M16x25 1
14 Washer M16 1
15 Handwheel 1
16 Stem 1 1
17 Wedge nut 1 1
18 Wedge 1 1
19 Wedge shoe 2 2
20 Indicator bracket 1
21 Sensor bracket 1
22 Inductive sensor 2
23 Bolt M6x10 4
24 Bolt M16x45 4
25 Nut M16 M6M 4
26 Hydraulic motor
27 Lid for actuator
28 Nut M12
29 Bolt 12x40
30 Nut M6
31 Actuator bottom
32 Chain
33 Spocket 35t
34 Spocket 14t
35 Set screw M8
36 Slot key 14x9x40
37 MR80 service kit
Table 8. BOM spare part kits, part 1.

Indicator and Gear Service kit -
Inductive Hydraulic Hydraulic
bracket replacement hydraulic
sensor Actuator motor kit
replacement kit kit motor
LK art.no. kit 96437 96441 96438 96439 96440 96442
KM art.no. kit 424571 424575 424572 424573 424574 424576
No. Description
1 Wiper seal
2 Bushing
3 Axial bearing
4 Rotating key
5 O-ring
6 Grease fitting
7 O-ring
8 O-ring
9 Bonnet gasket
10 Indicator nut 1
11 Indicator rod 1 1
12 Nut M16 ML6M 2 2
13 Bolt M16x25
14 Washer M16
15 Handwheel
16 Stem
17 Wedge nut
18 Wedge
19 Wedge shoe
20 Indicator bracket
21 Sensor bracket 1 1
22 Inductive sensor 1 2
23 Bolt M6x10 4 12
24 Bolt M16x45 4
25 Nut M16 M6M 4
26 Hydraulic motor 1 1
27 Lid for actuator 1
28 Nut M12 2 2
29 Bolt 12x40 2 2
30 Nut M6 2
31 Actuator bottom 1
32 Chain 1 1
33 Spocket 35t 1 1
34 Spocket 14t 1 1
35 Set screw M8 3 3
36 Slot key 14x9x40 2 2
37 MR80 service kit 1
Table 9. BOM spare part kits, part 2.

9.2 Spare parts for power pack
Electric motor
3x400VAC 3x690VAC 3x230VAC
LK art.no: 96466 96479 96467
KM art.no: 424586 424587 424588
Spare part kit for electric motor (fan blade and protection cap)
LK art.no: 96490
KM art.no: 424589
Directional solenoid valve
LK art.no: 95197
KM art.no: 424590
Emergency hand lever

LK art.no: 94717
KM art.no: 424591
Tank level gauge
LK art.no: 96463
KM art.no: 424592
Knob for manual operation selector (5 pcs)
LK art.no: 96491
KM art.no: 424593

9.3 Spare parts for control unit
LOGO PLC and digital I/O module
LK art.no: 96492
KM art.no: 424594

10 List of figures
Figure 1. Outline dimensions for Gate Valve Soft Seal DN500, manual version. ......................................... 8
Figure 2. Detailed view A of Gate Valve Soft Seal DN500, manual version. ................................................... 9
Figure 3. Outline dimensions for Gate Valve Soft Seal DN500 with hydraulic actuator. .........................10
Figure 4. Detailed view A of Gate Valve Soft Seal DN500 with hydraulic actuator. ..................................11
Figure 5. Inductive sensor ...............................................................................................................................................12
Figure 6. Wiring schema for inductive sensor. ........................................................................................................12
Figure 7. Selector for manual operation. ...................................................................................................................13
Figure 8. Power Pack layout and dimensions. .........................................................................................................14
Figure 9. Selector for manual operation. ...................................................................................................................15
Figure 10. Front and mounting dimensions for control unit. ............................................................................17
Figure 11. Bottom of control unit. ................................................................................................................................18
Figure 12. Inside of control unit. ...................................................................................................................................18
Figure 13. Electrical block diagram of control unit. ...............................................................................................19
Figure 14. Main circuit diagram of control unit. .....................................................................................................20
Figure 15. Circuit diagram for NPN limit switches. ................................................................................................21
Figure 16. Circuit diagram for ADAM I/O-Relay. ....................................................................................................22
Figure 17. Dismantling the valve for service. ...........................................................................................................35
Figure 18. Dismantling the valve for service, step 1. .............................................................................................36
Figure 21. Components in spare part kits for Gate Valve Soft Seal DN500. ................................................37
Figure 22. Sealing kit. ........................................................................................................................................................38
Figure 23. Indicator replacement kit. ..........................................................................................................................39
Figure 24. Handwheel replacement kit.......................................................................................................................40
Figure 25. Stem replacement kit. ..................................................................................................................................41
Figure 26. Disc replacement kit. ....................................................................................................................................42
Figure 27. Disc and stem replacement kit. ................................................................................................................43
Figure 28. Inductive indication kit – manual valve. ................................................................................................44
Figure 29. Inductive sensor. ............................................................................................................................................45
Figure 30. Indicator and bracket replacement kit. .................................................................................................46
Figure 31. Hydraulic actuator. ........................................................................................................................................47
Figure 32. Hydraulic motor kit. ......................................................................................................................................48
Figure 33. Gear replacement kit. ...................................................................................................................................49
Figure 34. Service kit – hydraulic motor.....................................................................................................................50

11 List of tables
Table 1. Technical data for Gate Valve Soft Seal DN500. ...................................................................................... 7
Table 2. Material data for Gate Valve Soft Seal DN500. ........................................................................................ 7
Table 3. Technical data for manually actuated valve. ............................................................................................. 9
Table 4. Technical data for hydraulically actuated valve. ....................................................................................11
Table 5. BOM Power Pack ...............................................................................................................................................13
Table 6. Technical specification for Power Pack .....................................................................................................14
Table 7. Equipment list for control unit. ....................................................................................................................23
Table 8. BOM spare part kits, part 1. ...........................................................................................................................51
Table 9. BOM spare part kits, part 2. ...........................................................................................................................52

Gate Valve DN500 Instruction Manual 404896A - LK - Valves - DN500 - INM

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Gate Valve DN500 Instruction Manual 404896A - LK - Valves - DN500 - INM

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Instruction Manual

Gate Valve DN500 Soft Seal

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Body Ductile iron EN-JS1030 (GGG40)

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Figure 5. Inductive sensor

Figure 6. Wiring schema for inductive sensor.

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Figure 7. Selector for manual operation.

1 Steel tank 45 liter

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Figure 8. Power Pack layout and dimensions.

Power supply 3x400VAC 50Hz / 3x440VAC 60Hz

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B. Open valve manually

A. Close valve manually

Figure 9. Selector for manual operation.

3.5.4 Heat dissipation

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4.1 Description of gate valve control unit

4.2 Automatic control

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Figure 10. Front and mounting dimensions for control unit.

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Figure 12. Inside of control unit.

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Figure 13. Electrical block diagram of control unit.

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ID on drawings Description Manufacturer Part.no. Qty.

L1 LOGO 24/24RC logic module Siemens 6ED1052-1MD00-0BA6 1

L2 LOGO DM8 12/24 digital I/O-module Siemens 6ED1055-1MB00-0BA1 1

LOGO memory card 32kB Siemens 6ED1056-1DA00-0BA0 1

S1 / H1 Illuminated push button – green Schneider ZB4BW0B31 + ZB4BW333 1

S2 / H2 Illuminated push button – yellow Schneider ZB4BW0B51 + ZB4BW353 1

S3 Push button – red Schneider ZB4BZ101 + ZB4BA4 1

S4 / H4 Multi-function push button Schneider XB4BW84B5 1

S5 2-position knob selector switch Schneider XB4BD21 1

H3 Pilot lamp – green Schneider XB4BVB3 1

H7 Pilot lamp – red Schneider XB4BVB4 1

Nameplate 18x27mm Schneider ZBZ33 6

RJ-45 ethernet chassi contact Amphenol RJF544-21 1

RJ-45 ethernet cable house Amphenol RJF544-6 1

T1 Power supply 440VAC/24VDC 3,1A/75W Noratel 34RC75C400 1

K1 Contactor 24VDC 5,5kW/440V Siemens 3RT2017-1BB41 1

F1 Overload relay 4,5-6,3A Siemens 3RU2116-1GB0 1

X1-X3 Termination list ZDU 2,5/3AN Weidmüller - 35

Q1 Mini Circuit Breaker 6A/2P Siemens BB2P 5SY4 206-6 1

ADAM I/O module 6 channel I/O-relay Advantech ADAM-6066-A 1

Ethernet cable F/FTP CAT.6A 1M Excel - 1

APN wire rope isolator Vibratec A040127-045/8MM 4

Absorber bracket OSWO 394517/A 2

Absorber bracket OSWO 394518/A 2